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1. 112 Figure 7 3 Connections for thermocouple calibration 113 Figure 7 4 Thermocouple 114 Figure 7 5 Fuse 117 726 Spare FUSE EE RETE 117 Figure 9 2 101002025 Instln Hydraulics Pneumatics UCA Autoclave 127 Figure 9 3 101002025 Instln Hydraulics Pneumatics UCA Autoclave 128 Figure 9 4 5 qaos bes cuve Ud 130 Figure 9 6 O ring seating 135 Figure 9 7 Bottom chamber 0 136 Figure 9 6 POO ONO PING E MA 137 Fig re 9 9 Feed Sleeve ee erm eee ee 138 Figure 9 10 Feed sleeve casters dae sane 139 101443545 Revision B vi i fa Fr Fr UCA System User Manual List of Tables Table 3 1 Autoclave 11 Table 3 2 Processor Specifications 12 Table 3 3 Pressure Source 12 Table 5 1 Dwell for limited time and unlimited time 85 Table 5 2 Cooling at end of test 85 Table 7 1 Problems with General System 115 Table 7 2 Probl
2. 8 Figure 1 6 pressure source back view 8 Figure 3 1 processor main 14 Men OA Rm 14 Figure 3 3 Start machine buttons and tile buttons 16 Figure 3 4 DUT ON 16 Figure 3 5 Machine interface 17 Figure o O TUG Dal RR T uut 18 FOUG INdiCalO Suse T Um 19 Figure 3 8 Color selection 20 Figure 3 9 Results graph and signal 21 Figure 3 10 Context sensitive 22 Figure S 11 Start PER E 23 Figure 4 1 Configuration 42 FCS Craco mU T T 45 Figure 4 3 Test uidit m 47 Figure 4 4 Select Machine Quadrants window 49 Figure 5 1 Test 52 Figure 5 2 Inspecting metal seal o3 Figure 5 3 Autoclave chamber 54 Figure 5 4 Calibration rod and foam centering 55 Figure 5 5 Calibration rod and foam centering ring in chamber 55 Figure 5 6 Chamber assembly with calibration 56 Figure 5 7 Assembled test chamb
3. 60 5 6 62 62 5 8 Disassembly and Cleaning of the Chamber at the Conclusion of a Test 93 101443545 Revision B li 6 7 10 i fa Fr Fr UCA System User Manual 6 c 97 97 99 102 Pocm Y 103 5 Ub RE 105 0 0 SAVING TOL Spreads heei 107 Troubleshooting and 109 7 1 Restoring Interrupted 109 7 2 110 7 3 Test Eurotherm Controller Communication 110 7 4 Eurotherm 3504 Temperature 112 To 114 PRC CC SS OWNS e 119 circa ge 121 Warnan a 141 141 141 101443545 Revision B iii fa Fr UCA System User Manual List of Figures Figure 1 1 processor front 4 Figure 1 2 processor back view 5 Figure 1 3 autoclave front view 6 Figure 1 4 autoclave back 7 Figure 1 5 pressure source front
4. inearization lt Analogue Operators Multi input operator block eee Vere eee lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt cc cc Revision 2 fann UsrVal Enl UsrVal En2 User values UCA System User Manual lt lt lt lt lt lt lt lt lt lt lt lt lt lt Name to select Units ProgMode PVStart ImmSP ParameterDescription Value ORO to change Name ParameterDescription to select Home Timeout Revert to the HOME after a fixed time display Loop Summary Summary of the Loop Prog Summary Summary of the Program Bar Scale Max Upper limit of the vertical bar graph Bar Scale Min Lower limit of the vertical bar graph Main Bar Val Main bar graph value Aux Bar Val First auxiliary bar graph value Aux2 Bar Val Second auxiliary bar graph value Prog Edit Level in which a program 101443545 Revision B Value ORS to change English 26 UCA System User Manual Controll Page Level in which the control Off page is shown Control2 Page Level in which the control Off page 2 1s shown Alarm Page Level in which the alarm Levell page is shown OPI Beacon Output 1 beacons OP2 Beacon Output 2 beacons PV Input _ Name ParameterDescription Value to select ORO to change Fallback PV Filter Time Meas Value Current electrical val
5. 35 700 40 00 45 00 50 00 55 00 40 00 65 00 Time hh mm Data File c LabVIEW 8 5 TestData M2 090607 Figure 6 2 Results graph 101443545 Revision B 100 fann Aa Nore 6 2 2 101443545 UCA System User Manual 6 2 1 2 The user can right click on the graph to avail of the context sensitive menu which provides additional functionality to the graph 6 2 1 2 1 6 2 1 2 2 6 2 1 2 5 Enlarge Reduce By selecting this menu item the user can enlarge the graph to occupy all of the viewing space If the results graph is enlarged the test header will be hidden If the results graph 15 already enlarged then this menu selection will reduce the graph to its default state The test header will now be visible Show Hide Cursor Cursor visibility 1s toggled by selecting this item The cursor is a thin vertical dotted line which can be dragged by the mouse to a desired position When cursor 1s visible an associated cursor indicators are also made available on top which display the current cursor position in its associated X and Y axes scale values In this manner any parameter can be read out for any particular value of elapsed time Zoom There are three kinds of zoom available Pick the desired zoom tool to dig deeper into the graph The area zoom tool will allow the user to draw a rectangular area on the graph to zoom into The continuous zoom feature allows the user to pick a point on the graph and b
6. Name ParameterDescription Value Range Hi Range limits SP Select SPI RateDone Changing or completed set Yes point SP Trim Hi Set point trim high limit 0 0 SP Trim Lo Set point trim low limit 00 00 101443545 Revision B 33 UCA System User Manual ParameterDescription Value to select ORS to change Man Track Manual tracking SP Track Set point tracking Track PV Track PV Name to select Output Hi Output Lo Chl Output Rate Rate Disable Sbrk Mode Sbrk OP Safe OP Man Mode ManOP ForcedOP Pff En Pwr In FF Type Track OP 101443545 Maximum output power Minimum output power Channel 1 output Output rate from PID Action taken if sensor failed SbrkOP Output power if sensor failed Output rate disable Output level when loop inhibited Manual operation Manual loop output Forced manual output Power feed forward Measured power input Feed forward type Loop output value Revision B 34 UCA System User Manual to select ParameterDescription Value ORS to change RemOPL Remote output low limit 100 0 RemOPH Remote output high limit _ Name to select Operation Input Scale Input2 Scale Output Units Output Res n Low Limit High Limit Fallback Fallback Val Input Value Input2 Value Output Value Status ParameterDescription Operator type Scaling factor input 1 scaling factor input 2
7. 1 3 autoclave front view 101443545 Revision B 6 UCA System User Manual Minos m Mn Mi Jaan 308 7 Fo B Figure 1 4 UCA autoclave back view 1 5 UCA Pressure Source Two different models of the UCA Pressure Source provide hydraulic pressure to the UCA Autoclave s This pressure can be supplied directly to a single UCA Autoclave or through a manifold to supply pressure to a maximum of eight 8 UCA Autoclaves 101443545 Revision B UCA System User Manual Figure 1 5 UCA pressure source front view Figure 1 6 UCA pressure source back view 101443545 Revision B 8 fa Fr Fr UCA System User Manual 2 Safety 2 1 101443545 Machine Hazards 2 1 1 Pressure Pressurized air hydraulic and water lines present a hazard if not depressurized before maintenance or disassembly Domestic water 1s often used to cool the instrument In some labs a closed loop chilled water system 1s used for cooling Internal to the instrument the coolant supply and drain lines are copper Externally these may be plastic or copper Shut off the cooling supply line external to the instrument before working on it The drain line does not have pressure in it and it does not need to be disconnected unless it is connected to a chilled water return line The external cooling supply lines may be plastic The high pressure lines present the greatest hazard as they can h
8. 101443545 Revision B 43 UCA System User Manual Comms None Broadcast Press 8 9 times to get back to Access menu BED Press A button to change Goto to Level 1 This will cause the system to reboot The machine 1 ready to communicate with the UCA controller program Open UCA Controller program Open the respective machine for which all the steps 1 to 10 were performed 1 Open Temperature Profile Editor on this machine The editor will read a profile that 1s not correct Create a new Profile with Target Set Point of 80 degF and Time of 1 Hour 15 Click Write to download this new profile to the controller If any more machines need to be configured repeat steps 12 to 15 above for those machines 7 Exit out of the UCA Controller Program 8 Restart all the autoclaves for which the setup was performed Your system is set up to work with the Autoclaves 4 7 UCA Processor System Configuration 4 7 Configure System Configuring the system during initial installation 1s essential and must be performed for reliable operation The software recalls user settings so they do not have to be re entered each time To configure your system click on menu item Edit gt Configure System 101443545 Revision B 44 UCA System User Manual B8 nfigure System General Test Header Units Temperature Pressure degF v PSI v Temperature Controller
9. TERMINAL CRIMP 12 10 GA 10 STUD RING TYPE Sod m INSULATION CRIMP 101443545 Revision B 131 i fa Fr Fr UCA System User Manual Table 9 7 101002035 E INSTLN CONTROL PANEL UCA AUTOCLAVE Part Mat l 0002 390450 GAUGE PANEL MOUNT 0 20K SS 0003 100029053 SCREW BIND HEAD 10 24 NC x STAINLESS STEEL VALVE PANEL MOUNT BRASS STRAIGHT PATTERN 0004 100032016 1 VEE STEM 1 4 SWAGELOCK CONNECTIONS B 4JN PM NUPRO VALVE ANGLE AUTOCLAVE 30VM4072 ee TUBE 30000 PSI STAINLESS STEEL 0006 100002163 SCREW HEX SOCKET 10 24 NC 4 STAINLESS STEEL TEMPERATURE CONTROLLER 3504 EUROTHERM 0007 101653065 1 PROGRAMMED FOR UCA CONTROLLER FIRMWARE VERSION 2 33 MODBUS COMMUNICATIONS SWITCH TOGGLE DPST 0 468 DIA BUSHING WITH SCREW UU FORO LUGS 3 AMP AT 250 VAC 0009 100027339 NAME PLATE ON OFF TOGGLE SWITCH 0010 100013123 SWITCH CIRCUIT BREAKER DPST ELECTROMAGNETIC 10 AMBP 220 V 50 60 HZ TYPE 203 NEON BULB 0011 100027804 RESISTOR 10 0000 OHM 1 WATT 5 101443545 Revision B 132 i fa Fr Fr UCA System User Manual Table 9 8 101002037 M AUTOCLAVE ASSY ULTRASONIC CEMENT ANALYZER 6 10100214 2 SCREW SELF TAP 46 X 5 8 FH SLOT STNLS CORD SET ASSEMBLY ELECTRIC 230V CEMENT KIT SPARE PARTS UCA AUTOCLAVE xes awa ve warts Hi m EU RR TIE WRAP 1 16in TO 2in DIAMETER 100029508 TERMINAL CRIMP 12 10 GA 10 STUD RING TYPE INSULA
10. 3 4 9 3 4 10 3 4 11 101443545 The tables in this section contain the factory settings for the Eurotherm Model 3504 temperature controller when it 1s configured for the UCA Autoclave It is rare that the majority of these settings will need to be changed They are provided for reference should the temperature controller is responding in an unexpected manner and incorrect settings are suspected Press and hold until the display shows If an incorrect code is entered the display reverts to that shown in above If the default of 4 1s not accepted this means that the code has been changed on your particular controller Pass is displayed momentarily You are now in Config Level The symbol indicates further sub headers are available To select these press Cv A Revision B 24 D UCA System User Manual Inst Enab Name to select AnAlm En BCDIn En Counter En DgAlm En Humidity En IO Exp En IP Mon En Lgc2 ENI Lgc2 EN2 Lgc2 EN3 Lgc8 EN Linl6Pt En Load En Loop En Math2 Enl Math2 En2 Math2 En3 MultiOper En Mux En Poly En Progr En RTClock En SwOver En Timer En Totalize En TrScale En UsrText En 101443545 ParameterDescription Value ORO to change ecce ee rrr lt Humidity control IO expender Logic operators lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt Tose opener
11. Unscrew the top lid from the test chamber body Remove the test chamber body and bottom lid from the vise pour out the water and remove the hardened cement slurry and sample sleeve 1f used Properly dispose of the water and cement slurry Unscrew the bottom lid from the test chamber body If the sleeve was not used press out the cement from the top end of the test chamber Wipe all cement remnants and grease from the top and bottom chamber lids paying particular attention to clean the large flat surfaces on each lid and the groove in the bottom lid Wipe all cement remnants and grease from the inside of the sample chamber body Properly dispose of the cleaning materials used Inspect the seal rings for damage discarding those which are damaged Clean and wipe all surfaces on the UCA Autoclave and protect the transducers from mechanical damage Revision B 95 101443545 Revision B UCA System User Manual 96 fa Fr UCA System User Manual 6 Analyzing Results The data manager software allows the user to view print save and re characterize any of the test data The software supports an easy to use interface and allows the user to view the data for any test past or currently in progress The user may decide to print reports preliminary or final or save the data as PDF or in spreadsheet file formats The data manager is a stand alone utility and can be used to view test data on any computer or on t
12. 100 1000 Find Strength at Times hhimmy 900 1200 Test information Revision B 66 fa Fr Fr UCA System User Manual 101443545 57 9 Refer to 5 7 9 Start Test Wizard to understand the meaning of all the fields in this box None of the fields in this box can be edited This information is for viewing only 5 7 8 1 Help This brings up the relevant on line help 5 7 8 2 OK This closes the window Related Topics 3 3 2 Machine Interface 5 7 9 Start Test Wizard Start Test Wizard The feature that makes the UCA controller software perform consistent testing whether one is a novice or an expert user 1is the start test wizard The wizard walks the user through a series of steps to ensure all significant procedures are performed as a test begins The wizard 1 like a check list which assures that the user has indeed completed the relevant steps The four buttons at the bottom of the wizard help in navigating through the wizard 5 7 9 1 Back Press this button to go back one step At the first step this button is disabled 5 7 9 2 Next Press this button to advance to the next step At the last step this button will say Finish instead indicating this 1s the last step 5 7 9 3 Cancel This button exits the wizard without starting any test The wizard must be used to start a test 5 7 9 4 Help This brings up the relevant online help 5 7 9 5 Step 1 of 4 The first step in the process is to e
13. 5 2 1 The compressive strength calibration 1s performed to zero the time delays that may be present in the electronics associated with the ultrasonic transducers Before a compressive strength calibration can be performed the UCA System test chamber must be assembled with the calibration rod installed Revision B 51 fa Fr Fr UCA System User Manual 5 3 Assemble the Sample Chamber for Calibration 5 3 1 JN nore 101443545 i nmmmmm mmm HH AP d UL Figure 5 1 Test chamber To assemble the test chamber for calibration perform the following steps The top end of the test chamber body is marked 5 3 1 1 Check the sealing components of the upper and lower covers of the test chamber The sealing components are the O rings metal sealing rings and retaining rings Verify that they are in good condition if not in good condition replace them Revision B 52 UCA System User Manual 5 3 1 2 5 3 1 3 5 3 1 4 101443545 Figure 5 2 Inspecting metal seal ring Lightly lubricate the two covers and the O rings by applying a high temperature grease or Hitempco coupling agent Place the lower cover base in a vise with the threaded end pointing up Screw the test chamb
14. Eurotherm 3504 ka Figure 4 2 General tab 4 7 2 General Tab This 1s where the user can set the machine parameters The temperature controller and units of measurement can be set for each individual machine Using this tabular format the user can set up a mix and match of the temperature controllers and measurement units for the eight machines 4 7 2 1 Temperature Controller The software communicates with autoclave units that have a temperature controller This is where the users can select the temperature controller that is used on the autoclave Currently only Eurotherm models 818P and 3504 are supported 101443545 Revision B 45 i fa Fr UCA System User Manual AN norte When using model 3504 the Temperature units can be set to F C or K If model 818P is selected the temperature unit selection is limited to F only 4 7 2 2 Units The machine can operate in different units of measurement Generally the users will set the units in which they want to work The machine will remember these settings until the time system 15 reconfigured 4 7 2 2 1 Temperature Units Temperature Units can be F Fahrenheit C Celsius or K Kelvin 4 7 2 2 2 Strgth Units Pressure Units can be PSI pounds per square inch or MPa megapascal Once a suitable selection is made the user can navigate to the next tab 101443545 Revision B 46 UCA System User Manual Configure System General Test H
15. SPRING TOP 20K PSI UCA 1010 100072129 RETAINER TRANSDUCER CMT ANALYZER 1011 100031981 EE ETT KNOB ASSEMBLY STEEL KNURLED 1 4 20 NC 3 4 STUD 1012 EST CABLE ASSEMBLY COAXIAL TOP TRANSDUCER 6 IN UCA ADAPTER 31 219 STRAIGHT JACK JACK BNC FEMALE X e FEMALE AMPHENOL CABLE ASSEMBLY COAXIAL TOP TRANSDUCER 19 IN m nsu RG400 CEMENT ANALYZER LG 0 94SH 11 7 LB IN STAINLESS STEEL 101443545 Revision B 134 UCA System User Manual Figure 9 6 O ring seating tool The O ring seating tool consists of two parts the seating tool with handle left and the feed sleeve right 101443545 Revision B 135 UCA System User Manual d f Se Figure 9 7 Bottom chamber lid Unlike the top chamber lid the bottom chamber lid does not have a ring to retain the O ring When the test chamber is being threaded onto the bottom lid the O ring can become displaced or twisted The O ring seating tool retains the O ring in the proper location while the lid and chamber are being assembled 101443545 Revision B 136 UCA System User Manual Figure 9 8 Tool on O ring The O ring seating tool shown against the bottom lid O ring 101443545 Revision B 137 UCA System User Manual Figure 9 9 Feed sleeve The feed sleeve is inserted into the top end of the test chamber to compress the seating tool fingers as it 1s inserted 101443545 Revision B 138 UCA Syste
16. UCA Controller during calibration or testing Doing so can result Never disconnect any coaxial cable on the UCA Autoclave or NG caurioN in severe damage to the UCA Controller or UCA Autoclave 101443545 Revision B 92 i fa Fr Fr UCA System User Manual AN nore JN nore 5 8 WARNING 101443545 The only way to start a test is to go through the Start Test Wizard The user can navigate freely between the steps using Back and buttons Use Cancel button anytime to abort the starting of a test Related Topics 3 3 2 Machine Interface 5 7 7 View Edit Test Profile 5 7 6 Test Signal 4 7 1 Configure System Disassembly and Cleaning of the Chamber at the Conclusion of a Test At the conclusion of a test the test chamber and contents are hot and may contain high pressure Thermal protective gloves should be worn if handling the hot chamber The integral cooling system is designed to remove the heat from the test chamber and lower the pressure before it is fully released Rapidly releasing the pressure while the temperature is above 212 F 100 C could result in the water in the chamber flashing to super heated steam and becoming a burn hazard shut down the Temperature Control 5 8 1 1 Stop the temperature control program 5 8 1 2 Turn the Heat switch OFF 5 8 1 3 Inspect Autoclave for leaks and proper working conditions 5 8 1 4 Check the temperature of the unit and perform one of th
17. 1 6 Changing Parameter Color Right clicking on transit time compressive strength or temperature and selecting Color opens up a color selection box Users may choose the color of their choice for each of these parameters Clicking a color changes the plot scale and indicator color to the color selected 101443545 Revision B 19 UCA System User Manual aT Temperature Set Point Elapsed Time Transit Time Comp Str 00 00 00 Choose color for Cancel Figure 3 8 Color selection box 3 3 2 2 Set Point Set point is the current target temperature which the temperature controller on the autoclave is using to ramp up to in the specified time Refer to 5 7 7 View Edit Test Profile section to understand how set points are used The Set Point display is for reference only and 1 not plotted on the graph 3 3 2 3 Results Graph As the test progresses the current results are displayed in their respective indicators At the same time the values are plotted on the results graph 101443545 Revision B 20 Click on Scale to UCA System User Manual Cursor Values edit the values Yolts V 101443545 OU 3 01 00 01 02 03 at 04 00 Time hh mm 45 co 60 Transit Time ps Figure 3 9 Results graph and signal graph The graph plots elapsed time on the x axis and Transit Time Compressive Strength and Slurry Temperature on three differ
18. ASSEMBLY COAX TOP XDUCER 6 in 0011 101002196 FU 3 AMP 3AG SLW BLW 0012 101567732 U TUBE ASSEMBLY UCA AUTOCLAVE 101443545 Revision B 119 101443545 Revision B UCA System User Manual 120 fann UCA System User Manual 9 Parts List A ig p 101567732 Item 12 on Kit 100072557 E Figure 9 1 Test chamber assembly 101443545 Revision B 121 i fa Fr Fr UCA System User Manual Table 9 1100053514 D INSTALLATION CHAMBER AUTOMATIC ULTRASONIC CEMENT ANALYZER 0001 100072152 PRESSURE CHAMBER ASSEMBLY HIGH PRESSURE HIGH TEMPERATURE 0005 100004319 THERMOCOUPLE TYPE J 20KPSI SPEC 0006 100072570 CABLE ASSEMBLY EXTENSION T C LEAD WIRE PLUG N TYPE J SPEC 0007 100009519 j TRANSDUCER ULTRASONIC HIGH TEMP TESTED MATCHED PAIR 0008 100033505 SPRING COMPRESSION 0 72 OD X 0 072 WIRE DIA X 3 00 LG 0 94SH 11 7 LB IN STAINLESS STEEL 0009 100072172 SPACER COMPRESSION SPRING TOP 20K PSI UCA 0010 100072129 RETAINER TRANSDUCER TOP CMT ANALYZER 0011 100031981 KNOB ASSEMBLY STEEL KNURLED 1 4 20 NC 3 4 STUD 0012 100013730 CABLE ASSEMBLY COAXIAL TOP TRANSDUCER 6 IN UCA 0013 100031975 ADAPTER 31 219 STRAIGHT JACK JACK BNC FEMALE X FEMALE CABLE ASSEMBLY COAXIAL TOP BOTTOM 0014 100013729 1 TRANSDUCER 40 IN CEMENT ANALYZER 0015 101443543 CABLE ASSEMBLY
19. COAXIAL TOP TRANSDUCER 19 IN RG400 CEMENT ANALYZER 101443545 Revision B 122 NOILJ3S System User Manual DSSS dO 4 ANN N oc g 123 9 2 100072152 K pressure chamber assembly UCA high pressure high temperature Revision B 101443545 i fa Fr Fr UCA System User Manual Table 9 2 100072152 K PRESSURE CHAMBER ASSEMBLY UCA HIGH PRESSURE HIGH TEMPERATURE RING SEALING PRESSURE CHAMBER UCA 0010 100034509 1 GREASE MULT PURPOSE MYSTIK JT 6 14 OZ Table 9 3 100071996 F KIT TOOL AUTO ULTRASONIC CEMENT ANALYZER Paru Mati 0001 100072130 BAR CALIBRATION ULTRASONIC CEMENT ANALYZER SLEEVE CENTERING CALIBRATION BAR ULTRASONIC PUDE CEMENT ANALYZER GAUGE SLURRY LEVEL 20K PSI CHAMBER ULTRASONIC CEMENT ANALYZER 0005 100072157 WRENCH BOX END BOTTOM LID UCA WRENCH SPANNER FACE ADJUSTABLE 3 0 MAX SPAN MM BETWEEN CENTERS 1 4 DIAPINS 8 25 LG 0007 100029847 VISE GRIP CHAIN CLAMP WITH 19 IN EXTENSION CHAIN 0008 100072159 TOOL O RING SEATING PRESSURE CHAMBER UCA 101443545 Revision B 124 i fa Fr Fr UCA System User Manual Table 9 4 101002024 L INSTLN FRAME UCA AUTOCLAVE Part Mat l 0001 390448 mE CHASSIS ASSEMBLY UCA AUTOCLAVE VACSFEMSXISALONGSIANDSS _ iens SCREW SELF TAPPING 10 X 12 TRUSS HEAD SLOT 0
20. Each UCA Autoclave connects to the UCA Processor by data trigger and temperature cables The UCA Processor contains the computer pulse trigger data acquisition storage and display The Processor connects to up to eight UCA Autoclaves through data trigger and temperature cables The UCA Pressure Source provides the hydraulic pressure to the cement slurry sample chamber contained in the UCA Autoclave Each UCA Autoclave must be connected to a pressure source independently or through a common pressure system manifold Two Sources are available 6 000 psi and 20 000 psi Function The UCA System performs nondestructive compressive strength tests on cement slurry samples These tests are conducted under simulated down hole pressure and temperature conditions to determine the initial set time and the wait on cement WOC time of a slurry sample The initial set time 1s the time required for freshly mixed cement slurry to reach a compressive strength of 50 pounds per square inch psi This test helps provide an indication of the compressive strength behavior of a sample The WOC time 1s the time required for the slurry to reach a compressive strength of 500 psi This test helps to determine how much time should be allowed for the slurry to set during one stage of a cementing operation before the next stage can begin The System is used to determine not only these two specific times but also a continuous trend in the development o
21. Figure 5 25 Assembled test chamber with thermocouple and transducer 77 Figure 5 26 Bottom transducer in heating 78 mielUlg Koc AMI Eco cT 19 Figure 5 28 Temperature profile 81 Figure 5 29 Right click to edit 83 Figure 9 30 VV ANNO ce E T 84 Figure 5 31 86 OLS TO e 88 Figure 5 59 2 0 89 2 Of 90 Figure 5 35 Step 3 4 91 Figure 5 56 Step 4 Of 92 Figure 6 1 Main screen full screen 98 Figure 6 2 ERR EE 100 Figure 6 3 Test header IMG ACIS nta qud usse seus vocet ocu 102 Figure 6 4 Print preview screen 104 101443545 Revision B V fa Fr UCA System User Manual Figure 6 5 Print dialog 105 Figure 6 6 Printer and PDF 106 Figure 6 7 Windows dialog 107 Figure 7 1 Error 111 Figure 7 2 Connection for thermocouple calibration
22. Print General Select Printer EA NBCS32 001 E ANBCVD82 houprntOol v CA PDF XChange ABBYY PDF Transformer 2 0 44 Status Ready Preferences Location HOU NBC Comment xerox WorkCentre Pro C3545 Find Printer Page Range All Number of capies 1 4 t Pages 1 h Enter either a single page number a single page range Far example 5 12 6 5 Print dialog window The print dialog window allows the user to choose the printer of their choice to print to In most cases the default settings will work and should not be changed Click print to print the report or cancel to return back to the main screen of the data manager Related Topics 6 1 Main Screen 6 5 Printing to PDF 6 5 Printing to PDF If the computer has a PDF printer installed it is possible to save the test report as PDF file This 1s just like printing data to a printer refer to 6 4 Printing Data Instead of a regular printer the user will choose a PDF printer print 101443545 Revision B 105 UCA System User Manual amp Print General Select Printer EA NBC332 on nbeprnEDDH E ANBCVO82 hau 001 a PDF XChange For ABBYY PDF Transformer 2 0 1 PDF Printer Status Ready Frintto file Preferences Location HOU NBC N27 Default Printer Comment 2 7 sero WorkCentre Pro C3545 Find Printer Page Hange A
23. Rate Hldbck Type 101443545 Revision B 37 UCA System User Manual Program Edit Name ParameterDescription Value to select ORO to change Segment Type Type of segment End Access Press Dor C to change Goto to 1 3 5 UCA Pressure Source The hydraulic fluid normally water is pressurized by an air powered Maximator piston pump The output pressure is controlled by a manual air pressure regulator on the input side of the pump Front panel mounted gauges show the air and hydraulic pressures A filter on the air supply removes debris and condensation before reaching the regulator and pump Individual valves at each UCA Autoclave in a manifold system allow complete isolation of an autoclave for maintenance or when different pressures are used simultaneously An internal rupture disk prevents over pressurizing the system 101443545 Revision B 38 fann 4 Installation 4 1 4 2 4 3 4 4 4 5 101443545 UCA System User Manual Parts of the UCA Autoclave 4 1 1 Reference see Introduction Other Parts 4 2 1 several smaller items are packed separate from the UCA Autoclave to protect them during shipping When unpacking the UCA Autoclave verify that you have received the test chamber BNC connectors Category CAT 5 network cable high pressure U tubing calibration core and accessory kit Electric Power Supply 4 3 4 3 2 The Autoclave is supplied with a 5 ft po
24. Specifications 6 000 psi 42 mega Pascal MPa or Maximum Pressure 20 000 psi 138 MPa 21 inches 63 enters om Weight 6 000 psi 100 pounds Ib 45 kilograms kg 20 000 psi 70 pounds 16 32 kg Air Cooling Supply and Drain 1 4FNPT located on the rear 30 80 psi 0 21 0 55 MPa Coolant Supply Filtered 250 micron 60 mesh e can be connected to water drain 1f water 1s used as coolant Voltage and Current 3 1 UCA Autoclave Mechanical The Chamber Supply and Chamber Vent are manual valves that control the pressure going into and coming out of the sample chamber During testing the Chamber Supply valve is normally open 101443545 Revision B 12 fa Fr UCA System User Manual 3 2 3 3 101443545 The Chamber Pressure is a pressure gauge that indicates the pressure applied by the pressure source The Coolant Supply is a manual valve that allows coolant normally water to flow through the heating and cooling jacket During testing this valve 1s normally closed The high pressure sub system 15 protected by a burst disc that limits the pressure and safely controls the release of over pressure UCA Autoclave Controls and Indicators The Main Power switch illuminates when electric power is applied to the UCA Autoclave circuits The Heat switch located below the Main Power switch on the front panel enables and disables the heater circuit without interrupting power to th
25. Test Signal This brings up the test signal window Refer to 5 7 6 Test Signal section for more details 3 3 2 5 3 Temperature Profile Editor This opens a window for editing temperature profile Refer to 5 7 7 View Edit Test Profile tor more details 3 3 2 5 4 View Test Information This shows information about the current test Refer to 5 7 6 View Test Information for more details 3 3 2 5 5 View Alarms This brings up the current state of alarms for the respective machine Refer to Alarms for more details 3 3 2 5 06 Data Manager This brings up external program Refer to data manager help for more information Start Test lt Machine Function lt None gt Pulser Calibration Test Signal Temperature Profile Editor View Test Information View Alarms Data Manager Figure 3 11 Start test 3 3 2 5 7 Start Test Click the Start Test button to start a test The start test button will bring up theStart Test Wizard The user will 101443545 Revision B 23 fa Fr Fr UCA System User Manual be walked through a series of steps to start test Once all the steps have been completed the test can be started When the test starts the button becomes dark green and can be used to stop the test 3 3 2 6 Help This brings up the relevant online help Related Topics 3 3 1 Main Screen 5 7 9 Start Test Wizard 3 4 UCA Autoclave Temperature Controller Software 3 4 1 3 4 2 3 4 3 3 4 4 3 4 5 3 4 6 3 4 7 3 4 8
26. an alarm when these strength results are achieved These default values can be overridden for individual machines before starting a test Refer to 5 7 9 Start Test Wizard for more details A NOTE The default events for strength can only be entered in PSI Because the machines can be set to run in any units the default units will be converted to correct units for each machine 4 7 3 5 4 7 3 6 4 7 3 7 101443545 Events Time HH MM The user has four events that are triggered by time The user can set up default values for the time alarm here By doing so every test will start with these default values and trigger an alarm when a particular time has elapsed These default values can be overridden for individual machines before starting a test Refer to 5 7 9 Start Test Wizard for more details Help Clicking the Help button brings up relevant online help OK Clicking the OK button saves the settings closes the Configure System window and returns the user to main screen Revision B 48 fa Fr Fr UCA System User Manual The Configure System window can only be opened when all eight NOTE machine windows are closed NNNOTE A machine window can only be closed if no test is running Related Topics 3 3 1 Main Screen 5 7 9 Start Test Wizard 4 8 Select Machine Quadrants The software generates an individual window for each of the machines the users want to view and control Each of these windows 1s fully resiza
27. and Trigger connect the corresponding jacks on the rear of the UCA Autoclave and UCA Processor Any available channel 1 8 on the UCA Processor may be used The UCA Processor and UCA Autoclave Temperature Control must both be set to the same channel number used for the coaxial cables 4 6 2 Configure temperature controllers for Model 304 processor 4 6 2 1 For autoclaves with Eurotherm Model 818P Follow the following steps and configure the 818P to work with Model 304 Switch off power to the unit and remove it from the sleeve To remove the unit Unscrew the screw located inside the door and the unit should slide out Set the configuration Jumper to ENABLED Short position to put the unit in Config Mode Refer to the figure below 101443545 Revision B 41 fa Fr UCA System User Manual Link Switch bal Enabled Disabled Configuration Switch Microprocessor Board Figure 4 1 Configuration jumper Put the unit back in the sleeve Use the Screw located inside the door to Slide the unit in fully Make sure it 1s sitting flush with the sleeve Switch on the power 4 The upper display now reads CONF and lower display reads Pressing P button allows you to scroll through Config Items C1 C2 C3 etc The P button is located inside the door on the right Once a particular Config Item 1s selected Press the UP arrow to access its value and then use the UP DN arrow buttons to change the val
28. is reset at the beginning of the test and counts upward to indicate the total amount of time the test has run This parameter is plotted along the x axis of the Results Graph see Figure 5 9 Results graph and signal graph 3 3 2 1 3 Transit Time This indicator displays transit time in us The transit time 1s the amount of time it takes for the ultrasonic waves to travel through the cement sample The transit time 1s plotted along one of the three y axes of the Results Graph see Figure 3 9 Results graph and signal graph 101443545 Revision B 18 fa System User Manual Elapsed Time Transit Time Comp Str Temperature Set Point 4 Figure 3 7 Indicators 3 3 2 1 4 Comp Str The compressive strength derived from ultrasonic analysis 1s displayed in this screen The units of measurement for compressive strength can be PSI or MPa Refer to 4 7 1 Configure System on how to set up the desired units Compressive strength 1s plotted on one of the three y axes of the Results Graph see Figure 3 9 Results graph and signal graph 3 3 2 1 5 Temperature This indicates the current temperature of the system The temperature is read directly from the temperature controller on the autoclave unit Use 4 7 1 Configure System to set up the units of temperature measurement Temperature is also plotted on the y axis of the Results Graph see Figure 3 9 Results graph and signal graph 3 3 2
29. physical contact with the test chamber to maximize heat transfer to the sample Cooling tubes are cast into the heating jacket for end of test cooling Each UCA Autoclave contains a dedicated temperature controller to individually regulate the sample heating rate The temperature data is passed to the UCA Processor for display and recording with other test data A switch turns off the heating system while the temperature controller is programmed before a test begins Revision B 5 mE Ec E REB li E UCA System User Manual The Chamber Supply valve allows hydraulic pressure from the UCA Pressure Source to enter the test chamber After the chamber is at the desired pressure this valve is normally closed during a test The Chamber Vent valve allows hydraulic pressure in the test chamber to be released This valve is normally closed during a test A front mounted pressure gauge constantly provides immediate information about the pressure inside the sample chamber The Coolant Supply valve allows coolant normally water to flow through the cooling coils that are integral to the heating jacket During a test this valve 1s normally closed Two coaxial cables labeled Data and Trigger connect the UCA Autoclave to the UCA Processor An 8 conductor cable between the UCA Autoclave and UCA Processor permits the sample temperature to be recorded during a test COOLANT SUPPLY CHAMBER PRESSURE
30. setting values or you have previously defined the alarm settings for this channel then you don t have to perform this step Prepare the slurry and test cell Please refer to the UCA Manual section for slurry preparation Taking channel On Line When a channel is taken on line the system software loads various types of configuration data for this channel such as pulser calibration value alarm setup data etc into the system memory making it ready to run a cement test on this channel Test Signal In this optional step you check to see if system setup cable connections and pressure line on this channel are setup properly This 1s done by having the UCA Control System software apply an ultrasonic pulse to the cement slurry sample and graphically displays the shape of the sound wave that travels through the sample By visually inspecting the characteristic of this wave form you can see if everything 1s working properly For more information see 7 Revision B 63 101443545 Revision B UCA System User Manual 64 fann 101443545 UCA System User Manual Troubleshooting and Maintenance Selecting an existing Test Schedule or creating a new Test Schedule When the UCA Control System runs a test it progresses through a sequence of user specified pressures and temperatures that are planned to occur at a specific time during test This sequence of parameters 15 called test schedule In this step you can select a pre creat
31. sleeve into bottom lid groove Be certain the bottom side of the test chamber body is screwed onto the base The inside of the test chamber body is tapered from the bottom A to the top so that the bottom has a greater inner diameter than the top NOTE The top of the test chamber body is labeled top if this marking is obscured compare the inner diameters of the ends of the chamber body to determine which is the top 5 7 4 9 the cement slurry and pour cement into the sample sleeve 101443545 Revision B 69 UCA System User Manual Figure 5 15 Pouring cement slurry into sample sleeve Figure 5 16 Fill the sample sleeve to the top 101443545 Revision B 70 fa System User Manual CAUTION Do not overfill the sample sleeve so cement spills outside the sleeve 5 7 4 10 Slowly fill the chamber with water up to the top of the chamber to about in from threads Figure 5 17 Pouring water around sample sleeve 101443545 Revision B T1 UCA System User Manual Figure 5 18 Water just covers the cement slurry 5 7 5 Alternate Fill Method without the Sample Sleeve 5 7 5 1 Place a slurry level gauge on top of the open UCA Autoclave test chamber 5 7 5 2 Pour slurry into the chamber between the wet and dry levels marked on the gauge 101443545 Revision B 72 UCA System User Manual Figure 5 19 Slurry level gauge 5 7 5 3 Pour water over the top of the slurry until t
32. system plumbing has a leak Check repair or replace the The system does not hold The pressure system pressure system plumbing pressure plumbing has a leak Refer to the plumbing diagrams The pressure gauge does not The pressure gauge 15 Test the pressure gauge Zero faulty Table 7 4 Problems with End Caps Problem or Symptom Possible Cause Corrective Action The lid chamber threads are Clean the lid chamber dirty threads The O ring seal area in chamber is dirty Clean the chamber TIME The O ring is damaged or Check replace and lubricate not properly lubricated the lid O ring 101443545 Revision B 116 UCA System User Manual Figure 7 5 Fuse Location Figure 7 6 Spare Fuse 101443545 Revision B 117 101443545 Revision B UCA System User Manual 118 i fa Fr Fr UCA System User Manual 8 Accessories Table 8 1 100072557 Q KIT ACCESSORIES UCA AUTOCLAVE 0002 100072156 2 RING SEALING PRESSURE CHAMBER UCA RING SEALING PRESSURE CHAMBER UCA COUPLING AGENT ULTRASONIC HIGH 0005 100002386 TEMPERATURE 2 OZ TUBE 0005 100002001 O RING 90 DURO 2 3 4 X 2 1 2 X 1 8 0006 100003926 O RING SOUR GAS 2 3 4 X 2 1 2 X 18 0007 100033247 RING RETAINING RS 250 EXTERNAL SPIROLOX 0008 100034509 GREASE MULT PURPOSE MYSTIK JT 6 14 OZ SLEEVE SAMPLE 2 1 8 OD X2 ID X2 1 2 LENGTH ULTRASONIC CEMENT ANALYZER SPEC 0010 100013730 CABLE
33. temperature units are same as what was set during the 4 7 1 Configure System step 5 7 7 2 Time Temperature graph This graph plots the profile in graphical form The temperature profile graph updates in real time as the profile 1s being created This allows the user to see the temperature with respect to time when the test 15 run 5 7 7 3 Temp Setpoint The test profile comprises of steps Each step consists of a target temperature and time in which this target 101443545 Revision B 81 UCA System User Manual temperature is to be reached This column lists all the target temperatures to be attained in sequential steps 5 7 7 4 Time HH MM These two columns list the times in which the target temperature must be reached The left column lists the hours and the right column is for minutes The time of each step 1s independent of previous and next steps If step 2 has target temperature of 150 deg and time of 50 minutes the step will last 50 minutes and it will take all of these 50 minutes to reach 150 deg The steps in time temperature table can be quickly edited by right clicking on any step of the table and accessing the context menu for that step 5 7 7 4 1 row By selecting this item the user copies the current step and holds it in memory 5 7 7 4 2 Paste row before By selecting this menu any step that 1s held in the memory is inserted before the current step on which right click operation was perfor
34. test involves sending an ultrasonic pulse to measure the transit time and check the signal amplitude This prevents errors and assures that the signal 1 adequate for testing Never disconnect any coaxial cable on the UCA Autoclave or caution UCA Controller during calibration or testing Doing so can result in severe damage to the UCA Controller or UCA Autoclave gt Test Signal for Machine 1 20 5 Transit Time 15 Figure 5 27 Test signal 101443545 Revision B 79 fann 5 7 6 1 5 7 6 2 System User Manual signal Graph The signal graph shows the actual ultrasonic signal recovered by the system This graph is used to determine the transit time and the quality of the signal signal Quality The signal quality meter shows the quality as in a percent form The quality of the signal is judged based on the measurement resolution of the system If the signal has sufficient amplitude it can be measured with high fidelity and the meter will go in the yellow green zone gt 40 If the signal is poor and measurement accuracy 1s degraded then the signal will be in red zone lt 30 A NOTE It is recommended that a test should be started only if the signal quality is more than 30 Below this the system cannot consistently and accurately measure the ultrasonic signal 5 7 6 3 5 7 6 4 Help Clicking help brings up relevant on line help Start Stop Pressing this button starts the process of
35. testing the signal If the testing has already been started then press this button to stop the test The signal graph displays the signal and the meter shows the calculated signal quality This process is repeated continuously until the user stops the testing UCA Controller during calibration or testing Doing so can result Never disconnect any coaxial cable on the UCA Autoclave or in severe damage to the Controller or Autoclave 5 7 6 5 Close Use the standard windows close button to close this window Related Topics 3 3 2 Machine Interface 5 7 9 Start Test Wizard 101443545 Revision B 80 fa Fr Fr UCA System User Manual 5 7 7 View Edit Test Profile The UCA controller software facilitates communication with the temperature controller in the autoclave The view edit test profile screen allows the user to read or write a test profile to the temperature controller The test profile is a schedule for temperature and time 2 Machine 1 lemperature Profile Temperature 1 2 3 4 5 T 8 i 1 i i m i l Lie i 1 00 00 02 00 09 00 06 00 05 00 10500 12 00 14 00 16 00 18 00 20 00 22 00 24 00 26 00 Time Help Read Write New Profile Figure 5 28 Temperature profile 5 7 7 1 Temperature The temperature indicator shows the current temperature at the autoclave This temperature 1s used as baseline for all temperature calculations The
36. the graph and by continuously holding the left mouse button to progressively zoom to it The zoom extents menu discards the zoom tool and reverts the graph back to show the complete graph in its default state 5ShowJ Hide Cursor Continuous Extents 04 00 04 30 1 3 02 00 02 30 03 00 Time hh mm Figure 3 10 Context sensitive menu The x axis auto scales to current elapsed time so even any user desired scaling will be overridden as new data becomes available approximately in the next 10 seconds 3 3 2 4 3 3 2 5 signal Graph Just below the results graph 15 the signal graph This graph displays the ultrasonic signal as being measured by the system It plots the recovered signal as transit time on x axis against its amplitude on y axis This signal provides a good measure of system check to ensure that everything is progressing as desired This graph can be hidden when the results graph 1s enlarged Except for viewing and diagnostic reasons this graph does not have any more functionality and can be hidden if so desired Machine Function Revision B 22 UCA System User Manual The machine function drop down list allows the user to select any particular machine function Some of the items from this list of machine functionality are also a part of Start Test Wizard 3 3 2 5 Pulser Calibration This brings up the pulser calibration window Refer to 5 4 Pulser Calibration for more details 3 3 2 5 2
37. two machines will swap places Now Machine 6 will open from Tile A when the left top position 15 clicked Machine 1 will open from Tile B in the right top position Help Clicking help brings up relevant online help OK Press this button to make the program accept and save the current settings and close this screen Cancel Press Cancel to revert back to initial settings and exit this screen All changes made are voided by this button Related Topics 3 3 1 Main Screen 101443545 Revision B 50 fa Fr UCA System User Manual 5 Operation 5 1 5 2 101443545 Calibration 5 1 1 Calibration 1s an important part of preparing the UCA Autoclave and UCA Processor for use Calibrations must be performed when the UCA Autoclave and UCA Processor are first set up when the ultrasonic transducers or cables are replaced or every three months Calibration may be performed any time there 15 uncertainty about the test results Without proper calibration the UCA System provides inaccurate data During the calibration process the UCA Processor sends a trigger signal to the Autoclave and the return data pulse is measured A sample point is established by applying a known quantity to the transducers The UCA Processor measures the return signal s amplitude and frequency and records the measurements The known quantity value is altered sent to the transducer and the return data again measured Transit Time Calibration
38. used to bring up the user interface for machines 1 to 8 respectively Clicking these buttons will open a window for each machine If the machine window is already open then clicking the button will bring it to front and make it active 3 3 1 8 Tile Buttons There are two tile buttons on the tool bar that when clicked will open a set of four machines according to the layout depicted on each of the tile buttons All four machines opened will be neatly tiled according to the position reflected on the tile Refer to 4 8 Select Machine Quadrants to understand how to configure each of these tile buttons Figure 3 4 Help button 3 3 1 9 Help Button Clicking the Help button brings up this particular section of online help To exit this software use the close button or use the menu item File gt Exit 101443545 Revision B 16 fa Fr Fr UCA System User Manual The software cannot be closed or exited if any of the machine NOTE windows are open Please close each machine window before trying to exit the program A NOTE The machine windows cannot be closed or exited if any of the machines has a test running Please stop the test before trying to close the machine windows Related Topics 4 7 1 Configure System 4 8 Select Machine Quadrants 3 3 2 Machine Interface 2224 Machine Interface Clicking on any of the buttons the Main Screen see 3 3 1 Main Screen opens up the respective machine interface The mach
39. 00 Utility Read From Register vi gt Get SP U rom eE3504 vi Eurotherm Engine vi DA Main vi gt PZI vi Click here to Click here to abort acknowledge the process error amp try again CONFIRM 00 29 Figure 7 1 Error message In case of any malfunction the machine will prompt the user with an error dialog There are a few things to note about the error dialog e It indicates where the error is originating from in the Title Bar e It tells you what the problem is and what action can be taken to correct the error It provides additional information Most of this information may be helpful to technical support personnel to diagnose the problem The dialog box is self closing The user can acknowledge the error by pressing the Confirm button If the user decides not to close the error box it will close itself in one minute and try another attempt to do whatever it was doing 101443545 Revision B 111 fa Fr Fr UCA System User Manual 7 4 The user can actually decide to abort the process which resulted in the error Not all processes can be aborted If the process cannot be aborted the button will be unavailable to the user Eurotherm 3504 Temperature Calibration The Eurotherm 3504 temperature controller should be periodically checked and adjusted per standard laboratory practice The following procedures are specific to the Eurotherm 3500 series controlle
40. 012 100072171 1 HOLDER BOTTOM TRANSDUCER AUTOCLAVE ASSEMBLY HIGH PRESSURE CEMENT ANALYZER THERMOSTAT ASSEMBLY TEMPERATURE OVER RUN 0013 100072169 1 PROTECTION AUTOCLAVE ULTRASONIC CEMENT ANALYZER 0014 100028427 SCREW HEX CAP 1 4 20 NC X 3 4 STAINLESS STEEL 316 0015 100072118 STAND MOUNTING HEATING JACKET CMT ANALYZER GASKET BOTTOM HEATING JACKET CMT ANALYZER SPEC INSULATION FIBROUS GLASS 1200 DEGREE MAXIMUM 1 2 INCH THICK X 60 INCH WIDE X 75 FEET LONG ROLL 0018 100033598 BENE SCREW HEX CAP 1 4 20 NC X 1 STAINLESS STEEL JACKET HEATING COOLING CAST 110V 50 60 HZ 2000 WATT SPECIAL 0020 100029318 E EXTENSION 5 16 OD X 16 3 5 LONG BLACK SCREW SELF TAP 46 X 5 8 FH SLOT STNLS 2 SCR BIND HEAD 46S2NCX STAINLESS STEEL 0029 101002213 2 SCREW SELF TAP 8 X 5 8 PAN HD SLOT STNLS COUPLING BULKHEAD CMT ANALYZER ULTRASONIC 0030 100004321 HIGH PRESSURE 0031 100004318 2 NUT BULKHEAD FEMALE HALF UNION 20KPSI NUT BULKHEAD FEMALE HALF UNION 20KPSI SCREW FLAT HEAD MACHINE 6 32 NC X 1 2 idi STAINLESS STEEL FAN INSTRUMENT 37 CFM 50 60 HZ 230VAC 101443545 Revision B 125 UCA System User Manual Part Mat l4 0040 100028909 4 SCREW SELF TAPPING 46 X SCREW SELF TAPPING 6 X 1 2 HEAD SLOT PL PAN HEAD SLOT PL RAIL MOUNTING 35MM X 1 METER DIN 46277 0041 100033128 Em SYM
41. File menu currently has only one menu item called Exit The Exit menu item closes the program Edit The Edit menu has two menu items These two menu items are explained below 3 3 1 3 1 Screen Layout Use this item to set up the visualization of various machine windows Refer to 4 8 Select Machine Quadrants for detailed information on how to set up the screen layout 3 3 1 3 2 System Configuration Use this item to set system parameters The system parameters are set up once at the time of the machine installation Refer to 4 7 1 Configure System for detailed information about setting up system parameters View Use the items under the View menu to generate windows for each machine or use the two Tile menu items to open windows for four machines at a time All the functionality of the View menu 15 available on the tool bar for quick access Help The item called Online Help opens this help file The About menu item opens the about dialog box that shows the current revision of the software Tool Bar The tool bar gives access to all the day to day functionality of the program From here the user can open the machine interface for individual machines or view a set of four user defined machines in neatly arranged tile form Revision B 15 fa Fr Fr UCA System User Manual Jz Figure 3 3 Start machine buttons and tile buttons 3 3 1 7 Start Machine Buttons There are eight Start Machine buttons which are
42. KET LL1 S10 1 8 MPT STAINLESS STEEL HANSEN 0014 100027418 PLUG MALE LL1 T10 1 5MALE PIPE THREAD STAINLESS STEEL 0015 207377 7 IN TUBING SOFT COPPER 1 4 X 032 0017 10002475 ELBOW 1 8 MALE PIPE THREAD X 1 4 OD TUBE 0018 101566783 4 4 4 3 2 2 2 LOCK TO FIT 5 8 INCH HEX ON 1 4 IN FNPT END OF BULKHEAD FITTING FOR COPPER TUBING 1 1 1 1 1 3 101443545 Revision 129 90509 NH3A Od Sdn SISSVHO 3SV2 OLNI MOTs isn UCA System User Manual n A 310 1 NHMO A S 1ndino Woes Figure 9 4 Electrical schematic NOLINON OL 13 4 L TaN LN 130 Revision B 101443545 i fa Fr Fr UCA System User Manual Table 9 6 101002026 F INSTLN ELECTRICAL PANEL UCA AUTOCLAVE Part Mat l ADAPTER BULKHEAD BNC JAN TYPE UG Voua 492 A U 31 220 AMPHENOL PANEL SINGLE CIRCUIT THERMOCOUPLE a TOOU JX CALIBRATION 0004 100002384 HOLDER FUSE PANEL MOUNTING WATER TIGHT 0005 101002196 FUSE 3A 3AG SLO BLO INLET ELECTRICAL FLANGED 3 WIRE ane 20 250 VAC TWIST LOCK NO 2325 HUBBELL 1 0007 160038600 SCREW BIND HEAD NUMBER 6 32 NC x STAINLESS STEEL RELAY SOLID STATE 240 VAC 25 AMP 3 32 VDC CONTROL SCREW BIND HEAD 6 32 NC x STAINLESS STEEL Few ames wremsmxssanasSpMES 0 0015 207819 2 WASHERSPLIT6STAINLESSSTEEL
43. METRICAL BLOCK MODULAR TERMINAL SINGLE CONNECTOR FEED THROUGH GRAY 0043 100032909 PLATE 6MM END TYPE 9701 6 SINGLE 0044 205166 2 CLAMP END 35mm DIN RAIL 0045 100032225 2 STRIP RAPID MARKING NUMBERS 1 THRUIO STRIP RAPID MARKING NUMBERS 1 THRU 10 CABLE ASSEMBLY COAXIAL TOP BOTTOM TRANSDUCER 40 IN CEMENT ANALYZER WIRE THERMOCOUPLE 3W2P6 20 GA POLY VINYL OVER POLYVINYL 0049 204400 1 GUARD FAN FINGER 3 1 8 80 METAL GUARD FAN FINGER 3 1 8in f 30MM METAL 0050 373809 4 WIRE HOOK UCA AUTOCLAVE 0051 204950 RESISTOR 25 OHM 5 WATT 5 SLEEVING SIZE 6 CLASS R GRADE A WHITE FIBERGLASS wee SLEEVING 125 PER PACKAGE 101443545 Revision B 126 UCA System User Manual Pd npa Loy Y i dd a S 25 C3 lt N C Lam e Co P MS i 1 Y NN Ae HL p V alles N g m a a N J N bs D I n Ya 1 27 E I SEC 4 4 1 d m 2 L_ B mo 5 5 amp IPPE D Fd No j P SS ij y je VT 15 COPPER 4 ER 55 Yin N 2 N 1 A E BN N NON a Y e wf 2 Z Li E s Ne m L 2 S I 2 y s gt a f E m Y 5 Ca T Mem Ld OZ
44. Output units Output resolution Low limit High limit Fault condition Fault output value Input value Input 2 value Analog output value Operation status Value ORFO to change None XXXXX Clip Good Program Set Up Name ParameterDescription to select Value ORFO to change 101443545 Revision B 35 UCA System User Manual Program Set Up Name ParameterDescription Value to select D ORO to change Sa o deir mme mxmmmmbroona 0 _ Program Set Up Name ParameterDescription Value to select ORO to change Advance Set the program SP equal NO target Spem Sweat 0 _ 0 _ 101443545 Revision B 36 UCA System User Manual Program Set Up Name ParameterDescription Value to select ORFO to change Program Edit _ Name ParameterDescription Value to select ORO to change Program Program number or name Segments Used Number segment PVStart Starting point HIdBk Value Deviation between SP and PV Ramp Units Ramp units Number of repeats Segment to set up Type of segment Setpoint value Type of holdback Cycles Segment Segment Type Target SP Ramp Rate Hldbck Type Segment Segment to set up Type of segment Setpoint value Type of holdback Segment Type Target SP Ramp Rate Hldbck Type Segment Segment to set up Type of segment Setpoint value Type of holdback Segment Type Target SP Ramp
45. T A gt _ O T gt Y 4 Lid 3 GA LLAR UA 4 4 55 9 2 101002025 Instin Hydraulics Pneumatics UCA Autoclave 101443545 Revision B 127 101443545 SUPPLY K 42 2 GUPPER LH FRUM URI Figure 9 3 101002025 Instin Hydraulics Pneumatics UCA Autoclave Revision B IPPER je 4 wu N M System User Manual N Y 128 i fa Fr Fr UCA System User Manual Table 9 5 101002025 H INSTLN HYDRAULICS PNEUMATICS UCA AUTOCLAVE 0001 100072640 SAFETY HEAD ASSEMBLY 1 4 50000 PSI RUPTURE DISC DISC RUPTURE INCONEL 600 1 4 DIA ANGLE SEAT 24 000 PSI 400 DEG F RATED PRESSURE CROSS AUTOCLAVE ENGINEERS CX4444 PM 60 KPSI 0003 100033092 1 WITH F250C FEMALE HIGH PRESSURE EQUIPMENT CO 60 24HF4 SPI GLAND AUTOCLAVE ANGLE 40 60000 POUNDS PER SQ Mad IN FOR 1 4 TUBE F250C FEMALE THREAD COLLAR AUTOCLAVE ACLAO 1 4 TUBE 60000 PSI td STAINLESS STEEL 0006 100072134 AUTOCLAVE 1 8 FEMALE X 1 4 F250C 0007 380718 TUBING SET HIGH PRESS UCA AUTOCLAVE 4 TUBE SWAGELOC 90 DEG UNION 3 8 PLUG MALE LL1 T10 1 5MALE PIPE THREAD STAINLESS STEEL 0012 100024754 TEE 1 4 OD TUBE ALL TUBE 0013 100029298 SOC
46. TION CRIMP TERMINAL FEMALE 0 25 032 12 106 AM IN 30 6 TERMINALFORKSZHISAWG SSS 205296 TIE WRAP ADHESIVE PAD 209648 NETWORK JUMPER ASSEMBLY UCA 101443545 Revision B 133 i ca Fr Fr UCA System User Manual Part Mat l TERMINAL RING 10 12 AWG 10 HI TEMP HIGH 38 365255 4 TEMPERATURE RING TERMINAL NON INSULATED 10 STUD SIZE 900 DEGREES F MAX 204288 DISCONNECT FEMALE 110 TAB 22 101586615 COVER TERMINAL CERAMIC SET NO 10 32 CAP 204299 TERMINAL FEMALE Q C 25X 032 1 100031978 ADAPTER BULKHEAD BNC JAN TYPE UG 492 A U 31 220 PANEL SINGLE CIRCUIT THERMOCOUPLE JX 100002384 HOLDER FUSE PANEL MOUNTING WATER TIGHT 101002196 FUSE 3A 3AG SLO BLO INLET ELECTRICAL FLANGED 3 WIRE 20 AMP 250 VAC 207 100028609 3 SCREW BIND HEAD NUMBER 6 32 NC X 1 2 STAINLESS SIEEL RELAY SOLID STATE 240 VAC 25 AMP 3 32 VDC 22 100007784 2 SCREW BIND HEAD 6 32 NC X 1 4 STAINLESS STEEL SCREW BIND HEAD 6 32 NC X 1 4 STAINLESS STEEL PRESSURE CHAMBER ASSEMBLY UCA HIGH PRESSURE HIGH TEMPERATURE 1005 100004319 1 THERMOCOUPLE TYPE J 20KPSI SPEC THERMOCOUPLE TYPE J 20KPSI SPEC CABLE ASSEMBLY EXTENSION T C LEAD WIRE PLUG 1006 100072570 TYPE J SPEC TRANSDUCER ULTRASONIC HIGH TEMP TESTED 1007 100009519 E MATCHED PAIR 1008 100033505 SPRING COMPRESSION 0 72 OD X 0 072 WIRE DIA X 3 00 1009 100072172 SPACER COMPRESSION
47. Ultrasonic Cement Analyzer UCA System User Manual 101443545 Revision B i fa Fr UCA System User Manual UCA System User Manual 02009 Fann Instrument Company Houston Texas USA All rights reserved No part of this work covered by the copyright hereon may be reproduced or copied in any form or by any means graphic electronic or mechanical without first receiving the written permission of Fann Instrument Company Houston Texas USA Printed in USA The information contained in this document includes concepts A methods and apparatus which may be covered by U S Patents NOTE FANN reserves the right to make improvements in design construction and appearance of our products without prior notice FANN and the FANN logo are registered trademarks of Fann Instrument Company in the United States and or other countries UCA is a trademark of Fann Instrument Company Contact FANN Phone TELEPHONE 281 871 4482 TOLL FREE 800 347 0450 FAX 281 871 4358 Mail Fann Instrument Company Box 4350 Houston Texas 77210 USA Ec ums Location Eola Fann Instrument Company 15112 Morales Rd Gate 7 Houston Texas 77032 USA x Online www fann com fannmail fann com 101443545 Revision B fa Fr Fr UCA System User Manual Contents UU OCCU m 1 1 1 The UCA System consists of the following functional subsystems 1 L2 Funci
48. aph e Changing strength events will cause a corresponding change in its event results only e Changing time events will cause a corresponding change in its event results only Data Test ID Request ID My Test 4 My Reg Re Viel 2 Al Wiel Net Facies Test Date 3 2007 Strength 50 02 28 AtTime 06 0 PSIis 416 9 Strength 100 Polat 03 06 1240 P5lis 833 Strength 500 0708 1800 PSIis 1060 2 Strength 1000 atime 2400 Figure 6 3 Test header impacts The user may decide to alter any of the hest header parameters The user can tweak the event results if so desired and then decide to print a report or save data to other file formats The user may also decide to turn on the cursor and print the report If the cursor is on it will appear on the test report 101443545 Revision B 102 i fa Fr Fr UCA System User Manual Recharacterizing the test data does not change any of the raw data collected during the test The recast test data is held in computers volatile memory If it is not saved or printed it will be lost upon program exit or when new data is loaded Related Topics 6 1 Main Screen 6 4 Printing Data Once the user is satisfied with all the information presented in the data manager a test report can be printed out of the results including any changes made by the user to test header The printed test rep
49. at the end of calibration 15 displayed here Depending on the value of this offset the calibration 1s judged as follows e If the offset value 1s between 1 5 and 3 0 the calibration is a success If the offset value is outside the success limits but falls between 1 0 and 4 0 then such a calibration is marginal If the offset value falls outside the marginal limits the calibration 1s a failure gem Calibration Offset 2 19 La Calibration Marginal Figure 5 10 Calibration offset Calibration Status The status of the calibration is indicated here and appropriately messaged and color coded The user should use the status message to save or cancel the calibration Help Clicking Help brings up relevant online help Save Use this button to accept the offset value from current calibration and use it for future tests Pressing this button will also close this window and return you to Pulser Calibration window It is recommended that a calibration should only be saved if its status 1s successful A marginal or failed calibration should be investigated and another attempt at calibration should be made Revision B 61 fa Fr Fr UCA System User Manual 5 5 5 Cancel Use this button to discard the current calibration The offset from last calibration will then be used Pressing this button will also close this window and return you to Pulser Calibration window If the calibration 1s marginal or failed use this b
50. ated firstly by following the previous procedure for the mV ranges then calibrating the CJC This can be carried out using an external CJC reference source such as an ice bath or using a thermocouple mV source Replace the copper cable shown in the previous diagram with the appropriate compensating cable for the thermocouple in use Thermocouple simulator set to 52 T C type and 09C Controller Thermocouple Compensating cable x dae Figure 7 3 Connections for thermocouple calibration Set the mV source to internal compensation for the thermocouple in use and set the output for Then complete the following steps 101443545 Revision B 113 i fa Fr Fr UCA System User Manual 1 This example is for PV Input configured as a type K thermocouple 2 From the Cal State press or to select CJC 4 The remaining procedure 15 the same as described in the previous section 7 5 101443545 Do This The Display You Should See Additional Notes 3 Press 4 or en to select Go The controller automatically calibrates to the CJC input at OmV As it does this the display will show Busy then Passed assuming a successful calibration If it is not successful then Failed will be displayed This may be due to an incorrect input mV Figure 7 4 Thermocouple calibration Troubleshooting Tables These tables are provided to assist i
51. ble and can be positioned anywhere the users want to place them The two tile buttons on the Main Screen see 3 3 1 Main Screen provide a means for the users to open any of the four windows in tile fashion Using the two tile buttons the user can quickly view all eight machines easily The tiles can be configured as the user wishes as explained below Select Machine Quadrants Display Setup Drag and Swap the appropriate numbers onto the two Tile buttons below This will configure your screen to display machines in you chosen order Figure 44 Select Machine Quadrants window 101443545 Revision B 49 fa Fr UCA System User Manual Tile A Tile A displays four of the eight machines that are controlled by this tile The four numbers indicate which machines will open when the users click on Tile A The location where the machines will open is determined by the location of the four numbers In the case above Machine 1 will open in the left top corner of the screen Tile B The Tile B button functionality is identical to that of Tile A above Repositioning Machine Screens To reposition the machine screens drag any one of the desired machine numbers from either of the tiles to a new location within either of the tiles This will swap the desired machine to the new location selected For example Machine 1 in Tile A above is dragged and dropped on Machine 6 in Tile B The
52. d So at 50 PSI UCA System User Manual the time recorded is 9 minutes The rest of the strength events have not occurred yet as shown by At the same time none of the time events have occurred yet The event that has triggered the alarm 1s the one that 1s flashing gt Machine 1 Alarms Strength Events Time Events 50 PSI at 00 09 At Time 00 10 PSI is 76 150 PSI at 00 12 500 PSI at 22 2 00 20 PST is 227 1000 5 22 22 00 25 PSI is Close in 37 Sec Figure 5 12 Time events In the above case strength events of 50 PSI and 100 PSI have already been recorded The time event of 00 10 minutes has already been recorded earlier A time event of 00 15 minutes is the one that has triggered the alarm There are two strength and two 101443545 Revision B 66 fann UCA System User Manual time events that have yet to occur as evident by and in their results At any time the user can view this alarm window for any of the machines as explained in 3 3 2 Machine Interface The title bar of the alarm window shows the machine for which the alarms are displayed Related Topics 3 3 2 Machine Interface 5 7 9 Start Test Wizard 5 7 4 Assemble the Chamber for a Slurry Test 5 7 4 1 5 7 4 2 5 7 4 3 5 7 4 4 5 7 4 5 5 7 4 6 101443545 Assembling the test chamber test cell for a slurry test is similar to assembling the chamber for calibration except the calib
53. e following If the temperature is greater than 120 F open the cooling valve and allow the unit to cool to below 120 F Also ensure that the pressure drops Close the valve before moving on to the next step If the temperature is less than 120 F proceed to the next step 5 8 1 5 Turn the Main Power switch OFF Revision B 93 fann 101443545 22542 UCA System User Manual Disconnect the test chamber 5 8 2 1 5 6 2 2 5 6 2 3 5 6 2 4 5 6 2 5 5 6 2 6 9021 5 8 2 8 5 8 2 9 Close the Chamber Supply valve Open the Chamber Vent valve and perform one of the following If the pressure drops the high pressure lines are not plugged Keep the valve open briefly to purge the line from the supply through the vent valve to the drain then close the valve If the pressure does not drop vent to drain the high pressure lines are probably plugged and the UCA Autoclave needs to be repaired before it can be safely used again Close the Chamber Vent valve to prevent coolant spilling when the high pressure U Tube is disconnected Wrap a cloth around the high pressure U Tube connected to the top of the test chamber and disconnect the high pressure line from the pressure vessel It is not necessary to fully disconnect it from the bulkhead fitting the top of the UCA Autoclave Wipe up spills or drips and clean the connector ends Place a disposable cup under the disconnected high pressure line or p
54. e entire apparatus The Temperature Controller regulates the power applied to the heater circuit to achieve and maintain the desired temperature inside the sample chamber It constantly compares the desired temperature set point to the temperature reading from the sample chamber thermocouple UCA Processor When the UCA Control System Software is first started it displays the main screen as shown in Figure 3 1 3 3 1 Main Screen This 1s the first screen that displays when the program is opened Descriptions of some of the components of this screen follow Revision B 13 UCA System User Manual E Merskin i1 T Help Seat Sust 1131 sj L Fahina T i4 7 fann Fann Instrument Company Fennis Thee pi Pann icit Soares Ox Nm Fann binaran Cer alienis Figure 3 1 UCA processor main screen 3 3 1 1 Menu Bar The menu bar allows the user to access some of the overall functions of the program Use the menu bar to set the system configuration display windows and view the various machines The menu bar of the program has following items UCA Controller Version 1 21 File Edit View Help Start Start Start Sat Machine 1 Machine 2 Machine 3 Machine 4 Figure 3 2 Menu bar 101443545 Revision B 14 101443545 19 62 3 3 1 3 3 3 1 4 3 3 1 5 3 3 1 6 System User Manual File The
55. eader L ab Name Customers List Lement Type List ABC TV Apple Aramark BBC TV Bears Burger King CarMax Conoca Cowboys Disney Lions MacDonald Macy s MediaFlow i Figure 4 3 Test Header tab 4 7 3 Test Header The test header tab 1s a convenient place where the users can enter the lab name a list of frequently used customers cement types and events The software uses this list to populate and prompt when filling the relevant test information dialog Refer to 5 7 9 Start Test Wizard for more details 4 7 3 1 Lab Name The lab name is set up here Once it is entered it need not be entered again The entry here is used to populate the relevant field when starting a test 101443545 Revision B 47 4 7 3 2 4 7 3 3 4 7 3 4 UCA System User Manual Customers List This list of customers will be used to prompt the user for a customer during test setup A new customer is added to the bottom of this list and 1s sorted alphabetically when the OK button 15 clicked Cement Type List This list stores the cement types in use and those most frequently tested at a particular lab This list also alphabetizes the entries after the OK button is clicked Events Strength PSI The user has four events that are triggered by the strength value reached The user can set up default values of strength here By doing so every test will start with these default values to trigger
56. ed test schedule or to create a new one For detailed information on creating a new schedule please refer to the section 5 7 7 View Edit Test Profile Starting the Test Ending the Test The following sections describe these steps in detail 5 1 2 S Program Temperature Control for a Test Dod Sie 5 7 2 3 5 7 2 4 From the home display press until you reach Program Edit Press C For each program setting use A or to change the displayed value After releasing the button the display will blink to show the controller has accepted the new value Continue to press you have reviewed changed the desired program values Press the PROG button to return to the Program Status display setting Time and Cement Strength Alarms The setting time and cement strength alarms may only be changed when the user interface level 1s set to default Switching between simple and default user interface levels is done on the system settings panel and requires restarting the program after the change During step 1 of Start Test Wizard the user can enter certain events or alarms which trigger a dialog box and beep to let the user know that the user defined events have occurred Revision B 65 gt Machine 1 Alarms Strength Events Time Events 150 PSI at 22 727 500 PSI at 22 22 1000 PSI at 2 Figure 5 11 Strength events In the above example a 50 PSI event has occurre
57. ems with Temperature n 115 Table 7 3 Problems with 116 Table 7 4 Problems with End 116 Table 8 1 100072557 KIT ACCESSORIES AUTOCLAVE 119 Table 9 1 100053514 D INSTALLATION CHAMBER AUTOMATIC ULTRASONIC ANALYZE aaah 122 Table 9 2 100072152 PRESSURE CHAMBER ASSEMBLY HIGH PRESSURE HIGH ctae cnn Ern eret crede onc oii enim 124 Table 9 3 100071996 F KIT TOOL AUTO ULTRASONIC CEMENT ANALYZER 124 Table 9 4 101002024 L INSTLN FRAME UCA 125 Table 9 5 101002025 H INSTLN HYDRAULICS PNEUMATICS UCA AUTOCLAVE M 129 Table 9 6 101002026 INSTLN ELECTRICAL PANEL UCA AUTOCLAVE 131 Table 9 7 101002035 E INSTLN CONTROL PANEL UCA AUTOCLAVE 132 Table 9 8 101002037 M AUTOCLAVE ASSY ULTRASONIC CEMENT ANALYZER C 133 101443545 Revision B vii fa Fr Fr UCA System User Manual 1 Introduction 1 1 1 2 101443545 The UCA System consists of the following functional subsystems The UCA Autoclave contains the cement slurry sample heating and cooling Jacket temperature controller pressure gauge and ultrasonic transducers This device is the subject of this user manual
58. ent y axes in their respective units The x and y axis scales can be changed to show any range of values by clicking on the scale values and entering a new desired value This positions and scales the respective parameter graph to the new scale The user can right click on the graph to access the context sensitive menu that provides additional functionality to the graph e Enlarge Reduce By selecting this menu item the user can enlarge the graph to occupy all of the viewing space If the Results graph 1s enlarged the Signal graph will be hidden If the results graph 1s already enlarged then this menu selection will reduce the graph to its default state The signal graph will now be visible e Show Hide Cursor Cursor visibility is toggled by selecting this item The cursor 1s a thin vertical dotted line that can be dragged by the mouse to a desired position When the cursor 1s visible associated cursor indicators are also made available on top which display the current cursor position in its associated x and y axis Revision B 21 NNNOTE 101443545 UCA System User Manual scale values Any parameter can be read out for any particular value of elapsed time Zoom There are three kinds of zooms available Pick the desired zoom tool to dig deeper into the graph The area zoom tool will allow the user to draw a rectangular area on the graph to zoom to The continuous zoom feature allows the user to pick a point on
59. er The test header box displays all the relevant information about the test that was conducted It lists all the fields and their values which were filled in at the time the test was begun In addition it also lists all the strength and Time events and results which were recorded as part of the test The following fields are part of the test header Any of the fields here can be changed by the user Refer to 6 3 Recharacterizing Data for more details Lab Name Project name Test ID Tested By Request ID Customer Well No Rig Casing Liner Size Job Type Cement Type Cement Weight Pick from Standard Light Weight or Hi Dense 101443545 Revision B 99 i fa Fr Fr UCA System User Manual Comments Strength Units Temp Units strength Events 4 strength Results 4 Time Events 4 Time Results 4 6 2 1 Results Graph The results graph holds all the test data in graphical form The graph plots elapsed time on X axis and transit time compressive strength and slurry temperature on three different Y axes their respective units 6 2 1 1 X and Y axes scales can be changed to show any range of values by clicking on the scale values and entering a new desired value in This positions the respective parameter graph to the new scale Time 51 4 r Click on Scale to Edit Values Enlar ge R educe Show Hide Cursor Zoom Results Graph d 1 1 1 00 00 0500 10 00 15 00 20 00 2500
60. er body bottom down partially onto the base leaving about 4 in 2 cm of threads exposed The test chamber body cannot be completely screwed on because the calibration rod would not fit into the test chamber if the covers were screwed on completely Revision B 53 UCA System User Manual ri 4 Figure 5 3 UCA Autoclave chamber Be certain the bottom side of the test chamber body is screwed onto the base The inside of the test chamber body is tapered from the bottom to top so that the bottom has a greater inner Aa Nore diameter than the top The top of the test chamber body is labeled top if this marking is obscured compare the inner diameters of the ends of the chamber body to determine which is the top 5 3 1 5 Apply a thin layer of high temperature ultrasonic coupling gel to the ends of the calibration rod and place the rod into the sleeve using a foam centering ring 54 101443545 Revision UCA System User Manual Figure 5 4 Calibration rod and foam centering ring Figure 5 5 Calibration rod and foam centering ring in chamber 5 3 1 6 Apply a thin layer of high temperature ultrasonic coupling gel to the ultrasonic transducer in the lid of the test chamber 101443545 Revision B 55 fa Fr Fr UCA System User Manual Verify that the ultrasonic transducers are free of debris and are not chipped or cracked One small grain of contaminant can rui
61. er cap and to the bulkhead connection on the top of the UCA Autoclave and securely tighten both connections Clean the BNC connectors with a quick drying aerosol contact cleaner Connect the top transducer coax cable to the top connector on the rear of the UCA Autoclave Connect the top cap thermocouple to the thermocouple connector on the rear of the UCA Autoclave Fully close the Chamber Vent and Chamber Supply valves on the UCA Autoclave front panel Increase the pressure on the UCA Pressure Source to the desired pressure Open any manifold valves between the UCA Pressure Source and the UCA Autoclave Slowly open the Chamber Supply valve on the front panel of the UCA Autoclave Observe the pressure gauge and verify that the pressure increases to the desired value Revision B 78 fa Fr Fr UCA System User Manual 5 7 5 19 Check for leaks at all high pressure fittings Release all pressure from the UCA Autoclave before attempting to resolve any leaking fittings 5 7 5 20 If not done already set the desired temperature heating ramps and dwell time on the Temperature Control see 5 6 and press the Run button The basic heating ramp programmed into the temperature NOTE controller may be unsuitable for all tests Experiential knowledge indicates a slower heating rate is required for lower temperature tests to prevent overshooting the target temperature 5 7 6 Test Signal Test the system before starting any test The
62. er with thermocouple and transducer of Figure 5 8 Pulser Calibration window 58 Figure 5 9 Save calibration window 60 101443545 Revision B iv fa Fr UCA System User Manual Figure 5 10 Calibration 61 Figure 5 11 Strength 66 Figure 9 14 IER 66 Figure 5 13 Groove bottom test chamber lid for sample sleeve 68 Figure 5 14 Seating sample sleeve into bottom lid groove 69 Figure 5 15 Pouring cement slurry into sample sleeve 70 Figure 5 16 Fill the sample sleeve to the 70 Figure 5 17 Pouring water around sample sleeve 71 Figure 5 18 Water just covers the cement slurry 72 Figure 5 19 Slurry level 73 Figure 5 20 Tightening top lid water expelled through open port 74 Figure 5 21 Water coming out of test chamber 74 Figure 5 22 Top lid fully 15 Figure 5 23 Coupling gel on 75 Figure 5 24 Inserting the transducer into the top 1 76
63. es to maintain the 265 deg in the last step indefinitely The only way to stop the temperature control 1s to stop the test Dwelling for unlimited time is only possible on the last step of the temperature profile Cooling at end of test Table 5 2 Cooling at end of test 101443545 Revision B 85 5 7 8 L Machine 1 Test Information i sample Test Info 101443545 UCA System User Manual In the above example the test dwells twice and after 24 hours the test 1s done It 1s designed to cool down automatically after the test 1s over In this case enter a step which ramps the temperature down to 50 deg in 5 minutes The machine will not reach 50 deg in 5 minutes but it will turn off the heater and begin a natural cool down Since any temperature entered in the last step dwells indefinitely the autoclave heat will never turn on and the heat is effectively shut off The test however will continue until the user physically stops it in the machine interface see 5 3 2 Machine Interface Related Topics 3 3 2 Machine Interface 5 7 9 Start Test Wizard 4 7 1 Configure System View Test Information Anytime during the test the user can see all the pertinent test information that was entered as part of step 1 of the Start Test Wizard Figure 5 31 Fila Path C Documents and Settings Administrator Desktop Testi Fie Name Sample Test tdms Find Time to Strength for following Strengths MPa 50
64. f compressive strength in a sample In a compressive strength test the UCA System applies an ultrasonic high frequency sound pulse to a cement slurry sample and measures the length of time required for the sound wave to travel completely through the sample As the cement hardens the wave travels faster and takes a shorter time to reach the other end of the sample The UCA System converts this length of time called transit time to compressive strength for many sample points during a test The UCA System records the compressive strengths and the times at which they occur to compile a set of data that can then be analyzed to help plan a cementing schedule for a well Revision B 1 fa Fr Fr UCA System User Manual 1 3 101443545 UCA Processor The Ultrasonic Cement Analyzer provides a non destructive method for determining the relative strength development of a cement sample under down hole temperature and pressure conditions The theory of operation is based on the correlation between ultrasonic pulse velocity in the cement sample and its compressive strength Strength indications are determined by measuring the change in velocity of an ultrasonic signal transmitted through the cement sample as it cures The controller software 15 at the heart of ultrasonic cement testing system The software controls the computer which in turn controls the autoclave The UCA controller software controls the ultrasonic subsystem It triggers
65. g the actual test The user has an opportunity to verify the signal and if the signal is not adequate to correct the system before proceeding This step encapsulates all the functionality of the Test Signal section Follow the explanation in that section to understand this step The user can verify and test his signal from within this step of the test wizard Revision B 91 fa Fr Fr UCA System User Manual 5 7 9 8 Step 4 of 4 When the user reaches this step the test can be started However before starting the test the user needs to ensure that certain physical actions are completed before the test begins Start lost Wizard Step 4 of 4 We are ready to start the test If you need to change any information click the Back button or Cancel Please ensure the following items The Finish button will only become available after you have checked each item 1 All pertinent Test information 1 entered correctly Make Sure you have the correct Cement Sample Loaded The PRESSURE to the Autoclave unit is turned ON and set to the correct value 4 Ensure that the Heater Switch on the Autoclave is ON If you are ready to start the Test Click Finish and test will commence Figure 5 36 Step 4 of 4 In this step the check items will have to be checked by the user If all the items are checked the finish button will become available When the user clicks on the finish button the test will start
66. g this sound wave you will know if a cement test 15 setup properly before running the test Never disconnect any coaxial cable on the UCA Autoclave or 7 3 101443545 Controller during calibration or testing Doing so can result in severe damage to the UCA Controller or UCA Autoclave Test Eurotherm Controller Communication The UCA Control System communicates with the Eurotherm Controller on each autoclave via a communication card installed on each autoclave The UCA Control System identifies each Eurotherm Controller by an ID called Eurotherm Communication Card address To avoid communication conflicts each communication card should have a unique address There are up to eight autoclaves that can be connected to an UCA Control System so there should be eight different address settings for these communication cards The recommended settings are address 1 for channel 1 address no 2 for channel no 2 and so on Revision B 110 fa Fr UCA System User Manual 7 3 1 Error Message Test Signal for Machine 1 Error i 974 Problem amp Suggested Solution P The Data Acquisition system is not responding If this gn happens repeatedly it is recommended to restart the system If Problem persisits contact Technical Support C More Information Error 1073807346 occurred on 09 21 2007 at 04 34 36 PM VISA Flush I O Buffer in eE3500 Utility MODBUS RTU Send Message vi eb35
67. gram uses the latest value of offset from this calibration list to calculate the compressive strength Revision B 59 fa Fr UCA System User Manual 5 4 9 Help This opens the relevant online help documentation 5 4 10 Start Cal Pressing this button starts the actual calibration process This button then gets disabled as the actual calibration progresses At the end of the calibration the user will be prompted with the option to save the current calibration Refer to 5 5 Save Calibration for more details Never disconnect any coaxial cable on the UCA Autoclave or caution UCA Controller during calibration or testing Doing so can result in severe damage to the UCA Controller or UCA Autoclave 5 4 11 Exit Pressing this button lets the user close this window Related Topics 5 5 Save Calibration 3 3 2 Machine Interface 5 5 Save Calibration The save calibration window appears when the calibration process has finished and the program reaches its conclusion The window allows you to accept any calibration value It warns you however about the quality of the calibration readings Save Calibration Calibration Offset 12 8 Calibration Failure SAVE CANCEL Figure 5 9 Save calibration window 101443545 Revision B 60 fann Calibration 101443545 Calibration Offset Calibration Successful UCA System User Manual Calibration Offset The calibration offset calculated
68. he network Currently the data manager supports viewing of data written by UCA controller only Data Manager List of Features 6 1 Full re characterization of data 1s possible This includes cement type units of measurement Printing to printer and to a PDF file PDF printer must be installed saving data to spreadsheet file formats TXT and CSV strength and time events can be recast for any value Print with or without a user defined cursor Zoom to area for interest for viewing as well as printing Main Screen The data manager program allows the user to view re characterize and recast their data in a variety of ways It affords a simple user interface and has simple options to view print and export data to other file formats JN nore If the program is opened directly by the user it opens with no data loaded The program can be opened from within the UCA Controller Software In such cases the program opens with the current data of a test in progress The software can be maximized to occupy the entire screen and if he results graph is enlarged the user can see the graph in its entirety on the full screen 101443545 Revision B 97 UCA System User Manual Project Test ID Test My Test 4 My Reg R2D2 Customer Wed No Hali rton AT Wied hot Rigged Caung Liner Sie Cement Type Cement Viesght Test Date Test Time 11 Stand 11 56 Comments Strength 02 78 ROI PSli
69. he physical location needs to have access to the required electric hydraulic and cooling lines and be sufficiently sturdy to support the combined weight of the UCA Autoclave and sample chamber which can approach 150 pounds Ib 68 kg In routine cement slurry testing the 25 30 Ib 11 4 13 6 kg sample chamber must be lifted fully from the heating jacket a distance of about 10 in 25 cm Placing the top surface of the UCA Autoclave at 24 36 in 61 91 cm from the floor is an appropriate height for most people to lift the sample chamber Revision B 10 i fa Fr Fr UCA System User Manual 3 Features and Specifications Table 3 1 UCA Autoclave Specifications Cooling Supply and Drain e jOpsi min 0 07 MPa 212 F 100 C e Coolant Drain can be connected to water drain 1f water 1s used as coolant 230 Volts VAC single phase 50 60 Hertz Hz 20 ampere amp service National Electrical Manufacturers Association NEMA 6 15P plug provided Voltage and Current 101443545 Revision B 11 i fa Fr Fr UCA System User Manual Table 3 2 UCA Processor Specifications Width 2 inches 1n 53 centimeters cm him 2168650 Weight 30 pounds Ib 14 kilograms kg 115 or 230 Volts VAC single phase 50 60 Hertz Hz 15 ampere amp Voltage and Current service National Electrical Manufacturers Association NEMA 5 15P and 6 15P plugs provided Table 3 3 UCA Pressure Source
70. he volume reaches the Fill water to this level mark When performing tests without the sample sleeve the thermocouple MUST be fully removed BEFORE attempting to unscrew the test chamber lid Failure to remove the thermocouple results in it becoming bent and possibly unusable 5 7 5 4 Screw the sample chamber cap into the chamber Observe for water to be displaced through the high pressure connection or thermocouple hole in the cap The presence of water at either or both of these openings indicates the chamber 1s properly filled with water and excess air 1s displaced from the chamber 101443545 Revision B 73 UCA System User Manual Figure 5 20 Tightening top lid water expelled through open port Figure 5 21 Water coming out of test chamber lid 101443545 Revision B 74 UCA System User Manual Figure 5 22 Top lid fully tightened 5 7 5 5 Insert a thermocouple into the cap and fully tighten it 5 7 5 6 Clean the BNC connectors with a quick drying aerosol contact cleaner Connect a transducer to either end of the short coax cable Apply ultrasonic coupling gel to a transducer approximately 1 4 inch diameter by 1 8 inch thick Insert the transducer into the pocket in the sample chamber cap Figure 5 23 Coupling gel on transducer 101443545 Revision B 15 UCA System User Manual Figure 5 24 Inserting the transducer into the top lid 5 7 5 7 Slide a compression spring over
71. hese spikes occur when there 15 a sudden rapid voltage peak High voltage spikes are usually the result of nearby lightning strikes but there can be other causes as well Switching transients are commonly caused by arcing faults and static discharge In addition major power system switching disturbances initiated by the utilities to correct line problems may happen several times a day Power sags These are caused by voltages drop below normal for short periods of time Possible causes are heavy equipment being turned on large electrical motors being started and the switching of power mains internal or utility Electrical line noise Also defined as Radio Frequency Interference RFI and Electromagnetic Interference EMI and causes undesirable effects in the circuits of computer systems Sources of the problem include electric motors relays motor control devices broadcast transmissions microwave radiation and distant electrical storms etc Frequency variation These are changes in frequency from the normally stable utility frequency of 50 Hz to 60 Hz depending on the geographic location This may be caused by erratic operation of emergency generators or unstable frequency power sources Brownout This 1s caused a steady lower voltage state An example of a brownout happens during peak electrical demands in the summer when utilities can t always meet the requirements and must lower the voltage to limit maximum power Power failu
72. ine interface window can be resized by clicking the maximize button or by dragging the edge of the window to the desired size The respective plots will scale according to the size of the window E Machine 1 Elapsed Time Transit Time Comp Str Temperature Set Point 00 00 00 OE EL 4000 500 40 400 200 Transit Time Slurry Temperature 100 Compressive Strength 00 30 01 00 D1 30 02 00 02 30 03 30 04 00 04 30 Time hh mm volts V 45 581 S55 0 65 Transit Time 45 Machine Function gt Figure 3 5 Machine interface window 101443545 Revision B 17 fa System User Manual 3 3 2 1 Machine Interface Window 3 3 2 1 1 Title Bar The window title bar indicates which machine the window 1 referring to For example if Machine 1 is idle the window says Machine 1 If a test has been started on this machine it will change to Machine 1 Test Started Date lt Time gt where lt Date gt and Time refer to when the test was started 2 Machine 1 Figure 3 6 Title bar Double clicking on the title bar will maximize the window so that it occupies the entire screen space If the window 15 already maximized it will restore it to previous position and size 3 3 2 1 2 Elapsed Time This indicator displays elapsed time in HH MM SS format The elapsed time
73. items are to be returned Our correspondence address 1s Fann Instrument Company P O Box 4350 Houston Texas USA 77210 Telephone 281 871 4482 Toll Free 800 347 0450 FAX 281 871 4446 Email fannmail fann com Our shipping address is Fann Instrument Company 15112 Morales Road Gate 7 Houston Texas USA 77032 Revision B 141
74. lace a cloth around its open end to collect the flush water Open the Chamber Supply valve briefly to flush water through the disconnected high pressure line to remove any residue in the line Close the Chamber Supply valve Ensure the following settings on the UCA Autoclave e The power is OFF e The Chamber Vent valve is closed e The Chamber Supply valve is closed e The Coolant Supply is closed Remove the test chamber from the UCA Autoclave 5 8 3 1 Disconnect the cable from the transducer in the test chamber lid Revision B 94 fann 101443545 5 6 3 2 5 6 3 3 5 6 3 4 System User Manual Loosen the thumbscrew which retains the transducer in the top cap by no more than one full turn Use caution to keep the spring on top of the transducer from abruptly slipping from under the spacer washer Carefully slide the metal retaining clip away from the coax cable Remove the spacer washer and spring and then withdraw the transducer from the lid Using one hand on each of the test chamber handles and proper lifting techniques slowly lift the sample chamber assembly fully from the heating jacket Disassemble the test chamber 5 8 4 1 5 8 4 2 5 8 4 3 5 8 4 4 5 8 4 5 5 8 4 6 5 8 4 7 5 8 4 8 5 8 4 9 5 8 4 10 5 8 4 11 5 8 4 12 Place the test chamber in a vise clamping the bottom lid securely Remove the thermocouple from the lid not required if the sample sleeve was used
75. larm Summary Name ParameterDescription Value to select ORS to change Any Alum Any Alm a Comms v H Name ParameterDescription Value to select ORO to change Comms v J Name ParameterDescription Value to select ORO to change 101443545 Revision B 30 UCA System User Manual Comms Table Name ParameterDescription Value to select ORO to change Name to select Type Res n Units Gain TCI TC Ch 2 Gain PVFault PV Outl LoopOP CHI LoopOP CH2 Noise Offset 101443545 ParameterDescription Load type Output resolution PV units Load gain Time constant Time constant Relative gain Sensor fault First process value Loop output channel 1 Loop output channel 2 Noise added to PV Process offset Revision B Value ORS to change 10 31 UCA System User Manual Main Name ParameterDescription Value to select ORS to change ws Work OF IntHold Stop integral action No Setup _ Name ParameterDescription Value to select ORO to change Chl Control selects control algorithm Ch2 Control r m Tune Name ParameterDescription Value to select ORFO to change Time in the particular stage 101443545 Revision B 32 UCA System User Manual PID Name ParameterDescription Value to select ORS to change band 8 0 60 _ oo
76. ll Number of capies 1 s t Pages 1 Enter either a single page number a single page range Far example 5 12 Figure 6 6 Printer and PDF printer To save as PDF perform the following steps 6 5 1 In main screen choose menu item File gt Print This will open the print preview and print dialog boxes 6 5 2 In the print dialog box choose the PDF printer installed on your computer See above 6 5 3 Click the Print button 6 5 4 This will open a dialog for the user to choose the path and provide a file name of the PDF file to which to save the report Provide appropriate path and file name 6 5 5 This will print the test report as seen in the print preview dialog to a PDF file 6 5 6 If so configured the PDF file will open in the PDF viewer for user preview Related Topics 6 4 Printing Data 6 1 Main Screen 101443545 Revision B 106 fa Fr Fr UCA System User Manual 6 6 Saving for Spreadsheet Once a file has been opened in the data manager and any changes that a user desires has been made the test data can now be printed or saved to a file The process of saving to a spreadsheet compatible excel et al format 1s very easy Follow the following steps to save to file format of your choice 6 6 1 In main screen choose menu item File gt Save Then choose As CSV file or As TXT file based on which type of spreadsheet format the user desires 6 6 2 This will open a standard wind
77. lows the user to create a new profile from scratch If the test profile in the table does not match the profile on the NOTE machine warning appears inside the time temperature graph telling the user that the profile being seen is not the profile that will run when test is started The two ways to address this are to write the current profile in the table to temperature controller or read the existing profile in the temperature controller Figure 5 30 Warning NNNOTE If a machine uses Eurotherm 818P controller then the number of steps in the profile is limited to 8 This is the limitation of Eurotherm 818P controller 5 7 7 9 Temp Profile Tricks 5 7 7 9 1 Dwell for Limited time 101443545 Revision B 84 UCA System User Manual G w 3 3 m w m 3 0 0m 1035 09 8 0 28 _ 2 9 5 1 Dwell for limited time and unlimited time 5 7 7 9 3 100 150 In the above example the temperature stays at 150 deg for 3 hours as part of step 3 Since there is no change in temperature between steps 2 and 3 the temperature does not change only time does Dwell for Unlimited time In the above example the target temperature is 265 deg in 6 hours There are two ramps of 30 minutes and a dwell time at 150 deg for 3 hours Then ramp again for 2 hours to reach the target temperature Since there 1s no further step step 5 1s empty the program tri
78. m User Manual 4 Fi i E d A i j E EC XX s ae F l dd pe uir Figure 9 10 Feed sleeve cup Push the O ring seating tool through the feed sleeve and onto the bottom lid O ring Firmly press down on the handle while making up the lid chamber completely Remove the tool and sleeve 101443545 Revision B 139 UCA System User Manual 101443545 Revision B 140 fa Fr UCA System User Manual 10 Warranty and Returns 10 1 10 2 101443545 Warranty Fann Instrument Company warrants its products to be free from defects in material and workmanship for a period of 12 months from the time of shipment If repair or adjustment is necessary and has not been the result of abuse or misuse within the 12 month period please return freight prepaid and correction of the defect will be made without charge Out of warranty products will be repaired for a nominal charge Please refer to the accompanying warranty statement enclosed with the product Return of Items For your protection items being returned must be carefully packed to prevent damage in shipment and insured against possible damage or loss Fann will not be responsible for damage resulting from careless or insufficient packing Before returning items for any reason authorization must be obtained from Fann Instrument Company When applying for authorization please include information regarding the reason the
79. med This menu item becomes available only after the Copy row item has been clicked Once a row has been pasted this menu item is disabled and becomes available only after the Copy row menu item is clicked again 5 7 743 Delete row This deletes the step on which this context menu item is clicked 5 7 7 4 4 Insert row before This inserts a step of all zeroes before the current selected step 5 7 7 4 5 Empty Table This clears the entire table and user will have to start over again 101443545 Revision B 82 101443545 SN 3120 Jdel UCA System User Manual row Paste row befi ore Delete row Insert row before Empty Table Figure 5 29 Right click to edit steps Help This brings up the relevant on line help Read This reads the current temperature profile stored on the temperature controller on the autoclave This button is used for verifying that current temperature profile 15 correct for the test and can be used as part of the Start Test Wizard Write Once the user enters all the steps that make up the test profile he can send this test profile to the temperature controller on the autoclave by clicking this button The temperature controller will now hold the new profile and test will proceed according to the latest profile sent to the autoclave Revision B 83 fa Fr Fr UCA System User Manual 5 7 7 8 New Profile This button clears the current test profile and al
80. mments e Well No 101443545 Revision B 69 UCA System User Manual e File Path This field 1s entered using the Data file button as explained above e Find time to strength for following strengths Enter the strengths at which you want to record the time e Find strength at following times Enter times in hh mm format at which you want to record the strength A NOTE The default values for Customer List Cement Types Strength and Time Events can be set by using the Configure System menu item from the Main Screen see 3 3 1 Main Screen Stari lest Wirard Step 2 of 4 Verify your Test Profile 60 a 1 1 1 Li 1 n n a 00 00 02 00 04 00 06 00 10 00 12 00 14 00 16500 18 00 29000 22 00 24 00 25 00 Figure 5 34 Step 2 of 4 101443545 Revision B 90 Stari lost Wirard Step 3 of 4 Verify your Signal 101443545 5 7 9 6 Dar UCA System User Manual RT 5 Transit Time 5 17 98 Figure 5 35 Step 3 of 4 step 2 of 4 This step prompts the user to check the temperature profile that will be used to run the test This step encapsulates all the functionality of View Edit Test Profile section Follow the explanation in that section to understand this step The user may read edit and write a profile to the temperature controller from within the wizard Step 3 of 4 This step prompts the user to test the signal before startin
81. n test Clean the transducer BNC connector with a quick drying aerosol contact cleaner 5 31 7 Screw on the lid of the test chamber until it comes into contact with the calibration rod Both the lid and the base of the test chamber should be protruding about 74 in 2 cm to accommodate the calibration rod Figure 5 6 Chamber assembly with calibration rod 101443545 Revision B 56 101443545 5 3 1 8 3 991 9 5 3 1 10 UCA System User Manual Apply a thin layer of high temperature ultrasonic coupling gel to the ultrasonic transducer in the bottom of the chamber Lift the test chamber by the handles and place it into the chamber of the UCA Autoclave The test chamber will not fit all the way into the chamber because of the calibration rod Rotate the test chamber clockwise a full revolution to ensure that the chamber 1s firmly seated in the chamber to fully engage the bottom transducer Clean the transducer BNC connector with a quick drying aerosol contact cleaner Connect the thermocouple and the BNC connector to the test chamber lid Figure 5 7 Assembled test chamber with thermocouple and transducer Revision B 57 fa Fr Fr UCA System User Manual 5 3 1 11 Make sure the Heat switch 1s turned OFF and do NOT turn it on during calibration Doing so causes the foam centering ring to melt 5 4 Pulser Calibration Before ultrasonic testing can begin the user must establish a base line for ultrasonic
82. n troubleshooting when a variety of problems arise while operating the UCA Autoclave Included in the tables are symptoms of the problem possible causes of the problem and possible solutions to the problem The tables are grouped according to topic The following troubleshooting tables are provided in this section General troubleshooting Temperature troubleshooting Pressure troubleshooting End caps troubleshooting Revision B 114 fann UCA System User Manual Table 7 1 Problems with General System Problem or Symptom Possible Cause Corrective Action Check replace the power fuses located on the back of the unit See Figures 7 5 and 7 6 The power switch has Check replace the power malfunctioned or failed switch Check repair the power wiring Refer to the wiring diagram The power source 1s disconnected or turned off Check the power source Table 7 2 Problems with Temperature Problem or Symptom Possible Cause Corrective Action Check repair the heater wiring Refer to the wiring diagram The power fuses are blown The system does not power up The power wiring is faulty The heater wiring 1s faulty The over temperature Check and or replace the The system does not heat up but the heater indicator in the temperature controller 1s on The system does not heat up and the heater light is off The temperature reading 1s unreasonably high lt 1 000 F 101443545 switch has failed o
83. nsure all the relevant information about the test Revision B 87 UCA System User Manual GETTIBLZSTB ISI Step 1 of 4 Please enter information about the test below Find Time to Strength for following Strengths PST 0 3 0 0 Find Strength at Times homm 00 00 Figure 5 32 Step 1 of 4 5 7 9 5 1 Test Information The user must enter all relevant information about the test here The following fields are necessary e Lab Name e Project name e Test ID e Tested By e File name This field cannot be directly typed in Use the Data File button to open a standard window file dialog and navigate to the folder where you want to save the data file Enter the desired file name and click OK 101443545 Revision B 88 UCA System User Manual Save m 1 1 tme 1 Navigate to E desired folder 4 tdms 19 tdms E qvem 6 tdms 36 tdms Mi M2 dms 1 Enter desired File Name TOMS tdm Figure 5 33 Test information Other fields in the test information step are e Request ID e Customer The customer field is a free text field with a drop down list The drop down list allows the user to pick a customer from the list e Rig e Casing Liner Size e Job Type e Cement Type The Cement type 1s identical to Customer field above e Cement Weight Pick from standard light weight or high density e Co
84. old as much as 20 000 psi These lines are in OD stainless steel Operators must ensure that the pressure in these lines has been reduced to zero before attempting to disassemble any high pressure lines Open the Chamber Vent valve shown in the section on Controls and Indicators Confirm that all pressure in the system has been relieved using the pressure gauge on the front panel lemperature The pressure chamber has an electric heating jacket that can heat the cement slurry to 400 F 205 C The metal jacket itself can be considerably hotter Before removing the pressure chamber or performing any work on the heating Jacket use the cooling system to lower the temperature to at least 120 F 49 C Monitor the temperature by observing the temperature controller display when the chamber is in the heating jacket The coolant return line can be very hot 212 F 100 C at the beginning of a post test cool down Electrical The power source for the UCA Autoclave 15 230 Volts There are still electrically active terminals inside the instrument when the power switch 1s turned off Disconnect the power from the plug before attempting any electrical or mechanical maintenance Refer to the electrical schematic before performing any maintenance or troubleshooting Revision B 9 fa Fr Fr UCA System User Manual 2 2 101443545 Ergonomic Considerations After the UCA Autoclave is installed it is uncommon for it to be frequently moved T
85. on 1 2 od mm 2 bi U AAN INE 5 ko NPS SU O 7 2 9 P MENS ET eran ZORRO 9 22 Pie Omni tas tis 10 3 Features and 11 Sd UCA Autoclave Mechanical 12 3 2 UCA Autoclave Controls and Indicators eene 13 SX MEG Nui O 13 3 4 Autoclave Temperature Controller Software 0 24 o UCA Pressu uen UM MEE 38 EN 2 39 4 1 P rtsof the 3 39 39 kwo Tower SUPPI y 39 Aa H E E 39 25 UCA Pressure SOULCO 39 4 6 Autoclave and Processor 4 4 7 Processor System Configuration nnns 44 4 8 Select Machine Quadrants seeeeessseeeeene eee 49 CO Ua ee asic ese ce eet ree 51 NEG S CHUTE 51 32 Transit Time 07 ON 51 5 3 Assemble the Sample Chamber for Calibration eeeeeeseeeeess 52 3A Paker CANOE 58
86. ort will contain the following information All the information as present in the test header All events and their results The units of measurement The results graph will be printed as seen on the main screen If the cursor has been enabled on the result graph it will print The name of the data file will be printed 101443545 Revision B 103 UCA System User Manual 3 Print Preview x Fann R amp D PSIat 02 28 PSlat 0306 PSIat 07 08 Tm i T 1210 3 me mL 15805 1501 S 7 5 7 Die EIL E Lad L PJ i oa m 9 perg 30 i 120 1000 4 E d 500 s T i i E i i 10 00 40200 50500 60 00 Time hh mm Data File C LabVIEW 5 MZ 030507 tdms eg LLL Figure 6 4 Print preview screen The print preview screen is shown above This screen cannot be edited In fact a print dialog window will open on top of this window where the user can choose to print or cancel the process If canceled both windows will close As can be seen the items in the printed test report are identical to that of the test header The items are however repositioned to fit on a single page of paper and the printing is optimized to save ink It is recommended that a color printer be used to print the test NOTE 101443545 Revision B 104 UCA System User Manual
87. ows dialog box Navigate to the desired folder and provide a file name in which to save the data Spreadsheet File to save to Save TestData Mz2_O90607 tdpae ir TEST T Recent D acuments 1 Navigate to desired folder Desktop Documents 2 Type in lt a desired m File name ENALISODURZ293 2 3 Click Save cm My Network File name 2 090507 tdms Flaces Save type Text File 181 L ancel Figure 6 7 Windows dialog box 6 6 3 Click Save and the file will be saved Related Topics 6 1 Main Screen 101443545 Revision B 107 101443545 Revision B UCA System User Manual 108 fa Fr Fr UCA System User Manual 7 Troubleshooting and Maintenance 7 1 101443545 Restoring Interrupted Tests There are times when a running test is terminated abnormally This is usually caused by power supply related problems or a software related failure The UCA Controller System s electronic components are affected by the followings problems listed in the following paragraphs Any of these problems will cause data error data loss keyboard lockup and system lockup in the system Please note that these problems are common to all electronic devices Power surge The most common cause 1s heavy electrical equipment in you labs or other equipment that are drawing power on the same electrical circuit being turned off High voltage spikes switching transients T
88. ration rod and foam centering ring are not used Check the sealing components of the upper and lower covers of the test chamber The sealing components are the O rings metal sealing rings and retaining rings Verify that they are in good condition 1f not in good condition replace them Apply a very light film of high temperature grease to the inside of the two covers up to the O rings Apply a light film of Hitempco coupling agent or high temperature grease to the O ring surface Apply a very light film of high temperature grease throughout the inside of the test chamber body up to the threads Place the lower cover base in a vise with the threaded end pointing up A reusable sleeve is available to create samples suitable for a crush tests on a cured cement slurry sample If used grease the sleeve heavily on all surfaces and then insert the sleeve firmly into the base Revision B 67 UCA System User Manual Figure 5 13 Groove in bottom test chamber lid for sample sleeve 5 7 4 7 Apply a heavy layer of grease to the threads of the upper and lower lids 5 7 4 8 Screw the test chamber body bottom down fully onto the base It may be necessary to use the O ring Seating Tool and Feed TE Sleeve to keep the bottom lid O ring from becoming displaced NO while threading on the test chamber body See 9 Parts List for instructions 101443545 Revision B 68 UCA System User Manual Figure 5 14 Seating sample
89. rce of coolant water to the WATER IN port on the rear of the UCA Pressure Source 4 5 4 Connect a drain to the DRAIN port on the rear of the UCA Pressure Source 4 5 5 Connect high pressure tubing to the HIGH PRESSURE OUT port on the rear of the UCA Pressure Source This tubing may be connected directly to a UCA Autoclave or to multiple UCA Autoclaves through a manifold system 4 5 6 Purge air from the system 4 5 6 1 each Autoclave close the high pressure valve nearest the UCA Autoclave and the Chamber Supply valve on the UCA Autoclave 101443545 Revision B 40 4 5 6 2 4 5 6 3 4 5 6 4 4 5 6 5 4 5 6 6 4 5 6 7 UCA System User Manual Turn on the air and water supply to the UCA Pressure Source Adjust the UCA Pressure Source air regulator until the pressure 15 just high enough to operate the pump Starting with the Autoclave that 1 closest to the UCA Pressure source open the high pressure valve s until a solid stream of fluid flows from the open connection Close the valve Repeat the process in 4 5 6 4 working away from the pressure source until all the air has been removed from the supply manifold Adjust the UCA Pressure Source air regulator until the pump stops The UCA Pressure Source is ready for use 4 6 UCA Autoclave and UCA Processor Connections 4 6 1 Two coaxial cables labeled Data
90. re or blackout It may be caused by the tripping of a circuit breaker power distribution failure or utility power failure Revision B 109 fa Fr Fr UCA System User Manual 7 2 The UCA Controller System 1s configured with an external uninterrupted power supply UPS that provides protection against most of the problems listed above but not all To restore an abnormally terminated cement test do the following 1 Restart the Controller On your keyboard depress and hold Ctrl Alt keys and tap the delete key one time Window Security Dialog box appears Click on Shut down button Shutdown Windows Dialog appears Select Restart option from the list box then click OK button to restart your UCA Controller System 2 When you see the computer desk top screen wait for an additional one or two minutes to allow time for the UCA database software engine to get started then click on the shortcut UCA icon to start the software Test Ultrasonic Signal Before running a cement test on a particular channel you should make sure that various tasks such as BNC cable ultrasonic transducer and high pressure tubing connections are setup properly In addition to visually inspecting these components you should also perform an ultrasonic signal test as well In this test the UCA Control System applies an ultrasonic pulse to the cement slurry sample and graphically displays the sound wave that travels through the sample By visually inspectin
91. rs A thermocouple calibrator must be used when checking the controller 7 4 1 To Check Thermocouple Input Calibrations Connect a milli volt source traceable to national standards to terminals V and V as shown in the diagram below The mV source must be capable of simulating the thermocouple cold junction temperature It must be connected to the instrument using the correct type of thermocouple compensating cable for the thermocouple in use Controller Thermocouple Thermocouple 101443545 Compensating cable simulator set to T C type Figure 7 2 Connection for thermocouple calibration Set the mV source to the same thermocouple type as that configured in the controller Adjust the mV source to the minimum range For a type J thermocouple for example the minimum range is 210 C However if it has been restricted using the Range Low parameter then set the mV source to this limit Check that the reading on the display is within 0 25 of reading ILSD Adjust the mV source for to the maximum range For a type J thermocouple for example the maximum range is 1200 C Revision B 112 fa Fr Fr UCA System User Manual However if it has been restricted using the Range High parameter then set the mV source to this limit Check that the reading on the display is within 0 25 of reading ILSD Intermediate points may be similarly checked if required 7 4 1 1 Thermocouple Calibration Thermocouples are calibr
92. s 416 9 Strength 10 D 3 04 1248 PSI is H3 Strength Polis 1060 2 Strength ib PSlis 1210 3 Strength Uras v Temp Units deg TTE ILLIS 1 L i T 1 1 So 45300 5000 550 65000 65500 55100 SOOO Yo Time hihi Data Ale C LabVIEW B SATestDatalMw2 090607 teme Figure 6 1 Main screen full screen view 6 1 1 Menu Bar Menu bar allows the user to access some of the overall functions of the program Use the menu bar to perform a variety of functions with the data you want to view Refer to 6 3 Recharacterizing Data 6 1 1 1 File 6 1 1 1 1 Open This opens a standard windows dialog box through which the user can navigate to a folder and pick a data file to view in the data manager 101443545 Revision B 98 UCA System User Manual 6 1 1 1 2 Save Use this option to save data to a file for viewing later in a spreadsheet program Refer to Saving for Spreadsheet section for more details 6 1 1 1 3 Print Use this option to print a report about the test Refer to 6 4 Printing Data for more details Also refer to 6 5 Printing to PDF for using PDF printers 6 1 1 1 4 Exit Selecting this menu item exits the program 6 1 1 2 Help 6 1 1 2 1 Online Help This brings up the online help for this program 6 1 1 2 2 About This brings up an about this program dialog box which lists the copyright and version information about the program 6 2 Test Head
93. signal The concept of calibrating the cell is to zero the time delays that may be present in electronics associated with ultrasonic transducers The pulser calibration window relates to software portion of the calibration There are physical steps that need to be accomplished before invoking this window and proceeding with the calibration Refer to appropriate documentation to learn about steps that need to be taken for performing pulser calibration Pulser Calibration for Machine 1 o 8 5 Transit Time 45 Avg 10 AVG Std Dev Err Offset Figure 5 8 Pulser Calibration window 5 4 1 Title Bar The title bar indicates for which machine the pulser calibration 1s being performed 54 2 Signal Graph The ultrasonic signal is pulsed as part of calibration The received signal is plotted on the signal graph The graph plots transit time us against the signal amplitude The signal shown on this graph 101443545 Revision B 58 fa Fr Fr UCA System User Manual 101443545 5 4 3 5 4 4 5 4 5 5 4 6 5 4 7 5 4 8 is for reference and all the relevant calculations necessary for calibration are performed automatically by the program Current Reading When calibration is begun the system sends ultrasonic pulses through the calibration cell and measures the transit time This process is repeated 10 times As the calibration progresses through each iteration the transit time values in us recovered by the sys
94. strength Data Manager List of Features e Full recharacterization of data is possible if the operator makes an error at initial data entry This includes cement type and units of measurement e Print to printer or PDF file in accompanying data manager software e Data can be saved to spreadsheet file formats such as TXT and CSV e Strength and time events can be recast for any value e Print with or without a user defined cursor e Zoom to an area of interest Revision B 3 UCA System User Manual Figure 1 1 UCA processor front view 101443545 Revision B 4 1 4 101443545 A 2 2 m F CFR 2 js 222 72 Fi n 32 PAGES System User Manual e VIS o v NT oy 4d E Hm ud 1 PI uu a ee i 2777 2227 2 7 274 4 Wap Figure 1 2 processor back view UCA Autoclave The UCA Autoclave contains the cement slurry sample under test in a high strength steel test chamber suitable for tests up to 20 000 psi and 400 F This test chamber holds a metal sheathed thermocouple in direct contact with the cement slurry or in the water surrounding the sample Two ultrasonic transducers are centrally located above and below the sample to permit transit time measurement A spring loaded heating jacket maintains
95. tem are displayed in the current reading window Avg The average arithmetic mean of all values read during calibration process 1s shown here The average should not be too far off the values displayed in the current reading indicator Std Dev The standard deviation of all values read 1s indicated here The standard deviation indicates how far off the individual iteration values are form each other The closer to each other the individual transit time values are the lower the standard deviation This 1s a great way to determine if the system is consistent and repeatable Err Percentage error is another way of determining that the system 15 performing reliably Percentage error 1s calculated by comparing the average vale to each of the individual values and calculating the error Offset The offset is the actual calibration number we are interested in By using a steel calibration bar we know what the transit time of the ultrasonic signal should be By measuring the actual transit time and comparing it to the theoretical value we calculate the offset associated with the cell walls and all associated electronics This offset is used in determining the correct transit time of a cement sample History The history window shows the results of all past calibrations The 10 transit time values average standard deviation percentage error and offset values are shown as well as the date this calibration was performed The pro
96. the sending of the ultrasonic pulse through the sample inside the autoclave and in return measures the ultrasonic waveform at the other end of the sample The software then analyzes this to calculate the transit time Because the software knows the initial transit time the software can calculate the compressive strength for each subsequent transit time measurement At the same time the software also measures the current temperature and setpoint and plots all the information on an easy to see results graph The software also communicates with the temperature controller in the autoclave to read and write the desired temperature profile information 1 3 1 Features 1 3 1 1 Controller List of Features e Up to eight autoclaves can be controlled and monitored independently e Temperature Profile on the autoclave can be read or written to by the controller e Results graph can be maximized to any size up to full screen e Cursor can be put on the results graph to read out any point on the graph e Graph can be zoomed into to view more details e Start Test Wizard walks the user through starting a test e Fool proof wizard prevents starting a test before all steps are completed e Up to four strength events can set by the user to trigger and record the resultant time Revision B 2 101443545 1 3 1 2 System User Manual e Up to four time events can be set by the user to trigger and record the resultant
97. the coax cable and up to the back of the transducer 5 7 5 8 Secure the transducer into the sample chamber cap with the spacer washer retaining bracket and thumb screw 101443545 Revision B 76 UCA System User Manual PS 7 ae ee Ten fi TE NS Fo E c E me T 7 g apa EY a othe se T Br n RR TE o 47 E NL TM E sts T pr ae M E oou cR V Ra P E P fait 4 ye e No p 7 De Figure 5 25 Assembled test chamber with thermocouple and transducer 5 7 5 9 Look inside the heating jacket to verify that the bottom transducer and compression spring are in place Clean the BNC connectors with a quick drying aerosol contact cleaner Apply ultrasonic coupling gel to a transducer approximately 1 4 inch diameter by 1 8 inch thick Place the transducer and spring into the tube extending upwards from the heating jacket base 101443545 Revision B 77 101443545 UCA System User Manual 5 7 5 10 5 7 5 11 MIS M Darel 5 7 5 14 5 7 5 15 5 7 5 16 5 7 5 18 Figure 5 26 Bottom transducer in heating jacket Lift the assembled test chamber by the handles and slowly lower it into the UCA Autoclave heating jacket Rotate the test chamber clockwise one full revolution to ensure that the chamber 1s firmly seated in the heating jacket Connect the high pressure U Tube to the test chamb
98. ue 7 Once the value is changed to what is desired press the P button to go to next item Set the Config items to the values identified as per steps 9 through 16 below 9 C1 4100 10 C2 0000 11 C3 0000 12 C4 1555 13 C5 0000 14 C6 1105 15 C7 0500 16 C8 4003 17 ADD Respective address of the unit from to 8 The address entry will take the form of 0 1 0 2 0 3 etc for addresses 1 2 3 etc respectively Do not use 1 0 2 0 etc for addresses 101443545 Revision B 42 i fa Fr UCA System User Manual 18 Scroll to Clr using the P button 19 Press both UP DN arrows simultaneously till you see the Clr blink twice This is Important to save all changes 20 Switch off the controller and remove from sleeve 21 Move jumper back to DISBALED Open to put the unit in Run mode 22 Put the unit back in the sleeve and switch on Make sure the unit 1 sitting flush with the sleeve by tightening the screw located inside the door Switch on the power You are in Normal mode 4 6 2 2 For autoclaves with Eurotherm Model 3504 Press A button till you see Config After a second it will prompt to enter Pass Code 8 times to go to Comms Menu Press to scroll to different items Press A button to change the value of these items Set the value of following items as follows Protocol MODBUS Baud Rate 9600 Parity None Address 1 for Machine 1 2 for Machine 2 and so on
99. ue of the PV input PV Current value of the PV input after linearization 101443545 Revision B 27 UCA System User Manual PV Input _ Name ParameterDescription Value to select ORO to change Offset Constant offset to the PV Lo Point Allows a two point offset Lo Offset to be applied to the controller to compensate for sensor or connection Hi Point errors between sensor and Hi Offset the input to the controller Temperature of the rear terminals SBrk Value Sensor break Value Cal State Calibration state Idle LgclO LA LgclO LB Name ParameterDescription Value to select ORO to change IO Type IO Type 101443545 Revision B 28 UCA System User Manual Rly AA on ParameterDescription Ov select Meas Val o fy fo S ID Name ParameterDescription Value to select ORO to change Module 1 Module SingLogic Module 2 No Module Module 3 No Module Module 4 No Module Module 5 No Module Module 6 No Module Name ParameterDescription Value to select ORO to change Ident Channel type Logic Out IO Type Relay function Time Prop Min OnTime The minimum logic on time 0 01 Disp Hi Max output signal Disp Lo Min output signal Range Hi Electrical output high Range Lo Electrical output low SbyAct standby action Meas Value Digital output status PV PID output 101443545 Revision B 29 UCA System User Manual A
100. utton to discard it and attempt another calibration A NOTE Closing the window using the standard windows close button in the top left corner of the window is akin to using the cancel button and discarding the calibration Related Topics 5 4 Pulser Calibration 5 6 Remove the Test Chamber 5 6 1 To remove the test chamber perform the following steps 5 6 1 1 Disconnect the thermocouple and BNC connector from the test chamber lid 5 6 1 2 Remove the test chamber from the chamber 5 6 1 3 Place the chamber in a vise with the vise clamped around the base 5 6 1 4 Unscrew and remove the lid and the test chamber body Remove the calibration bar and the sleeve 5 6 1 5 Clean transducers with a clean dry cloth only Many solvents will damage the transducer 5 6 1 6 Clean all the parts in a solvent appropriate for the high temperature grease used when assembling the chamber 5 6 1 7 Inspect the O rings metal sealing rings and retaining rings for damage or corrosion Replace them if necessary 5 7 Running a Test Sol After all configurations and calibrations have been completed tests may be run using the UCA Controller The followings are an outline of steps that are involved in running a test Program the Eurotherm Temperature Controller for a test 101443545 Revision B 62 fa Fr Fr UCA System User Manual 101443545 Setting Time and Cement Strength alarms This is an optional step If you are using the default alarm
101. ver temp switch The heater malfunctioned or failed Check and or replace the heater Solid state heater relay has failed Check replace if necessary The heater fuses are blown the heater Check the heater solid state relay and the heater circuit wiring Refer to the wiring diagram The heater s control electronics malfunctioned or failed Look for and repair the broken wire or loose connection Possible open circuit in thermocouple or thermocouple cables Revision B 115 UCA System User Manual Problem or Symptom Possible Cause Corrective Action The temperature reading 1s about room temperature even though the chamber 15 hot Possible short circuit in Look for and repair the thermocouple or short in the thermocouple or thermocouple cables thermocouple cables The water control valve 15 Open the water control closed valve The water supply plumbing System does not cool Check and clear the water kinked The water source is heck th disconnected or turned off Table 7 3 Problems with Pressure Problem or Symptom Possible Cause Corrective Action The high pressure plumbing Check clear the high lines are obstructed pressure plumbing lines The system does not Tae Replace the rupture disc limit was exceeded pressure up Check repair or replace pressure system plumbing Refer to schematic supply plumbing lines The pressure
102. wer cord with a NEMA 6 15P plug Because of the diversity in types of electrical outlets throughout the world it may be necessary to replace this plug Alternatively the UCA Autoclave can be directly wired into an electrical disconnect switch Regardless of the connection ensure that proper power 1s provided The electric power supply must be 230 VAC single phase 20 amp and 50 60 Hz Hydraulic Supply 4 4 1 4 4 2 4 4 3 Three hydraulic connection ports are located on the back of the as shown in Figure 1 4 The two female National Pipe Thread ports are for cooling water inlet and drain Flexible tubing is recommended for the cooling water inlet and drain connections The upper of the two ports is the cooling water inlet and the lower is the drain The F250C Autoclave high pressure port connects the UCA Autoclave to an external pressure source and or manifold Reference See 3 Features and Specifications for the specifications of the cooling supply and drain UCA Pressure Source 4 5 1 Locate the UCA Pressure Source relative to the UCA Autoclave s as desired Depending on the distance high pressure tubing and fittings in addition to those provided may be necessary The UCA Pressure Source should be lower than the UCA Autoclave s Revision B 39 fa Fr UCA System User Manual 4 5 2 Connect a source of compressed air to the AIR IN port on the rear of the UCA Pressure Source 4 5 3 Connect a sou
103. y continuously holding the left mouse button at this point to progressively zoom into it The zoom extents menu discards the zoom tool and reverts the graph back to show the complete graph in its default state When a data file is opened the X axis and Y axis of the result graph are automatically scaled such that the data fits cleanly and occupies optimum space for ease of reading Data File This indicator shows the path and file name of the test data file currently loaded in the data manager This field cannot be edited Revision B 101 fa Fr UCA System User Manual Related Topics 6 5 Printing to PDF 6 6 Saving for Spreadsheet 6 4 Printing Data 6 3 Recharacterizing Data 6 3 Recharacterizing Data The data manager allows the user to change any of the test header information and creating a test report with modified information There are two impacts that result due to any change in the test header information 1 Changes to certain fields do not have any impact on test results The field itself is changed but data remains intact For example changing the customer name changes the name of the customer on the test report but has no impact on the test data 2 There are fields which when changed will have impact on the results graph and also on event data e Changing cement type and strength units will change the results graph and event data and event results e Changing temperature units only changes the results gr

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