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Model 9000 Drilling Fluids Simulator

Part Number 9000-1050

Revision 4 - 9/05/08

S/N _________________

P.O. Box 470710

Tulsa, Oklahoma 74147 Phone: 918-250-7200 FAX: 918-459-0165

Email: [email protected] Website: www.chandlereng.com

Copyright 2007-2008, by Chandler Engineering Company L.L.C.

All rights reserved. Reproduction or use of contents in any manner is prohibited without express permission from Chandler Engineering Company L.L.C. While every precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein.

TABLE OF CONTENTS i

TABLE OF CONTENTS General Information ................................................................. P-1

Introduction ........................................................................................................................... P-1 Purpose and Use ............................................................................................................... P-1 Description ....................................................................................................................... P-2

Theory .................................................................................................................................... P-3 Permeability Calculation .................................................................................................. P-3 Formulas Used for Permeability ...................................................................................... P-3

Features and Benefits ............................................................................................................ P-4 Specifications ........................................................................................................................ P-4 Safety Requirements .............................................................................................................. P-5 Where to Find Help ............................................................................................................... P-5

Section 1 - Installation ............................................................. 1-1

Unpacking the Instrument ..................................................................................................... 1-1 Transporting the Oven Assembly .......................................................................................... 1-1

Equipment Required ........................................................................................................ 1-1 Drain Pipe Locations – Caution!...................................................................................... 1-1

Utilities Required ................................................................................................................... 1-2 Setting up the Instrument ....................................................................................................... 1-2 Electrical Connections ........................................................................................................... 1-2

Instrument Power ............................................................................................................. 1-2 Ethernet Cable .................................................................................................................. 1-3 Serial Expander ................................................................................................................ 1-3 Transducer Cables ............................................................................................................ 1-3 Temperature Controller Serial Cable ............................................................................... 1-3 Alarm Scanner Serial Cable ............................................................................................. 1-3 Balance Serial Cable ........................................................................................................ 1-3 Nitrogen Flow Controller Interface Cable ....................................................................... 1-4 Oven Door Actuator Cable .............................................................................................. 1-4 Sample Fluid Selection Valve Cable ............................................................................... 1-4 Power Distribution ........................................................................................................... 1-4

Pneumatic Connections ......................................................................................................... 1-4 Water Connection .................................................................................................................. 1-4 Nitrogen Connection ............................................................................................................. 1-4 Drain Connections ................................................................................................................. 1-5 UPS (Uninterruptible Power Supply) Recommendations ..................................................... 1-5 Minimum System Requirements for PC ................................................................................ 1-5

Section 2 - Operation ............................................................... 2-1

Components – Location, Description and Purpose ............................................................... 2-1 Air Regulators .................................................................................................................. 2-1 Inlet Filters ....................................................................................................................... 2-3 Core Holder ...................................................................................................................... 2-3 High-Precision Differential Pressure Transducers ........................................................... 2-6 High-Precision Pressure Transducers .............................................................................. 2-6

ii TABLE OF CONTENTS

Fluid-Recirculation System Pressure Transducers .......................................................... 2-7 Nitrogen Pressure Transducer .......................................................................................... 2-7 Sample Injection Pump .................................................................................................... 2-8 Sample Fluid Selection Valves ........................................................................................ 2-9 High-Viscosity Fluid Delivery Accumulators ............................................................... 2-10 Fluid Recirculation Accumulators ................................................................................. 2-10 Fluid Recirculation Pump .............................................................................................. 2-11 Fluid Recirculation Oil Reservoir .................................................................................. 2-12 Back Pressure Regulators .............................................................................................. 2-13 Back Pressure Regulator Control Pump ........................................................................ 2-14 Sand Injection Accumulator .......................................................................................... 2-15 Sand Injection Screen Filter Valve ................................................................................ 2-16 Sand Injection / Screen Placement Selection Valve ...................................................... 2-17 Sand Injection Accumulator Isolation Valve ................................................................. 2-18 Sand Injection / Screen Placement Pump Cylinder ....................................................... 2-19 Confining Oil Pump Cylinder ........................................................................................ 2-20 Confining Oil Reservoir ................................................................................................. 2-21 4-Way Valve .................................................................................................................. 2-21 Cone and Seat Valves .................................................................................................... 2-22 Cartridge Valves ............................................................................................................ 2-22 Vindum Shuttle Valves .................................................................................................. 2-23 Nitrogen Flow Controller ............................................................................................... 2-23 Nitrogen Pressure Regulator .......................................................................................... 2-24 Nitrogen Shut-Off Valve................................................................................................ 2-24 Nitrogen Humidifier ....................................................................................................... 2-25 Fluid Preparation Cart .................................................................................................... 2-25 Fluid Transfer Pump ...................................................................................................... 2-26 Front Control Panels ...................................................................................................... 2-27

Lower-Right Panel ................................................................................................... 2-27 Upper-Right Panel ................................................................................................... 2-30 Lower-Left Panel ..................................................................................................... 2-31 Upper-Left Panel ...................................................................................................... 2-34

Power Distribution / Heater Control Cabinet................................................................. 2-35 Temperature Controller ............................................................................................ 2-35 Alarm Scanner ......................................................................................................... 2-35 Heater Contactors..................................................................................................... 2-36 Solid State Relays .................................................................................................... 2-36 Fuses ........................................................................................................................ 2-36 Circuit Breakers ....................................................................................................... 2-37 Power Strip............................................................................................................... 2-37

Thermocouples ............................................................................................................... 2-38 Thermocouple Connections ........................................................................................... 2-39 Electronic Balance ......................................................................................................... 2-39 Data Acquisition / Valve Control Cabinet ..................................................................... 2-40

Data Acquisition Modules ....................................................................................... 2-40 Air Solenoid Valves ................................................................................................. 2-41 Serial Hub ................................................................................................................ 2-41 Fuses ........................................................................................................................ 2-42 Panel Connections .................................................................................................... 2-42

TABLE OF CONTENTS iii

Oil Filter ......................................................................................................................... 2-43 Hastelloy Fluid Path Filters ........................................................................................... 2-43 Oven Door Actuators ..................................................................................................... 2-44

Software Organization ......................................................................................................... 2-45 Program Components and Directories ........................................................................... 2-45 Starting and Exiting the Program ................................................................................... 2-45 On-Line Help ................................................................................................................. 2-45

Description of Primary Software Functions ........................................................................ 2-46 Permeameter Screen ....................................................................................................... 2-46

Menus ....................................................................................................................... 2-47 Numeric and Slider Controls and Indicators ............................................................ 2-49

Fluid Recirculation Screen ............................................................................................. 2-55 On-Screen Data Plotting ................................................................................................ 2-58 Schedule Editor Screen .................................................................................................. 2-59 Units Screen ................................................................................................................... 2-59 Calibration Screen .......................................................................................................... 2-60 Viscosities Screen .......................................................................................................... 2-61 Alarms Screen ................................................................................................................ 2-62 Communications Screen ................................................................................................ 2-63 Core Holder Screen ........................................................................................................ 2-64 Alarm Monitor Screen ................................................................................................... 2-65

Monitored Alarms .................................................................................................... 2-66 PumpWorks Settings ...................................................................................................... 2-66

Safety Pressures ....................................................................................................... 2-67 Operating Modes ...................................................................................................... 2-67 Sequencer Operation – Evacuating the Confining Oil ............................................. 2-67 Pump Tuning Parameters ......................................................................................... 2-67 Soft Limits ............................................................................................................... 2-68 Error Log .................................................................................................................. 2-68

Core Preparation .................................................................................................................. 2-68 Loading the Core Sample .................................................................................................... 2-69 Loading a Drilling Fluid ...................................................................................................... 2-70 Filling the Sand Injection Accumulator .............................................................................. 2-71 Injecting Sand (Simulated Gravel Pack) ............................................................................. 2-72 Dynamic Screen Placement ................................................................................................. 2-73

Required Screen Dimensions ......................................................................................... 2-73 Preparing the screen for a test ........................................................................................ 2-73 Operating a Test without a Screen ................................................................................. 2-74 Changing the Screen Adapter ........................................................................................ 2-75 Setting the Maximum Slot Height ................................................................................. 2-76

Nitrogen Permeability Measurement ................................................................................... 2-76 Filling the Nitrogen Humidifier ..................................................................................... 2-76

Starting a Permeability Test ................................................................................................ 2-77 Recirculating Fluids ............................................................................................................. 2-78 Dynamic Mud-Off ............................................................................................................... 2-79 Static Mud-Off ..................................................................................................................... 2-79 Test Clean-up ....................................................................................................................... 2-79 Unloading a Drilling Fluid .................................................................................................. 2-80 Cleaning the Fluid Recirculation System ............................................................................ 2-80

iv TABLE OF CONTENTS

Unloading the Core Sample ................................................................................................. 2-81 Notes on Confining Pressure ............................................................................................... 2-82

Section 3 - Maintenance ........................................................... 3-1

Core Holder Assembly / Disassembly ................................................................................... 3-1 Back Pressure Regulator Diaphragm Replacement ............................................................... 3-7 Filling the Confining Oil ....................................................................................................... 3-9 Evacuating the Confining Oil .............................................................................................. 3-11 Oil Filter Replacement ........................................................................................................ 3-12 Cone and Seat Valve Service .............................................................................................. 3-12

Replacing a Valve Seat (Ring) ....................................................................................... 3-12 Replacing a Valve Cone (Stem) ..................................................................................... 3-13 Adjusting the Valve Packing ......................................................................................... 3-15

Cartridge Valve Replacement / Repair ................................................................................ 3-15 Replacing the 4-Way Valve Rotor ...................................................................................... 3-16 Re-Installing Software and Drivers ..................................................................................... 3-17

Network Settings ............................................................................................................ 3-17 Quizix PumpWorks ........................................................................................................ 3-22 9000DACS and 9000Utils ............................................................................................. 3-22 Comtrol Devicemaster RTS 8-Port Serial Hub .............................................................. 3-23 WatView Software ......................................................................................................... 3-45

Maintenance Schedule ......................................................................................................... 3-46

Section 4 - Troubleshooting Guide .......................................... 4-1

Potential Problems and Solutions .......................................................................................... 4-1

Section 5 – Replacement Parts ................................................. 5-1

Section 6 – Drawings and Schematics ..................................... 6-1

TABLE OF CONTENTS v

List of Figures Figure 1 - Model 9000 Drilling Fluids Simulator .................................................................................... P-1 Figure 2 - Circuit Breakers ...................................................................................................................... 1-2 Figure 3 - Bottom Panel of Rear Electrical Enclosure ............................................................................. 1-3 Figure 4 - Main Air Regulator ................................................................................................................. 2-1 Figure 5 - Confining Oil Fill Tank Regulator .......................................................................................... 2-1 Figure 6 - Fluid Transfer Pump Controls ................................................................................................. 2-2 Figure 7 - Recirculation Oil Fill Tank Controls ....................................................................................... 2-2 Figure 8 - Inlet Filters .............................................................................................................................. 2-3 Figure 9 - Core Holder ............................................................................................................................. 2-4 Figure 10 – Core Holder Sleeve with Pressure Taps ............................................................................... 2-4 Figure 11 – Hydraulic Piston with Screen Holder ................................................................................... 2-5 Figure 12 - Hydraulic Piston without Screen Holder ............................................................................... 2-5 Figure 13 - High-Precision Differential Pressure Transducers ................................................................ 2-6 Figure 14 - High Precision Pressure Transducers .................................................................................... 2-6 Figure 15 - Fluid-Recirculation System Pressure Transducers ................................................................ 2-7 Figure 16 - Nitrogen Pressure Transducer ............................................................................................... 2-8 Figure 17 - Sample Injection Pump ......................................................................................................... 2-9 Figure 18 – High-Viscosity Fluid Delivery Accumulators .................................................................... 2-10 Figure 19 - Fluid Recirculation Accumulators ...................................................................................... 2-10 Figure 20 - Fluid Recirculation Pump ................................................................................................... 2-11 Figure 21 - Fluid Recirculation Oil Reservoir ....................................................................................... 2-12 Figure 22 - Back Pressure Regulators .................................................................................................... 2-13 Figure 23 - Back Pressure Regulator Control Pump .............................................................................. 2-14 Figure 24 - Sand Injection Accumulator ................................................................................................ 2-15 Figure 25 - Sand Injection Screen Filter Valve ..................................................................................... 2-16 Figure 26 - Sand Injection / Screen Placement Valve ........................................................................... 2-17 Figure 27 - Sand Injection Accumulator Isolation Valve ...................................................................... 2-18 Figure 28 - Sand Injection / Screen Placement Pump Cylinder ............................................................. 2-19 Figure 29 – Confining Oil Pump Cylinder ............................................................................................ 2-20 Figure 30 – Confining Oil Reservoir ..................................................................................................... 2-21 Figure 31 - 4-Way Valve ....................................................................................................................... 2-21 Figure 32 - Cone and Seat Valve ........................................................................................................... 2-22 Figure 33 - Cartridge Valves.................................................................................................................. 2-22 Figure 34 - Vindum Valves.................................................................................................................... 2-23 Figure 35 - Nitrogen Flow Controller .................................................................................................... 2-23 Figure 36 - Nitrogen Pressure Regulator ............................................................................................... 2-24 Figure 37 - Nitrogen Shut-Off Valve ..................................................................................................... 2-24 Figure 38 - Nitrogen Humidifier ............................................................................................................ 2-25 Figure 39 - Fluid Preparation Cart ......................................................................................................... 2-25 Figure 40 - Fluid Transfer Pump ........................................................................................................... 2-26 Figure 41 - Lower-Right Panel .............................................................................................................. 2-27 Figure 42 - Fluid Transfer Pump Controls ............................................................................................. 2-28 Figure 43 - Recirculation Oil Fill Tank Controls ................................................................................... 2-28 Figure 44 - Return Valve ....................................................................................................................... 2-28 Figure 45 - Water Valve ........................................................................................................................ 2-29 Figure 46 - Drain Valve ......................................................................................................................... 2-29

vi TABLE OF CONTENTS Figure 47 - Cooling Valve ..................................................................................................................... 2-29 Figure 48 - Upper-Right Panel ............................................................................................................... 2-30 Figure 49 - Lower-Left Panel ................................................................................................................ 2-31 Figure 50 - Nitrogen Pressure Regulator and Gauge ............................................................................. 2-31 Figure 51 - Back Pressure Gauge ........................................................................................................... 2-32 Figure 52 - Confining Pressure Gauge................................................................................................... 2-32 Figure 53 - Top Cell Pressure Gauge ..................................................................................................... 2-32 Figure 54 - Bottom Cell Pressure Gauge ............................................................................................... 2-33 Figure 55 - Water Valve ........................................................................................................................ 2-33 Figure 56 - Nitrogen Shut-Off Valve ..................................................................................................... 2-33 Figure 57 – Upper-Left Panel ................................................................................................................ 2-34 Figure 58 - Power Distribution / Heater Control Cabinet ...................................................................... 2-35 Figure 59 - Heater Contactors ................................................................................................................ 2-36 Figure 60 - Solid State Relays ............................................................................................................... 2-36 Figure 61 - Fuses .................................................................................................................................... 2-36 Figure 62 - Circuit Breakers .................................................................................................................. 2-37 Figure 63 - Thermocouple Connections ................................................................................................ 2-39 Figure 64 - Electronic Balance .............................................................................................................. 2-39 Figure 65 - Data Acquisition / Valve Control Cabinet .......................................................................... 2-40 Figure 66 - Data Acquisition Modules................................................................................................... 2-40 Figure 67 - Air Solenoid Valves ............................................................................................................ 2-41 Figure 68 - Serial Hub............................................................................................................................ 2-41 Figure 69 - Fuses .................................................................................................................................... 2-42 Figure 70 - Panel Connections ............................................................................................................... 2-42 Figure 71 - Oil Filter .............................................................................................................................. 2-43 Figure 72 - Hastelloy Fluid Path Filters ................................................................................................. 2-43 Figure 73 - Filter Element Removal ...................................................................................................... 2-44 Figure 74: Permeameter Screen ............................................................................................................. 2-46 Figure 75: File Menu ............................................................................................................................. 2-47 Figure 76: Schedule Menu ..................................................................................................................... 2-47 Figure 77: Operation Mode Menu ......................................................................................................... 2-48 Figure 78: Setup Menu........................................................................................................................... 2-48 Figure 79: Help Menu ............................................................................................................................ 2-49 Figure 80: Permeability Displays........................................................................................................... 2-49 Figure 81: Pressure Displays ................................................................................................................. 2-50 Figure 82: Pressure Displays ................................................................................................................. 2-50 Figure 83: Quizix Pumps ....................................................................................................................... 2-51 Figure 84: Valves ................................................................................................................................... 2-52 Figure 85: Clean Fluid Reservoirs ......................................................................................................... 2-53 Figure 86: Balance ................................................................................................................................. 2-54 Figure 87: Schedule Control .................................................................................................................. 2-54 Figure 88 - AB Flow Path ...................................................................................................................... 2-55 Figure 89 - CD Flow Path ...................................................................................................................... 2-55 Figure 90 - EF Flow Path ....................................................................................................................... 2-56 Figure 91 - General Valve Configuration .............................................................................................. 2-56 Figure 92 - Accumulator Volume Indicator ........................................................................................... 2-56 Figure 94 - Fluid Recirculation Pump ................................................................................................... 2-57 Figure 95 - On-Screen Plotting .............................................................................................................. 2-58 Figure 96 - Schedule Editor Screen ....................................................................................................... 2-59

TABLE OF CONTENTS vii

Figure 97: Unit Selection Screen ........................................................................................................... 2-59 Figure 98 - Calibration Screen ............................................................................................................... 2-60 Figure 99: Viscosities Screen ................................................................................................................. 2-61 Figure 100: Alarm Configuration Screen .............................................................................................. 2-62 Figure 101: Communications Screen ..................................................................................................... 2-63 Figure 102: Core Holder Screen ............................................................................................................ 2-64 Figure 103: Alarm Monitor Screen ........................................................................................................ 2-65 Figure 104 - Screen Holder .................................................................................................................... 2-73 Figure 105 - Hydraulic Piston without Screen Holder ........................................................................... 2-74 Figure 106 - Core Holder Head Assembly ............................................................................................ 2-75 Figure 107 - Removing the Piston Assembly ........................................................................................ 2-75 Figure 108 – Core Holder Assembly Rotation ........................................................................................ 3-1 Figure 109 - Removing Spacers with the Core Extraction Rod ............................................................... 3-2 Figure 110 - Internal Core Holder Assembly .......................................................................................... 3-2 Figure 111 - Sleeve Stiffening Rods ........................................................................................................ 3-2 Figure 112 - Core Sleeve Assembly Removal ......................................................................................... 3-3 Figure 113 - Brass Ring Removal ............................................................................................................ 3-3 Figure 114 - Sleeve Insert Removal ......................................................................................................... 3-4 Figure 115 - Pressure Tap Cutting Tool .................................................................................................. 3-4 Figure 116 - Core Sleeve Installation ...................................................................................................... 3-5 Figure 117 - Installing the Sleeve Adapter .............................................................................................. 3-5 Figure 118 - Pressure Tap Installation ..................................................................................................... 3-6 Figure 119 - Installing the Core Sleeve Assembly .................................................................................. 3-6 Figure 120 - Sleeve Stiffening Rods ........................................................................................................ 3-6 Figure 121 - Back Pressure Regulators .................................................................................................... 3-7 Figure 122 - Teflon Diaphragm and O-Ring ........................................................................................... 3-8 Figure 123 - Installed Teflon Diaphragm and O Ring ............................................................................. 3-8 Figure 124 – Core Holder Assembly Rotation ........................................................................................ 3-9 Figure 125 - 1/16" and 1/8" Confining Oil Plugs .................................................................................. 3-10 Figure 126 - 1/16" and 1/8" Confining Oil Plugs .................................................................................. 3-11 Figure 127 - Cone and Seat Valve ......................................................................................................... 3-12 Figure 128 - Valve Actuator Removal ................................................................................................... 3-13 Figure 129 - Air Actuator and Valve Stem Assembly ........................................................................... 3-13 Figure 130 - Internal Valve Stem Assembly.......................................................................................... 3-14 Figure 131 - Loosening the Air Actuator Screws .................................................................................. 3-15 Figure 132 - 4-Way Valve ..................................................................................................................... 3-16 Figure 133 - 4-Way Valve Rotor ........................................................................................................... 3-16 Figure 134: Start Menu .......................................................................................................................... 3-17 Figure 135: Network Connections ......................................................................................................... 3-18 Figure 136: Identifying the Network Connection .................................................................................. 3-19 Figure 137: IPX/SPX/NetBIOS Compatible Transport Protocol .......................................................... 3-20 Figure 138:Adding a Protocol ................................................................................................................ 3-20 Figure 139: Selecting TCP/IP Properties ............................................................................................... 3-21 Figure 140: TCP/IP Settings .................................................................................................................. 3-22 Figure 141: Control Panel ...................................................................................................................... 3-23 Figure 142: System Properties ............................................................................................................... 3-24 Figure 143: Device Manager ................................................................................................................. 3-25 Figure 144: Control Panel ...................................................................................................................... 3-26 Figure 145: Add Hardware Wizard........................................................................................................ 3-27

viii TABLE OF CONTENTS Figure 146: Add Hardware Wizard Dialog ............................................................................................ 3-27 Figure 147: Add Hardware Wizard Dialog ............................................................................................ 3-28 Figure 148: Add Hardware Wizard Dialog ............................................................................................ 3-29 Figure 149: Add Hardware Wizard Dialog ............................................................................................ 3-29 Figure 150: Add Hardware Wizard Dialog ............................................................................................ 3-30 Figure 151: Install from Disk Dialog ..................................................................................................... 3-30 Figure 152: Locate File Dialog .............................................................................................................. 3-31 Figure 153: Install from Disk Dialog ..................................................................................................... 3-31 Figure 154: Add Hardware Wizard Dialog ............................................................................................ 3-32 Figure 155: Hardware Installation Dialog ............................................................................................. 3-32 Figure 156: Software Installation Dialog ............................................................................................... 3-33 Figure 157: Add Hardware Wizard Dialog ............................................................................................ 3-33 Figure 158: Found New Hardware Dialog............................................................................................. 3-34 Figure 159: Found New Hardware Dialog............................................................................................. 3-35 Figure 160: Found New Hardware Dialog............................................................................................. 3-36 Figure 161: Hardware Installation Dialog ............................................................................................. 3-36 Figure 162: Found New Hardware Dialog............................................................................................. 3-37 Figure 163: Control Panel ...................................................................................................................... 3-38 Figure 164: System Properties ............................................................................................................... 3-39 Figure 165: Device Manager ................................................................................................................. 3-40 Figure 166: Properties Menu ................................................................................................................. 3-41 Figure 167: Network Connections Tab .................................................................................................. 3-42 Figure 168: MAC Address Label Location ........................................................................................... 3-43 Figure 169: Port Settings Tab ................................................................................................................ 3-44 Figure 170: COM Port Properties Dialog .............................................................................................. 3-45

GENERAL INFORMATION P-1

General Information

Introduction

Figure 1 - Model 9000 Drilling Fluids Simulator

Purpose and Use

The Model 9000 Drilling Fluids Simulator is designed to study permeability changes in a core as a result of fluid invasion, chemical reactions, and filter cake deposition. The system maintains the core at elevated temperature and confining pressures to simulate well bore conditions. The core can be exposed to fluids in several different ways. Fluids can be injected through the core holder in either direction. They can also flow across the face of the core to simulate slot flow during drilling or fracturing. When exposed to various fluids, the permeability of the core is affected due to a number of causes, including chemical reactions, particle invasion, filter cake deposition, etc. This system is designed to cover a broad range of treating scenarios and measure the resulting permeability changes.

P-2 GENERAL INFORMATION

Description

This instrument allows the technologist to sequence numerous fluids (including acids) through a core sample. The system is designed to handle acids and other corrosive fluids at temperatures up to 350F (177°C). The core must be either 1 inch (2.54 cm) or 1.5 inches (3.81 cm) in diameter and up to 6 inches (15.24 cm) long. Operating pressure and temperature are limited to 5,000 PSI (41,344 kPa) and 350F (177°C), respectively. The direction of flow is extremely flexible – top to bottom, across the core face, system flush, etc. The system consists of the following components:

Flush-face core holder Dynamic screen placement system Sand injection system Precision injection pump – Quizix QX-6000 Four (4) clean fluid reservoirs Three (3) piston accumulators for viscous fluids Quizix QX-6000 pump to control fluid recirculation pressure Quizix QX-6000 pump to control confining pressure Valving and instrumentation to direct fluids in desired flow paths Drilling fluid circulation system Temperature controlled oven Computer data acquisition system and custom software Humidified Nitrogen injection Drilling Fluid Circulation System, Including:

o Six (6) piston accumulators o Precision Quizix 6205 pump system o Automatic valve control system

Fluid Preparation system The drilling fluid circulation system is designed to flow drilling fluids past the face of a core at velocities representative of typical well bore treatments. The major specifications include the following.

Flow velocity: 0-6 ft/min @ 400 ml/min Max temp: 350°F Max pressure: 5000 PSI

The Model 9000 Drilling Fluids Simulator is equipped with a software platform that provides both manual and automatic operation of the instrument. The software allows a user to perform tests, log data, and generate reports using a comma separated ASCII file format. Automatic scheduling allows the user to sequence fluids through, or across the face of the core at various flow rates as desired.


To maintain the system temperature, up to 15 independent heater control channels are provided. A standalone controller provides safe and precise temperature control of each channel. In addition, a standalone alarm scanner continuously monitors a set of redundant thermocouples, to ensure safety. These units are located on the front panel of the Model 9000. Temperature control channels include the following.

Piston Accumulators (2-4 channels) Fluid Recirculation Accumulators (6 channels) Core Holder (1 channel) Mud Recirculation Pump (1 channel) Oil Fill Tank (1 channel) Oven Heaters (2 channels)

Temperature control parameters are displayed on the front panel of these instruments, and are controlled and recorded via software. The Quizix pumps can be controlled via the Model 9000 control software. Software controlled operation allows the pumps to operate at multiple flow rates and pressures throughout the course of a scheduled test.

Theory

Permeability Calculation

During execution of a test, the permeability of the core sample is automatically calculated several times a second. The result of this calculation is considered valid once the core is fully saturated and the differential pressure reading stabilizes. Formulas Used for Permeability

The permeability formula used by the Model 9000 Software is based on core length, diameter, fluid viscosity, flow rate, and differential pressure. The equation is:

)(*)(

)(cos*min)/(*)(*245)(

2cmAreaPSIDP

cPityVisFluidmlRateFlowcmLengthCoremdtyPermeabili

Core length and diameter are manually entered on the Core Holder screen. The viscosity for each sample fluid is entered via the Viscosity screen. The viscosity entered for a sample fluid will appear on the main screen whenever that sample fluid is selected.

P-4 GENERAL INFORMATION

Features and Benefits

Unique design allows fluids to be injected in either direction or across either end of a core

Accurate temperature control to 350°F (177°C) Accurate pressure control to 6,000 PSI Confining (41,344 kPa) or 5,000 PSI (34,474

kPa) in the flow path. Core holder pivots for easy access to internal components. Semi-autonomous operation for ease of use Digitally controlled confining pressure Nitrogen-controlled back pressure (manual) Pump enabling flow rates of 0-50 mL/min for permeability testing Pump enabling flow rates of 0-400 mL/min for fluid recirculation Dynamic screen placement Sand / gravel pack placement capability

Specifications

Operating Conditions: 75°F - 350°F (24°C - 177°C) Maximum Temperature: 350°F (177°C) Maximum Confining Pressure: 6,000 PSI (41,344 kPa) Maximum Pumping Pressure: 5500 PSI (37,899 kPa) Input Voltage: 200-240 VAC, 90A maximum, 50/60 Hz Heater Power: 20KW @ 240 VAC, 15KW @ 208VAC Dimensions: 125” (318 cm) wide X 91” (231 cm) high X 52” (132

cm)


Safety Requirements

Note: Before attempting to operate the instrument, the operator should read and understand this manual.

The Chandler Engineering Model 9000 Drilling Fluids Simulator is designed for operator safety. Any instrument that is capable of high temperatures and pressures should always be operated with CAUTION!! To ensure safety:

Locate the instrument in a low traffic area. Post signs where the instrument is being operated to warn non-operating personnel. Read and understand the instructions before attempting instrument operation. Observe all caution notes! Observe and follow the warning labels on the instrument. Never exceed the instrument maximum temperature and pressure ratings. Always disconnect main power to the instrument before attempting any repair. Turn off the heater at completion of each test. Appropriately rated fire extinguishers should be located within close proximity. Instrument should not be left unattended when running at elevated temperatures or

pressures. Never heat the system while fluids are trapped in a piston accumulator. Use the

“Accumulator Heating” flow path when heating fluids. Never heat the system while a piston accumulator is completely full of fluid. Always

maintain a balance of oil to drilling fluid, to ensure that fluids can expand into the recirculation oil fill tank without building pressure.

Never leave the system unattended while the “Water” valve is in the “ON” position. In case of power failure or loss of air pressure, a flow path can be inadvertently opened that could cause flooding.

Note: All Chandler Engineering equipment is calibrated and tested prior to

shipment.

Where to Find Help In the event of problems, your local sales representative will be able to help or you can contact the personnel at Chandler Engineering using the following: Telephone: 918-250-7200 FAX: 918-459-0165 E-mail: [email protected] Website: www.chandlereng.com Contact Chandler Engineering with all inquiries, orders for spare parts, and technical support.

SECTION 1 – INSTALLATION 1-1

Section 1 - Installation

Unpacking the Instrument Remove the instrument from the packing crates carefully. The unit comes fully equipped with all the necessary components and ordered spare parts. Make sure that no parts are lost when discarding the packing materials. Select a location that allows access to all sides of the instrument, for ease of use. The instrument location should be near a 90A, 200-240VAC electrical outlet, a Nitrogen bottle, water source and a drain. After the instrument is removed from the shipping crates, the equipment and spare parts should be checked against the packing list to ensure that all parts have been received and none are damaged. Note: File an insurance claim with your freight carrier if damage has occurred

during shipping. Verify all parts shown on the enclosed packing list have been received. If items are missing, please notify Chandler Engineering immediately.

Transporting the Oven Assembly The Model 9000 is shipped in several boxes and crates. In order to move the instrument through doorways and corridors, the main oven assembly must remain detached from the rest of the system. Equipment Required

To move the main oven assembly, a fork-lift or pallet jack is required. A set of 4-wheel furniture dollies are included in the packing crate. The oven assembly must be lifted out of the crate, onto the 4-wheel furniture dollies, to allow the unit ample height clearance to enter a standard doorway. Drain Pipe Locations – Caution!

Two drain pipes extend from the bottom of the oven assembly. These pipes will not support the weight of the oven assembly. If a drain pipe is caught on a door jam or other obstacle, the oven assembly must either be lifted over the obstacle, or the obstacle must be removed or avoided if possible. If the oven is allowed to rest on the drain pipes, irreversible damage to the structure of the oven assembly and drain pan may occur. The oven is to be crated in such a way that the drain pipes do not support the oven, and a set of forks may be safely positioned underneath the oven without interference from the drain pipes.

1-2 SECTION 1 – INSTALLATION

Utilities Required

Tap Water Nitrogen – Maximum of 4500 PSI 200-240VAC, 90A Power Air – Minimum of 100 PSI Drain

Setting up the Instrument The Model 9000 is shipped with a pre-configured PC, including all necessary hardware and software components. No initial software installation or setup is required. The Model 9000 requires partial disassembly to facilitate shipping as well as navigation through corridors and doorways. Therefore, the instrument must be re-assembled on-site. All tubing and ancillary components are labeled according to location and/or function prior to disassembly for shipping. Due to the complexity of the system, only qualified Chandler Engineering personnel should attempt to re-assemble the equipment.

Electrical Connections

Instrument Power

The instrument must be connected to a 1-phase 200-240VAC power source, capable of providing at least 90A at 50 or 60 Hz. The power connection is made at the top of three 30A circuit breakers near the top of the power distribution / heater control cabinet on the left side of the instrument. The circuit breakers may be connected to a single source using the supplied bus bar. Conversely, if multiple 2-phase supplies are used, the bus bar connected to the top of the circuit breakers must be REMOVED.

Figure 2 - Circuit Breakers


Ethernet Cable

An Ethernet cable is provided for connection between the instrument and a PC. The required cable is a CAT 5 10/100 Base T Ethernet cable (chandler Engineering Part Number C10592). Should a longer connection be required, the cable may be replaced by any CAT5 10/100 Base T Ethernet cable of appropriate length. Connect the Ethernet cable between the bottom panel of the rear electrical enclosure and the PC.

Figure 3 - Bottom Panel of Rear Electrical Enclosure

Serial Expander

A Quizix serial expander hub is provided for communication between the PC and the Quizix pumps. The serial expander must be connected to the PC built-in serial port (COM1) via the provided 9-pin serial cable. The pumps are connected to the serial expander via RJ-11 telephone-style cables. Looking at the rear of the instrument, from right to left, each pump should be connected to ports 1 thru 4, respectively, as follows: Sample Fluid Delivery Pump – Port 1 (A) Fluid Recirculation Pressure Control Pump – Port 2 (B) Confining Pressure / Sand Injection Pump – Port 3 (C) Fluid Recirculation Pump – Port 4 (D) Transducer Cables

Pressure transducer cables (PR1 – PR12) should arrive pre-installed. Refer to electrical schematic 9000-0034 – Page 3 for details. Temperature Controller Serial Cable

The temperature controller serial cable (S1) should arrive pre-installed. Refer to electrical schematic 9000-0034 – Page 3 for details. Alarm Scanner Serial Cable

The temperature controller serial cable (S2) should arrive pre-installed. Refer to electrical schematic 9000-0034 – Page 3 for details. Balance Serial Cable

Connect the balance to S3. The temperature controller serial cable (S2) should arrive pre-installed. Refer to electrical schematic 9000-0034 – Page 3 for details.

1-4 SECTION 1 – INSTALLATION

Nitrogen Flow Controller Interface Cable

The Nitrogen flow controller serial cable (N2) should arrive pre-installed. Refer to electrical schematic 9000-0034 – Page 3 for details. Oven Door Actuator Cable

The oven door actuator cable (A1) should arrive pre-installed. Refer to electrical schematic 9000-0034 – Page 3 for details. Sample Fluid Selection Valve Cable

The sample fluid selection valve cable should be connected to the “Sample Valves” port. Refer to electrical schematic 9000-0034 – Page 3 for details. Power Distribution

A power distribution strip is located on the back of the instrument. The power supplied to this strip is the same voltage and frequency as the instrument power. An assortment of standard power cables is provided for connection to each ancillary device. Refer to electrical schematic 9000-0034 – Page 3 for connection details.

Pneumatic Connections A minimum 100 PSI air supply is required for valve operation, fluid transfer pump operation, and oil reservoir pressurization. The air connection is located on the left side of the instrument, near the back. A filter is supplied to keep particles and contaminants out of the system.

Water Connection A clean tap water supply is required for system cooling, and filling / flushing the system for easy cleanup. The water connection is located on the left side of the instrument, near the back. A filter is supplied to keep particles and contaminants out of the system.

Nitrogen Connection A bulkhead connector for Nitrogen is attached to the panel on the left side of the instrument. A clean, dry Nitrogen supply is required, with a maximum of 4500 psi. Note: Use ONLY UHP GRADE Nitrogen, as any impurities or moisture in the

Nitrogen supply will damage the Nitrogen flow controller / meter.


Drain Connections The following drain connections are available for use:

Coolant Water Discharge (may be connected to building sewage) - A bulkhead connector is attached to a panel on the left side of the instrument. The drain at this location is for cooling water only.

Oven Drip Pan (x2) – Two drain pipes are located underneath the oven assembly, to allow the integral spill pan to drain. It is recommended that a large container be placed directly underneath each drain pipe.

Rear Bleed Port – A bleed valve protrudes from the rear of the instrument. This valve allows the operator to flush fluids through the accumulator fluid transfer pump and fluid recirculation fill lines. A container should be placed under the outlet of this valve, before it is opened.

Drilling Fluid Discharge – A drain valve is located on the lower-right front panel of the instrument. This valve allows fluid to be pumped directly out of the fluid preparation tank, and into a waste container. The discharge for this drain is located near and is connected to the outlet of the fluid transfer pump.

Fluid Preparation Cart Drain – A drain valve is located at the bottom of the fluid preparation cart. The outlet of this valve may be connected to a waste container, to allow fluids to drain from the mixing tank.

UPS (Uninterruptible Power Supply) Recommendations It is strongly recommended that the rear electrical enclosure and the PC be connected to a UPS, to prevent loss of connectivity during a power failure. The power connection to the rear electrical enclosure is designed for easy connection to a 200-240VAC UPS. Note: Any component connected to a UPS will continue to operate, even if the

main power switch is disengaged. Therefore, connection of a Quizix pump to a UPS will render the main power disconnect ineffective for stopping the pumps.

Minimum System Requirements for PC The Model 9000 comes equipped with a PC. Should the PC need replacement, the following minimum requirements must be met.

Operating System - Windows XP (32 bit) Graphics Adapter - Dual Display (1280 x 1024 minimum) Monitors - Dual LCD Monitors (1280 x 1024 minimum) Memory - 256 MB RAM Processor - Pentium D, Core 2 Duo or better Built - In Serial Port 100 Base-T Ethernet

SECTION 2 – OPERATION 2-1

Section 2 - Operation Components – Location, Description and Purpose

Air Regulators

Air regulators are provided with the equipment in the following locations: Main Air Supply: An air pressure regulator is located on the rear of the instrument.

This regulator controls the air pressure for pneumatic valves. This regulator should be adjusted to 100 PSI.

Figure 4 - Main Air Regulator

Confining Oil Fill Tank: An air pressure regulator is located on the rear of the

instrument, above the confining oil tank. This regulator is used to supply a positive inlet pressure on the confining oil pump and back pressure regulator control pumps. During normal operation, this regulator should be set to 50 PSI.

Figure 5 - Confining Oil Fill Tank Regulator

2-2 SECTION 2 – OPERATION

Fluid Transfer Pump Control: An air pressure regulator is located on the lower-right front panel. This regulator is used to control the operating pressure of the fluid transfer pump. During normal operation, this regulator is set to 100 PSI. A 3-way valve is located below the regulator to disengage the pump from the air supply.

Figure 6 - Fluid Transfer Pump Controls

Recirculation Oil Fill Tank: A second air pressure regulator is located on the lower-

right front panel. This regulator is used to control the operating pressure of the recirculation oil fill tank. During normal operation, this regulator is set to 80 PSI. A 3-way valve is located below the regulator to disengage the fill tank from the air supply.

Figure 7 - Recirculation Oil Fill Tank Controls


Inlet Filters

Filters are provided for water, nitrogen and air, at the bulkhead connections, to provide protection from particle contamination. These filters have replaceable elements. Should a filter become clogged, spare elements are provided in the instrument spares kit (optional).

Figure 8 - Inlet Filters

Core Holder

The core holder is designed to hold cylindrical core samples, with diameters of either 1.0 inch diameter or 1.5 inches, and lengths up to 6 inches. Fluids can flow across the core face, or through the core in either direction. Additionally, a variable-depth slot is provided at the face of the core holder, to allow simulation of drilling fluid exposure, filter cake placement and removal, as well as injection of a gravel pack and dynamic screen placement.


Figure 9 - Core Holder

The core is constrained by a molded Viton sleeve. The sleeve contains ports along the side, to allow pressure readings at user-selectable lengths along the core. Pressure taps are provided for 2 user-selectable ports, as well as plugs for unused ports.

Figure 10 – Core Holder Sleeve with Pressure Taps


The core sample is exposed at one end to a slot. The slot width is 1.0 inch for a 1.5 inch diameter core sample, and 0.75 inches for a 1.0 inch core sample. Drilling fluids may be recirculated across the slot to perform a dynamic or static test. Sand may be injected dynamically into the slot to simulate a gravel pack. Additionally, a screen sample may be hydraulically pressed into the gravel pack during a test by use of an integrated hydraulic piston and screen holder.

Figure 11 – Hydraulic Piston with Screen Holder

Conversely, the screen holder may be replaced with an adapter for operation without a screen.

Figure 12 - Hydraulic Piston without Screen Holder

The slot has a variable height of 0 to 0.5 inches, depending on operator preference. The slot height is adjusted prior to loading the core sample, by the placement of spacers above the screen actuator piston. The screen holder may be pressed into the slot during a test using a Quizix pump.


High-Precision Differential Pressure Transducers

A set of three (3) high-precision differential pressure transducers are used to measure the differential pressure between the core top and bottom, as well as between the core top and the two (2) pressure taps along the core sleeve. These transducers are located on the back of the instrument. The range of each transducer is from -100 PSI to 100 PSI.

Figure 13 - High-Precision Differential Pressure Transducers

High-Precision Pressure Transducers

A set of four (4) high-precision pressure transducers are used to measure core inlet and outlet pressure, as well as up to two (2) pressures along the core sleeve. These gauge-pressure transducers are located on the back of the instrument. If the differential pressure is above the range of the differential pressure transducers, the software will calculate the differential pressure across the core, using these transducers. The range of each transducer is from -14.7 PSI to 6000 PSI.

Figure 14 - High Precision Pressure Transducers


Fluid-Recirculation System Pressure Transducers

A set of seven (7) pressure transducers are used to monitor pressures for the fluid recirculation system. A pressure transducer is provided for each accumulator, and for the flow loop pressure. Each accumulator transducer measures the oil pressure in the accumulator. By monitoring these pressures, the user can determine when a piston has reached the end of its travel in either direction. Each transducer is connected to a redundant mechanical gauge on the front panel.

Figure 15 - Fluid-Recirculation System Pressure Transducers

Nitrogen Pressure Transducer

A pressure transducer is provided upstream of the Nitrogen injection system, to provide a software indication of inlet Nitrogen pressure for gas permeability studies. The pressure transducer is connected to a redundant mechanical gauge on the front panel.


Figure 16 - Nitrogen Pressure Transducer

Sample Injection Pump

A Quizix model QX6000HC-1-0-A-H-0 pump is provided for sample fluid delivery. It can operate at flow rates up to 50 mL/min and pressures up to 6000 PSI. Two cylinders work in conjunction to provide smooth, constant flow or constant pressure fluid delivery. Each cylinder has a working volume of 11 mL. Fluid path construction is Hastelloy C-276. A wash pump is provided to flush the back side of the piston seals during operation. Each Quizix pump is controlled via software (see the software section of this manual), and is equipped with a detailed user manual.


Figure 17 - Sample Injection Pump

Sample Fluid Selection Valves

The sample injection pump can deliver up to four (4) software-selectable fluids, by use of a 4-way sample selection valve manifold. Each valve can be connected to a different sample fluid container.


High-Viscosity Fluid Delivery Accumulators

A set of three (3) piston accumulators are provided for permeability or treatment fluids. These accumulators are driven by the sample injection pump. Viscous fluids may be placed in these accumulators.

Figure 18 – High-Viscosity Fluid Delivery Accumulators

Manual valves are connected to the top and bottom of each accumulator, for filling and evacuating fluids.

Fluid Recirculation Accumulators

The fluid recirculation system is designed to recirculate fluid across the core face using up to three (3) piston accumulator pairs. The drilling fluid recirculation pump is used to flow oil into one accumulator while displacing drilling fluid out of the accumulator, across the core face and into a second accumulator.

Figure 19 - Fluid Recirculation Accumulators


The fluid recirculation system consists of a pressurized oil tank, an oil filter and a back pressure regulator. The oil tank is pressurized with air, so that a positive inlet pressure is present at the mud recirculation pump. This positive inlet pressure facilitates faster flow rates, because each pump cylinder would otherwise create a partial vacuum when filling at high speeds. The back pressure regulator is used to maintain a constant pressure while recirculating fluid, and is controlled via a Quizix Model QX6000 precision pump. The back pressure set point may be adjusted via software. Note: When performing a static test phase, the back pressure regulator will not

prevent the system pressure from decreasing as fluid is filtered through the core sample. Therefore, the fluid recirculation pump must be operated in constant pressure mode for static tests, and in constant rate mode for dynamic tests.

Fluid Recirculation Pump

A two-cylinder Quizix 6205 series pump is provided to drive the fluid recirculation accumulators at flow rates up to 400 mL/min and pressures up to 5000 PSI. Each pump cylinder has a working volume of 550mL. Both pump cylinders work in conjunction to provide smooth, constant pressure or constant flow rate fluid delivery. Fluid path construction is Hastelloy C-276. Each Quizix pump is controlled via software (see the software section of this manual), and is equipped with a detailed user manual.

Figure 20 - Fluid Recirculation Pump


Fluid Recirculation Oil Reservoir

A 5 gallon pressurized oil reservoir contains oil to drive the fluid recirculation accumulator pistons. The oil tank may be pressurized up to 100 PSI using an air regulator located on the lower-left front panel. Oil is delivered to and from the tank using dip tubes, which are installed in the tank. A removable lid is provided with an o-ring seal for easy filling.

Figure 21 - Fluid Recirculation Oil Reservoir


Back Pressure Regulators

A back pressure regulator is provided to maintain an elevated pressure on the core holder outlet. It is controlled by a Nitrogen regulator, located on the left front panel of the instrument. A second back pressure regulator is provided to maintain a constant elevated pressure while recirculating fluid at a constant flow rate. It is controlled by a Quizix model QX6000 Pump. Teflon and Viton diaphragms are provided for each back pressure regulator. Viton can be used for precise control at differential pressures up to 1500 PSI. For higher differential pressures, a Teflon diaphragm must be used, at the expense of less precise pressure control at low flow rates. It is recommended that a Viton diaphragm be used for the core holder back pressure regulator and a Teflon diaphragm be used for the fluid recirculation system back pressure regulator.

Figure 22 - Back Pressure Regulators


Back Pressure Regulator Control Pump

A Quizix model QX6000 pump provides precise, digital control of the back pressure regulator. It can operate at flow rates up to 50 mL/min and pressures up to 6000 PSI. One cylinder is dedicated to the back pressure regulator, and has a working volume of 11 mL. The pump receives its oil supply from the pressurized confining oil reservoir, located on the back of the instrument. Each Quizix pump is controlled via software (see the software section of this manual), and is equipped with a detailed user manual.

Figure 23 - Back Pressure Regulator Control Pump


Sand Injection Accumulator

A small accumulator, located above the core holder, is designed to inject sand across the core face. It is a piston-driven accumulator, with a working volume of 50mL. The accumulator is hydraulically actuated by a Quizix pump, during normal operation.

Figure 24 - Sand Injection Accumulator


Sand Injection Screen Filter Valve

The Sand Injection Screen Filter Valve allows the carrier fluid to be filtered out of the solution downstream of the core face, when injecting sand. When the valve handle is rotated outward, a screen is placed in the flow path, causing the sand to begin packing off and fill the slot across the core face. When the valve handle is rotated inward, fluids are allowed to bypass the screen.

Figure 25 - Sand Injection Screen Filter Valve

Note: The valve handle will be hot, if the oven is heated. Please use caution, and

wear appropriate insulated gloves when operating this valve.


Sand Injection / Screen Placement Selection Valve

A three-way valve is mounted near the core holder, upstream of the sand injection accumulator. This valve can be set manually, before and during operation, to select the functionality of the sand injection / screen placement pump cylinder. The outlet of the pump cylinder is directed toward the sand injection accumulator when the valve handle is pointing downward. When the valve handle is pointing upward, the pump cylinder outlet is directed toward the screen placement actuator.

Figure 26 - Sand Injection / Screen Placement Valve

Note: Before heating the oven or core holder, be sure to place the valve in the

“Screen Placement” (handle pointing upward) position. This will allow the oil in the hydraulic piston to expand during heating, and allows the pump cylinder to maintain a lower pressure than at the face of the core, thus keeping the piston from closing the slot, due to thermal expansion.

Note: The valve handle will be hot, if the oven is heated. Please use caution, and

wear appropriate insulated gloves when operating this valve.


Sand Injection Accumulator Isolation Valve

A two-way valve is located directly below the sand injection accumulator. This valve is used to isolate the sand injection accumulator during a test. When an operator is ready to inject sand, this valve must be opened manually.

Figure 27 - Sand Injection Accumulator Isolation Valve

Note: The valve handle will be hot, if the oven is heated. Please use caution, and wear

appropriate insulated gloves when operating this valve.


Sand Injection / Screen Placement Pump Cylinder

A single cylinder of a Quizix model QX6000 pump provides precise, digital control of both the sand injection accumulator and the hydraulic screen actuator. It can operate at flow rates up to 50 mL/min and pressures up to 6000 PSI. The pump cylinder has a working volume of 11 mL. The pump receives its oil supply from the pressurized confining oil reservoir, located on the back of the instrument. Each Quizix pump is controlled via software (see the software section of this manual), and is equipped with a detailed user manual.

Figure 28 - Sand Injection / Screen Placement Pump Cylinder


Confining Oil Pump Cylinder

A single cylinder of a Quizix model QX6000 pump provides precise, digital control of the core holder confining oil pressure. It can operate at flow rates up to 50 mL/min and pressures up to 6000 PSI. The pump cylinder has a working volume of 11 mL. The pump receives its oil supply from the pressurized confining oil reservoir, located on the back of the instrument. Each Quizix pump is controlled via software (see the software section of this manual), and is equipped with a detailed user manual.

Figure 29 – Confining Oil Pump Cylinder


Confining Oil Reservoir

A pressurized tank supplies oil to the back pressure regulator control pump, as well as the confining oil pump cylinder and sand injection accumulator and dynamic screen placement pump cylinder. The oil reservoir is equipped with an air pressure regulator and a sight-glass tube. A positive inlet pressure is required, to allow the pump cylinders to fill with oil at the maximum operating speed of 50 mL/min per cylinder. Typically, the vessel is pressurized to 50 PSI, during normal operation.

Figure 30 – Confining Oil Reservoir

4-Way Valve

A 4-way valve keeps the flow direction constant while recirculating fluids across the core face. As fluids are reciprocated back and forth between accumulators, the 4-way valve is automatically configured to achieve a constant flow direction, via software. The valve is equipped with replaceable internal components, and is easily serviced from the front of the instrument.

Figure 31 - 4-Way Valve


Cone and Seat Valves

Pneumatically actuated, software-controlled cone and seat valves are used throughout the fluid recirculation system, to select the desired fluid flow path. These valves are designed to handle particle-laden fluids, and are rated for pressures up to the maximum system pressure of 5,000 PSI. The cone and seat valves are equipped with air actuators, mounted on the rear of the instrument, and contain easily replaceable internal components.

Figure 32 - Cone and Seat Valve

Cartridge Valves

The system is equipped with compact, air-actuated cartridge valves that control the flow path for fluids not containing large particles. These valves are located in the oil path of the fluid recirculation system, as well as in the flow path of the permeability fluids. The cartridge valves are attached to custom-designed manifolds, and have replaceable o-ring seals. Depending on each manifold location, the manifold construction is either 316 Stainless Steel or Hastelloy C-276, although the fluid path for each valve is Hastelloy C-276.

Figure 33 - Cartridge Valves


Vindum Shuttle Valves

A pair of Vindum shuttle valves is installed in the recirculation oil flow path to direct the flow of oil from the pump outlet and the recirculation accumulator outlets. Each four-way Vindum valve is plumbed in a three-way valve configuration. An additional pair of Vindum valves is installed on the fluid recirculation pump to direct the fluid flow into and out of each pump cylinder.

Figure 34 - Vindum Valves

Nitrogen Flow Controller

A Nitrogen flow controller is provided for gas permeability studies. The flow controller is used to measure and control the flow rate of Nitrogen through the core sample. It is equipped with a proportional valve that may be used to control the flow rate digitally. Conversely, the proportional valve can be left open for constant pressure operation.

Figure 35 - Nitrogen Flow Controller


Nitrogen Pressure Regulator

A pressure regulator is located on the lower-left front panel, for controlling the pressure upstream of the Nitrogen flow controller. The regulator may be used to control the injection pressure of Nitrogen, for constant-pressure Nitrogen permeability operation.

Figure 36 - Nitrogen Pressure Regulator

Nitrogen Shut-Off Valve

A valve is located on the lower-left front panel to stop the flow of Nitrogen into the permeameter. The valve is located downstream of the Nitrogen flow controller.

Figure 37 - Nitrogen Shut-Off Valve


Nitrogen Humidifier

A Nitrogen humidifier is located inside the oven, downstream of the Nitrogen shut-off valve. The vessel can be partially filled with water, by removing the top cap. Manual bleed valves are located at the top and bottom of the vessel. A check valve protects the vessel from being contaminated by fluids in the permeameter flow path. A second check valve prevents water from draining out of the vessel.

Figure 38 - Nitrogen Humidifier

Fluid Preparation Cart

The fluid preparation cart contains a five gallon 316 Stainless Steel mixing tank with a drain and a variable speed mixer. Drilling fluids and other fluids can be loaded into the fluid recirculation accumulators from this mixing tank. A return line is located at the top of the tank, for flushing or filling with water. Used drilling fluids can also be diverted to the return line, to relocate the fluid from the accumulators to the mixing tank. A drain at the bottom allows the tank contents to be collected into a container, or pumped into the system using the fluid transfer pump.

Figure 39 - Fluid Preparation Cart


Fluid Transfer Pump

The fluid transfer pump is an air-driven diaphragm pump, located on the right side of the instrument. It is used to fill the fluid recirculation system with fluids from the fluid preparation cart. The pump will transfer fluid and build pressure until the back pressure at the pump outlet is equal to the air pressure. Air pressure is controlled by the “Loading Pump” air regulator, found on the lower-right front control panel of the instrument.

Figure 40 - Fluid Transfer Pump


Front Control Panels

Four control panels are located on the front of the instrument, for ease of use and operation. These contain the primary gauges, regulators, valves and electronic controls of the instrument. Lower-Right Panel

Figure 41 - Lower-Right Panel

The lower-right panel includes the primary manual controls for loading, unloading and cleaning the fluid recirculation system, as well as the control valve for the cooling system. It contains the following controls:


Fluid Transfer Pump Controls: An air pressure regulator is located on the lower-right front panel. This regulator is used to control the operating pressure of the fluid transfer pump. During normal operation, this regulator is set to 100 PSI. A 3-way valve is located below the regulator to disengage the pump from the air supply.

Figure 42 - Fluid Transfer Pump Controls

Recirculation Oil Fill Tank Controls: A second air pressure regulator is located on

the lower-right front panel. This regulator is used to control the operating pressure of the recirculation oil fill tank. During normal operation, this regulator is set to 80 PSI. A 3-way valve is located below the regulator to disengage the fill tank from the air supply.

Figure 43 - Recirculation Oil Fill Tank Controls

Return Valve: A three-way valve allows fluids to be diverted from the fluid

recirculation accumulators into the fluid preparation cart tank, or into the fluid transfer pump. At the fluid transfer pump inlet, the fluid can optionally be diverted into a drain, located at the right side of the instrument.

Figure 44 - Return Valve


Water Valve: A three-way valve allows tap water to be delivered to the fluid preparation cart tank, or to the fluid transfer pump. This provides a convenient way to clean and flush the fluid recirculation system.

Figure 45 - Water Valve

Drain Valve: A two-way valve, located in the lower-left corner of the panel allows

fluid to be diverted from the fluid transfer pump or into a drain, located at the right side of the instrument. It is recommended that a large container be placed beneath the drain prior to use.

Figure 46 - Drain Valve

Cooling Valve: A two-way valve, located in the lower-right corner of the panel

allows tap water to flow through the cooling circuit, and out of the drain, located on the left side of the instrument. The cooling system drain should be connected to the building waste water plumbing.

Figure 47 - Cooling Valve


Upper-Right Panel

The upper-right panel includes pressure gauges for the fluid recirculation system. Each gauge is plumbed to an electronic pressure transducer. The redundant mechanical gauges on this panel are provided for convenience and safety.

Figure 48 - Upper-Right Panel

The panel includes the following gauges:

Pressure A – Pressure F: Each gauge displays the pressure on the oil-side of the floating piston for fluid recirculation accumulators A-F, respectively.

Loop Pressure: Displays the pressure inside the fluid recirculation loop.


Lower-Left Panel

The lower-left panel includes the primary manual controls for the permeameter. Each gauge is plumbed to an electronic pressure transducer. The redundant mechanical gauges located on the lower-left panel are provided for safety and convenience.

Figure 49 - Lower-Left Panel

The lower-left panel contains the following controls:

Nitrogen Pressure: A pressure regulator is located on the lower-left front panel, for controlling the pressure upstream of the Nitrogen flow controller. The regulator may be used to control the injection pressure of Nitrogen, for constant-pressure Nitrogen permeability operation. A mechanical gauge is also provided for convenience and safety.

Figure 50 - Nitrogen Pressure Regulator and Gauge


Back Pressure: The back pressure gauge is connected to Nitrogen supply line for the permeameter back pressure regulator. It provides an indication of the pressure on the regulator dome. Generally, when the pressure at the regulator inlet is less than the pressure indicated, fluid will not flow through the regulator. If the pressure at the regulator inlet is higher than the pressure indicated, fluid will flow through the regulator.

Figure 51 - Back Pressure Gauge

Confining Pressure: The confining pressure gauge is connected to the core holder

confining oil supply line. It provides an indication of the confining pressure on the core. This gauge provides a constant indication of the confining pressure, as opposed to the software indicator. The software indicator for confining pressure is only updated when the fluid delivery valve is open on the pump cylinder, since the pressure transducer for the confining pressure is located inside the confining oil pump cylinder. Thus, the mechanical gauge should be used as the primary indicator for confining pressure.

Figure 52 - Confining Pressure Gauge

Top Cell Pressure: The top cell pressure gauge is connected to the top of the core

holder. It is also connected to an electronic pressure transducer. The redundant mechanical gauge is provided for convenience and safety.

Figure 53 - Top Cell Pressure Gauge


Bottom Cell Pressure: The bottom cell pressure gauge is connected to the bottom of the core holder. It is also connected to an electronic pressure transducer. The redundant mechanical gauge is provided for convenience and safety.

Figure 54 - Bottom Cell Pressure Gauge

Water Valve: The water valve is located near the bottom of the lower-left panel. It

controls the tap water supply to the fluid delivery section of the permeameter. It does not control the water supply to the controls located on the lower-right panel of the instrument. It is provided as a means to flush the permeameter lines with high-velocity tap water. The valve is protected by a one-way check valve, located downstream of the water valve.

Figure 55 - Water Valve

Nitrogen Shut-Off Valve: A valve is located on the lower-left front panel to stop the flow of Nitrogen into the permeameter. The valve is located downstream of the Nitrogen flow controller.

Figure 56 - Nitrogen Shut-Off Valve


Upper-Left Panel

The upper-left front panel of the instrument provides access to the temperature controller and alarm scanner, as well as heater controls and the main power switch.

Figure 57 – Upper-Left Panel

Temperature Controller: A 16-channel temperature controller is located on the front

panel, which controls the temperature of each heater in the system independently. During normal operation, the software controls each temperature channel, displays each set point and measured temperature, and logs the data to a file. The temperature controller has a complete user manual, which can be found on the software installation CD. Pertinent information about configuring the controller can be found in the “Maintenance” section of this manual.

Alarm Scanner: A redundant device monitors the temperature of each heater, and displays an alarm, automatically removing power from the heaters, any time a thermocouple sensor is removed, or a temperature climbs above the user-defined maximum. For more information, refer to the “Alarms” screen in the software section of this manual, and in the online help files.

Heaters ON / OFF: Pressing the heater OFF button effectively removes power from the heater circuits. When the red “OFF” button is illuminated, no heating is allowed. Conversely, when the green “ON” button is pressed, it will become illuminated and heater power may be applied, depending on the temperature controller set point.

Note: If the green “ON” button does not remain illuminated after it is pressed

and released, there may be an alarm condition present on the alarm scanner. Alarm conditions may be cleared via software.


Power Distribution / Heater Control Cabinet

The power distribution / heater control cabinet is located directly behind the upper-left front panel of the instrument. It houses the temperature controller, alarm scanner, heater contactors, solid state relays, fuses, circuit breakers and power distribution strip.

Figure 58 - Power Distribution / Heater Control Cabinet

Temperature Controller

A 16-channel temperature controller is located on the front panel, which controls the temperature of each heater in the system independently. During normal operation, the software controls each temperature channel, displays each set point and measured temperature, and logs the data to a file. The temperature controller has a complete user manual, which can be found on the software installation CD. Pertinent information about configuring the controller can be found in the “Maintenance” section of this manual.

Alarm Scanner

A redundant device monitors the temperature of each heater, and displays an alarm, automatically removing power from the heaters, any time a thermocouple sensor is removed, or a temperature climbs above the user-defined maximum. For more information, refer to the “Alarms” screen in the software section of this manual, and in the online help files.


Heater Contactors

Three heater contactors are used to control the power to the heaters. When the green “ON” front-panel button is illuminated, these contactors are engaged, supplying power to the solid state relays, which provide digitally controlled power to each heater.

Figure 59 - Heater Contactors

Solid State Relays

A set of solid state relays provide digitally controlled power to each heater. As power is applied to each circuit, a green LED is illuminated on the corresponding solid state relay.

Figure 60 - Solid State Relays

Fuses

Three fuses, located inside the heater control / power distribution cabinet, provide additional short circuit protection. Each fuse holder may be opened by pulling on the top of the black plastic holder. A hinge at the bottom allows the fuse holder cover to swing open, for easy access.

Figure 61 - Fuses


The fuses include the following: Temperature Controllers (LEFT) – 1A, SLO-BLO, 3AG Power Distribution Strip (CENTER) – 10A, SLO-BLO, 3AG Blower Motors (RIGHT) – 3A, SLO-BLO, 3AG

Caution! To avoid electric shock, always disconnect power from the entire

instrument before attempting to access any fuses. Power may be disconnected at the circuit breakers.

Circuit Breakers

Three 30A circuit breakers provide high-current short-circuit protection for the entire system. These circuit breakers serve as the entry point or power to the entire system. To reset these breakers, the switches should be pointing upward.

Figure 62 - Circuit Breakers

Power Strip

A power distribution strip is located on the back of the heater control / power distribution cabinet. The power distribution strip should only be used to provide power to the following devices:

Data Acquisition / Valve Control Cabinet Balance QX Pump 1 – Sample Delivery QX Pump 2 – Confining Pressure / Sand Injection QX Pump 3 – Back Pressure Control

The power distribution strip provides 200-240VAC at 50/60 Hz, depending on the system input power.


Thermocouples

Two K-Type thermocouples are provided for each heater circuit. The first is used for temperature control and measurement, and the second provides feedback to a redundant alarm scanner. The following temperature control channels are included:

Channel 1-6, Fluid Recirculation Accumulators A-F: These bayonet-style thermocouples are located on the side of the heater band of fluid recirculation accumulators A-F, and provide feedback to heater control channels 1-6, respectively.

Channel 7-8, Piston Accumulators A and B: These bayonet-style thermocouples are located on the side of the heater band of piston accumulators A and B, and provide feedback to heater control channels 7 and 8, respectively.

Channel 9-10, Piston Accumulators C and D (optional): These bayonet-style thermocouples are located on the side of the heater band of piston accumulators C and D, and provide feedback to heater control channels 9 and 10, respectively.

Channel 11, Core Holder: A probe-style thermocouple is inserted into the bottom of the core holder, and directly monitors the confining oil temperature. This thermocouple is utilized for heater control feedback. A bayonet-style thermocouple is connected directly to the core holder heater band, and is utilized by the redundant alarm scanner.

Channel 12, Fluid Recirculation Pump: Two bayonet-style thermocouples are mounted on the heater bands of the fluid recirculation pump. These thermocouples measure the temperature of the pump cylinders.

Channel 13, Fluid Recirculation Oil Fill Tank: Two bayonet-style thermocouples are mounted on the heater band of the fluid recirculation oil fill tank. These thermocouples measure the temperature of the pump cylinders.

Channel 14, Unused: Channel 14 is unused by the Model 9000. No thermocouples are connected to channel 14.

Channel 15, Oven Right: Two washer-style thermocouples are connected to the strip heaters, located inside the ducting at the top of the oven, to monitor and control the air temperature of the right-side of the oven.

Channel 16, Oven Left: Two washer-style thermocouples are connected to the strip heaters, located inside the ducting at the top of the oven, to monitor and control the air temperature of the left-side of the oven.


Thermocouple Connections

Thermocouple connections are provided at the back of the instrument, for easy thermocouple replacement. Refer to electrical schematic 9000-0035, page 4 for details concerning the arrangement of these connectors.

Figure 63 - Thermocouple Connections

Electronic Balance

An electronic balance is located on the left side of the instrument, behind the front panel. The balance is used to collect fluid that flows through the permeameter back pressure regulator. It is monitored remotely via software, and provides the basis for the “Filtrate” and “Filtration Rate” software signals.

Figure 64 - Electronic Balance


Data Acquisition / Valve Control Cabinet

The data acquisition / valve control cabinet is located at the rear of the instrument. It houses the data acquisition hardware and air solenoid valves.

Figure 65 - Data Acquisition / Valve Control Cabinet

Data Acquisition Modules

Data acquisition modules provide the interface between the PC and the pressure transducers, as well as the electronically controlled valves and air solenoids. For further information regarding service or troubleshooting, please contact Chandler Engineering.

Figure 66 - Data Acquisition Modules


Air Solenoid Valves

Air solenoid valves provide electronic control of the pneumatically-actuated cone and seat, Vindum, 4-way and cartridge valves. For valve connectivity information, refer to the 9000-PNEU drawing.

Figure 67 - Air Solenoid Valves

Serial Hub

An 8-port serial hub is located inside the cabinet, to provide an interface to various electronic components, including the temperature controller, alarm scanner, balance and Nitrogen flow controller. The serial hub utilizes drivers for Microsoft Windows, which must be installed on the PC, prior to first use. Refer to the “Maintenance” section of this manual for driver installation and reinstallation instructions.

Figure 68 - Serial Hub


Fuses

Two fuses, located inside the data acquisition / valve control cabinet, provide additional short circuit protection. Each fuse holder may be opened by pulling on the right side of the black plastic holder. A hinge on the left side allows the fuse holder cover to swing open, for easy access.

Figure 69 - Fuses

The following fuses are included:

Oven Lights (TOP) – 1A, SLO-BLO, 3AG Data Acquisition Cabinet – 1A, SLO-BLO, 3AG

Panel Connections

Various connectors are supplied at the bottom of the cabinet for pressure transducers, sample valves, Nitrogen flow controller, PC Ethernet cable and serial devices. Refer to electrical schematic 9000-0034, page 3 for details.

Figure 70 - Panel Connections


Oil Filter

An automotive-type oil filter is located near the fluid recirculation pump. It is used to filter particles from the oil in the fluid recirculation system. The filter has a maximum pressure of 150 PSI, and is protected by spring-relief valves at the inlet and outlet. It is located downstream of the back pressure regulator, and upstream of the oil tank and fluid recirculation pump.

Figure 71 - Oil Filter

Hastelloy Fluid Path Filters

Hastelloy filters are located near the left, inside wall of the oven. These filters are connected to the bottom of a Hastelloy cartridge valve manifold, upstream of a pair of cartridge valves and the permeameter back pressure regulator.

Figure 72 - Hastelloy Fluid Path Filters


The filter elements are accessed by spinning the cups off of the manifold and unscrewing the filter stems, as shown below.

Figure 73 - Filter Element Removal

Oven Door Actuators

The oven doors are equipped with a rubber seal, which is engaged by retracting the doors. The doors are retracted automatically by a set of pneumatic actuators when the green button is pressed at either end of the top oven door. When the green button is illuminated, the seal is engaged and the oven doors are locked in place. When the green button is not illuminated, the oven seal is not engaged and the doors can move freely.


Software Organization

Program Components and Directories

The Model 9000 software consists of the following components: 9000DACS – The data acquisition and control software for the Model 9000. 9000Utils – Ancillary program components required by the 9000DACS software

application. National Instruments Software – Program Components that are automatically

installed by the 9000DACS installation program, if required. PumpWorks – The data acquisition and control software for the Quizix pumps. This

software can operate in a stand-alone configuration, but in normal machine operation, it interfaces directly with 9000 DACS.

DeviceMaster RTS Serial Hub Driver – Required to operate the Ethernet-based serial hub, located in the Data Acquisition and Valve Control electrical cabinet.

Starting and Exiting the Program

The Model 9000 software can be started via the windows start menu, under Program Files, Chandler Engineering, 9000DACS. This shortcut should also be located on the Windows desktop. On-Line Help

A complete description of each software function can be accessed via the “Help” menu.


Description of Primary Software Functions This section provides a brief overview of the software and its primary functions. For more details and updated descriptions, refer to the online help files.

Permeameter Screen

The software consists of two primary screens. These are the Permeameter Screen and the Drilling Fluid Screen. The Permeameter Screen appears in the left monitor, and represents the functionality of the left side of the instrument. Most functionality related to permeability measurement is accessed by this screen. For a complete description of each component of this screen, refer to the online help files under the “Help” menu.

Figure 74: Permeameter Screen

The Permeameter Screen consists of digital displays and controls, as well as an active flow schematic with active valve controls. A green valve indicates that the valve is open. A red valve indicates that it is closed. The state of a given valve will change when it is clicked.


Menus

File Menu

Figure 75: File Menu

The File Menu provides the following selections:

Log Data o Manual: Select this option to enable Manual Data Logging Mode. The

Elapsed Log Time Display and Log Data button will become visible. o Automatic: Select this option to enable Automatic Data Logging Mode. The

Elapsed Log Time Display will appear. Exit: Select this option to exit the application.

Schedule Menu

Figure 76: Schedule Menu

The Schedule Menu provides the following selections:

Load: Select this option to load a schedule from a file. Edit: Select this option to open the Schedule Editor window.


Operation Mode

Figure 77: Operation Mode Menu

The Operation Mode menu provides the following selections:

Online: Select this option to set the software in "Online" mode. In this mode, the software will attempt to make connections to all external devices (Valve Control, Balance, Flow Controller, etc.). In this mode, clicking the Valve icons will actuate the appropriate valve; Pump Set Points will be sent to the pumps; etc.

Simulation: Select this option to set the software in "Simulation" mode. In this mode, the software will not attempt connections to external devices. If this option is selected after the connections to external devices are made, those connections will remain in effect.

Setup

Figure 78: Setup Menu

The Setup Menu provides the following selections:

Units: Select this option to open the Unit Selection window. Calibration: Select this option to open the Calibration window. Viscosities: Select this option to open the Define Viscosities window. Alarms: Select this option to open the Alarm Configuration window. Communications: Select this option to open the Communication configuration

window. Core Holder: Select this option to open the Core Holder Dimensions configuration

window.


Help

Figure 79: Help Menu

The Help menu provides the following selections:

Index: Select this option to open this help file. About: Select this option to open the About window.

Numeric and Slider Controls and Indicators

All Numeric Controls (the user can edit these values) on this window have an off-white background with black text; Indicators (these values are calculated; user cannot directly edit these) have a dark teal background with white text.

Permeability

Figure 80: Permeability Displays

Permeability: This indicator displays the calculated Permeability using the Darcy

equation. Permeability P Tap 1 & Permeability P Tap 2: These indicators display the

calculated Permeability at Pressure Tap 1 and Pressure Tap 2, respectively. These are calculated the same as "Permeability" above except different Core Length and Differential Pressure values are used based upon direction of flow.

Length: This indicator displays the user-defined Sample Length as defined on the Core Holder Dimensions configuration window.

Viscosity: This indicator displays the user-defined Viscosity as defined on the Viscosities window depending on which Clean Fluid Reservoir or Piston Accumulator is in use.

Slot Width: This control allows the user to define the width of the slot in the Core Holder.

Diameter: This control allows the user to define the Diameter of the Core Sample.


Pressure

Figure 81: Pressure Displays

These indicators display the pressure reading from the appropriate pressure transducers.

Temperature

Figure 82: Pressure Displays

Controls The Temperature Set Point Controls (off-white background, black text, up/down arrows) allow the user to adjust the set point for the appropriate heater. If the appropriate Set Point Source Control (see below) is in "Global" or "Disabled" mode (see below), the appropriate Set Point control is disabled. Note: If the Alarm monitor detects an error condition, the control changes to have

a red background and white text to indicate a problem with the appropriate heater.

Indicators The Temperature Indicators (dark teal background and white text) display the temperature feedback for the appropriate heater.


Set Point Source Controls The circle-shaped buttons next to the Piston Accumulators and the Core Holder Temperature indicators allow the user to select the source of Set Point for each of these controls.

Global (top green button): Placing the temperature control in "Global" mode instructs the software to use the Oven Temperature Set Point as the Set Point for this control. When this mode is selected, the appropriate Set Point control is disabled.

Local (middle green button): Placing the temperature control in "Local" mode instructs the software to use the Set Point defined in the appropriate Set Point Control.

Disabled (bottom red button): Placing the temperature control in "Disabled" mode instructs the software to disable the appropriate heater. When this mode is selected, the appropriate Set Point control is disabled and the appropriate heater is set to 0° (both °F and °C; effectively sets the heater to "ambient" temperature).

Turn All Heaters OFF at end of Schedule: When this button is "active" (green indicator is lit), the software will turn all of the heaters off (heaters will be set to ambient) when the Schedule completes. If the schedule is manually stopped by the user (i.e., the schedule does not end by itself), all heaters will be turned off if this button is active. If this button is not active when the schedule ends (either automatically or manually stopped by the user), the heater Set Points are not changed.

Quizix Pumps

Figure 83: Quizix Pumps

The Quizix Pumps control Fluid Delivery (QX1), Sand Injection and Confining Pressure (QX2) and Back Pressure (QX3). Pump QX1 (Cylinders 1a and 1b) runs in "Paired Delivery" mode; both cylinders are used to deliver fluid at a constant pressure or flow. Pump QX2 (Cylinders 2a and 2b) runs in "Independent Constant Pressure" mode; Cylinder 2a is used to control the Sand Injector; Cylinder 2b is used to control the Confining Pressure in the Core


Holder. Pump QX3 (Cylinder 3b) runs in “Independent Constant Pressure” mode, and is used to control the Back Pressure Regulator for the fluid recirculation loop. Note: The 9000 DACS software controls the Quizix pumps through a DDE

(Dynamic Data Exchange) interface with Quizix PumpWorks. PumpWorks is launched (if it is not already running) when the software starts. The operator may use PumpWorks to control all of the pumps in the system. Control of each pump is also provided within the 9000 DACS software for convenience and ease of use.

Cylinder Volume: These indicators (located just below the blue bars) display the current volume for the appropriate cylinder. Run / Stop: These buttons start and stop the appropriate pump or cylinder. The button is red and displays "Stop" when the pump is running. Set Point: These controls (off-white background, black text) allow the user to enter the set point for the appropriate pump or cylinder. Pump QX1 can be set to "Constant Pressure" or "Constant Flow" mode (see Pump QX1 Mode Select below). Thus, the units for the QX1 Set Point is the defined pressure units (see Unit Selection window) when operating in "Constant Pressure" mode or milliliters per minute (ml/min) when operating in "Constant Flow" mode. Pumps QX2 and QX3 are always in "Pressure" mode. Thus, the units for the Set Point are always the defined pressure units (see Unit Selection window). Output: These indicators display the current output of the pump in the same units as the Set Point (see above). Pump QX1 Mode Select: This drop down control allows the user to set Pump QX1 in either "Constant Pressure" or "Constant Flow" mode. If the pump is running when the mode is changed, the pump is first stopped and then the mode is changed (the pump is not restarted). Stop All Pumps: This button allows the user to stop all running pumps (including pumps used on the Fluid Recirculation window).

Valves

Figure 84: Valves

These controls allow the operator to actuate the appropriate valve. When the control is green, the valve is open; when the control is red, the valve is closed. The color of the pipe section running through the valve control does not change when the valve is clicked. The pipes only change color when an appropriate flow path is selected (see below). This control allows the user to select a common valve configuration. The following table describes which valves are opened / closed when selecting the different Flow Loop options:


V17 V18 V19 V20 V21 V22 V23

Upward Injection Closed Open Closed Open Closed Open Closed

Bottom Flush Closed Open Closed Open Closed Closed Open

Downward Injection Open Closed Closed Open Closed Closed Open

Top Flush Open Closed Closed Open Closed Open Closed

Table 1: Permeameter Flow Path Selection

There are two remaining modes:

Close All Loop Valves: Closes all computer controlled valves on this window. User Defined: Selecting this mode does not automatically open or close any valves.

This mode is used to indicate that the user has selected a valve combination that does not allow for any of the above defined Flow Loop valve configurations.

Note: When a recognized flow loop is detected, the pipe colors will change to

indicate how fluid will flow.

Clean Fluid Reservoirs

Figure 85: Clean Fluid Reservoirs

These controls allow the user to select which Clean Fluid Reservoir to use for Pump QX1. As pictured above, Fluid Container 1 is being used. The user can click on either the valve or the container icon. Note: These controls are mutually exclusive; i.e. selecting one reservoir will

deselect the others.


Balance

Figure 86: Balance

Grams: This indicator displays the mass reading as reported by the balance. gm/min: This indicator displays the Effluent Rate of fluid through the core. Tare: This button allows the user to re-zero the balance.

Schedule

Figure 87: Schedule Control

Current: If the current schedule step is based on Time (see Schedule Editor), this indicator displays the time that has elapsed since the current step began. If the current schedule step is based on Volume, this indicator displays the amount of volume that has been injected since the current step began. Target: If the current schedule step is based on Time (see Schedule Editor), this indicator displays the time when the schedule will be automatically advanced to the next step. If the current schedule step is based on Volume, this indicator displays the volume when the schedule will be automatically advanced to the next step. Step: This indicator displays the currently executing schedule step. Run / Stop Schedule: This button allows the user to start and stop the schedule. Pause Schedule: This button allows the user to pause the schedule. If this button is "active" the schedule will not automatically advance to the next step. Advance Schedule: This button allows the user to manually advance the schedule to the next step.


Fluid Recirculation Screen

The Fluid Recirculation Screen is displayed on the right-hand monitor, and represents the right side of the instrument. Pressure indicators and valve selections are similar to those on the Permeameter Screen. In addition to the type of controls found on the Permeameter Screen (see Permeameter Screen), the following controls and indicators are located on the Fluid Recirculation Screen. For a complete description of each control, refer to the online help files under the “Help” menu.

AB Flow Path: Allows the user to select a pre-defined flow path for Recirculation Accumulators A and B.

Figure 88 - AB Flow Path

CD Flow Path: Allows the user to select a pre-defined flow path for Recirculation

Accumulators C and D.

Figure 89 - CD Flow Path


EF Flow Path: Allows the user to select a pre-defined flow path for Recirculation Accumulators A and B.

Figure 90 - EF Flow Path

General Valve Configuration: Allows the user to select a pre-defined flow path for

all Recirculation Accumulators.

Figure 91 - General Valve Configuration

Accumulator Volume Indicators: Provide the user with a visual representation of

the piston position in each accumulator. Volumes are updated via software, when a pre-defined flow path is selected, using the cumulative volume delivered by the fluid recirculation pump. Volume values may be reset manually using the “Reset” button, shown below.

Figure 92 - Accumulator Volume Indicator


Fluid Recirculation Pump: Provides control of the fluid recirculation pump. This is

the large Quizix pump, located at the rear of the instrument. This pump may be used to recirculate fluids across the core face in constant rate mode, or to maintain a static pressure at the core face in constant pressure mode.

Figure 93 - Fluid Recirculation Pump


On-Screen Data Plotting

Most of the measured signals may be plotted dynamically, on one of two plot screens. The first plot screen is accessed via the Plot tab on the Permeameter window. This plot is capable of showing the signals pertinent to the Fluid Recirculation window. Similarly, the second plot screen is accessed via the Plot tab on the Fluid Recirculation window, and displays the signals pertinent to the Permeameter window. For a complete description of each control, refer to the online help files under the “Help” menu.

Figure 94 - On-Screen Plotting


Schedule Editor Screen

Many of the instrument functions may be automated through use of a schedule. A schedule editor screen is provided, that allows the user to edit, save and recall pre-defined custom schedules. For a complete description, refer to the online help files under the “Help” menu.

Figure 95 - Schedule Editor Screen

Units Screen

Figure 96: Unit Selection Screen

The Units Screen allows the user to define which units are used for various controls.


OK: Click this button to accept any changes and close the window. Cancel: Click this button to discard any changes and close the window. Note: Changing the units will clear the data from each plot. Calibration Screen

The Calibration Screen allows the user to re-calibrate each pressure transducer, as well as define the working volumes for each fluid recirculation accumulator. For a complete description of each control, refer to the online help files under the “Help” menu.

Figure 97 - Calibration Screen


Viscosities Screen

The Viscosities Screen allows the user to define the viscosity of the fluids in the Sample Fluid Containers and the Piston Accumulators on the Permeameter Screen. These values are used for the permeability calculation.

Figure 98: Viscosities Screen

OK: Click this button to accept any changes and close the window. Cancel: Click this button to discard any changes and close the window.


Alarms Screen

Figure 99: Alarm Configuration Screen

The Alarms screen allows the user to define the "trip point" for the appropriate alarms. High Process Temperature: This control defines the alarm temperature that is used by the temperature controller. If any temperature is above this point, the temperature controller will raise a "Master Alarm" which will turn off all of the heaters. High N2 Pressure: This control defines the alarm pressure for the Nitrogen pressure. If the Nitrogen pressure rises above this point, an alarm is raised. High Drilling Fluid Pressure: This control defines the alarm pressure for all pressure gauges on the Fluid Recirculation Screen. If any pressure rises above this point, an alarm is raised.


High Core Holder Pressure: This control defines the alarm pressure for the Core Holder on the Permeameter Screen. If the core holder pressure rises above this point, an alarm is raised.

Show Alarms: This button will show the Alarm Monitor window.

Default: This button will reset all alarm controls to the default value (default values are depicted in the image above). OK: This button saves any changes that were made and closes the window.

Cancel: This button will discard any changes that were made and closes the window. Note: Changes to the control on this window do not take effect until the "OK"

button is clicked. Communications Screen

Figure 100: Communications Screen

The Communications Screen allows the user to define which COM port is used for each serial device. If two or more devices are assigned to the same COM port, the control name will turn red and the OK button will become disabled.


OK: Clicking this button will save any changes and close the window. Cancel: Clicking this button will discard and changes and close the window. Core Holder Screen

Figure 101: Core Holder Screen

The Core Holder Screen allows the user to define the Sample Length and Pressure Tap locations. These values are used in the Permeability calculations. OK: Click this button to accept any changes and close the window.


Cancel: Click this button to discard any changes and close the window. Alarm Monitor Screen

Figure 102: Alarm Monitor Screen

The Alarm Monitor Screen displays any detected alarms. If no alarms are detected, the window has a green background. If any alarms are detected, the window has a red background (pictured above) and the specific alarms are displayed in the grey text area. For a complete description of each alarm condition, refer to the online help files under the “Help” menu. Acknowledge ALL Alarms: Clicking this button will acknowledge all alarms currently displayed. An acknowledge signal is sent to the temperature controller (if a temperature alarm exists) thus resetting the alarm. Acknowledging a Closed Flow Path alarm will reset the corrective action.


Monitored Alarms

Temperature: The Watlow CLS216 Temperature Controller and CAS200 Temperature Alarm Scanner have several conditions that they monitor (the High Deviation, High Process, T/C Reversed, T/C Short, T/C Break, Ambient Warning, Ambient Cal Error, Full Scale Cal Error and Offset Cal Error conditions are enabled by the software; see your Watlow documentation for more information regarding these errors). If any of these error conditions are detected an alarm is raised and all heaters are disabled. New Temperature Set Points will not be accepted until the alarm has been acknowledged.

Pressure: All pressure gauges are compared to the appropriate Alarm Condition defined on the Alarm Configuration window. If any pressure is out of range, an alarm is raised and the appropriate Pressure Indicator on either the Permeameter or Fluid Recirculation Windows changes to a red background with white text. Acknowledging this alarm has no effect.

Boiling: The Temperature and Pressure of the Core Holder on the Permeameter Window and Bladder Accumulators on the Fluid Recirculation Window are monitored. If the temperature is greater than 90 °C (194 °F) and the pressure is less than 50 psi (344.7 kPa or 3.5 bar) a Boiling Alarm is raised and the appropriate control will "blink." Acknowledging this alarm has no effect.

Closed Flow Path: If Pump QX1 on the Permeameter Window or Pump 4 on the Fluid Recirculation Window is in "Constant Flow" mode and the software detects that the fluid has nowhere to go, a Closed Flow Path alarm is raised and the appropriate pump is set to a Flow Rate of 2 ml/min. At this time, the pump can be set to a different set point (anything above 2 ml/min is not recommended). Acknowledging this alarm while a Closed Flow Path is still detected will result in the 2 ml/min set point being set again.

Heaters Disabled due to Pump or Pressure Status: If both of the back pressure regulator control pumps are not running, or an overpressure condition exists, the heaters are automatically disabled via software.

PumpWorks Settings

The 9000 DACS software application works in conjunction with Quizix PumpWorks to control the Quizix pumps. The PumpWorks user manual and the PumpWorks online help files explain the operation of the PumpWorks software in detail. Pump features that are accessed during normal operation of the equipment are provided within the 9000 DACS software interface for convenience and ease of use. However, it is useful for the operator to understand the following concepts when operating the PumpWorks software in conjunction with the 9000DACS application.


Safety Pressures

Safety pressures refer to digital alarm set points for each pump cylinder. Any time a pump pressure exceeds its safety pressure, the pump is automatically stopped and an error is logged. 9000DACS attempts to automatically adjust the safety pressures, according to the operational requirements. However, it may become necessary to reset a pump safety pressure and restart the pump from the PumpWorks application, in order to relieve pressure stored in a pump cylinder. Refer to the PumpWorks online help files for more information about setting safety pressures.

Operating Modes

The Quizix pumps are designed to operate in several modes, which are accessible via PumpWorks. Some commonly used modes are:

Independent Constant Rate: Allows a piston to be moved independently of the other pistons at a user-specified rate. This mode is useful for manually positioning a piston, without automatic valve switching.

Paired Constant Rate Delivery: Allows a pair of pump pistons to work in conjunction to deliver fluid at a smooth, constant flow rate.

Paired Constant Pressure Bi-Directional: Allows a pair of pump pistons to work in conjunction to deliver or receive fluid at a constant pressure.

Independent Constant Rate Cycled: Allows a pump piston to deliver fluid at a constant rate, refill, and resume fluid delivery at a constant rate.

Independent Constant Pressure Cycled: Allows a single pump piston to achieve a constant pressure by delivering fluid, filling and resuming constant pressure operation.

Sequencer Operation – Evacuating the Confining Oil

PumpWorks allows the use of user-defined custom programs or scripts, called sequences. For example, a custom sequence exists to evacuate the confining oil from the core holder. The sequence causes the pump cylinder to open its delivery valve, close its fill valve and retract at 50 mL/min. When the pump reaches its maximum travel, the delivery valve is closed, the fill valve is opened, and the piston is extended, to deliver fluid to the confining oil fill tank at 50 mL/min. Once the piston has reached the end of its travel, the process is repeated. The sequencer continues until it is stopped by the operator.

Pump Tuning Parameters

Most operating modes require each pump cylinder to control its pressure in a precise, safe manner. Due to the varying dynamic conditions that each pump may encounter, a set of tuning parameters are provided within PumpWorks. Two sets of gains are provided per pump cylinder: Open Valve Gains and Closed Valve Gains. The Closed Valve Gains are used when the pump cylinder is trying to maintain a


constant pressure with both its valves Closed. The Open Valve Gains are used when the pump cylinder has a valve open to the rest of the system. Two gain adjustments are available: Proportional and Derivative (Differential). The proportional gain affects how quickly the pump reacts to a change in pressure or pressure set point. The differential gain affects how quickly the pump pressure attempts to converge to a new set point.

Soft Limits

Each pump cylinder is equipped with position sensors. When a pump cylinder reaches a software-defined limit, a “Soft Limit” error is displayed, and the pump is automatically stopped. When a pump is at a soft limit, it may be moved in one direction only.

Error Log

PumpWorks provides a log of all errors and events, pertaining to the Quizix pumps. It is accessible by pressing the red “Errors Present” or gray “No Errors Present” button at the bottom of the PumpWorks screen.

Core Preparation Before loading the core into the core holder, the operator should ensure that the core is properly prepared. The following list provides guidelines for core preparation before testing.

1. Insure that both ends of the core have edges that are sharp and not rounded. Any gaps in the ends of the core sample will cause failure of the test. 2. Insure that the diameter of the core meets the requirements of the tester. 3. Insure that the ends of the core are perpendicular to the axis so the core fits flush against the ends of the holder and/or the spacers. 4. It is helpful to have the core fully saturated before loading it into the core holder. This can be achieved by soaking the core in brine under a vacuum.


Loading the Core Sample

Note: The core holder is designed for convenient loading and unloading. The unit can be rotated for easy access. Core sample size must be 0.98-1.2” (2.49 – 2.59 cm) in diameter and 5.5-6.5” (13.97 – 16.51 cm) in length (with spacers). Alternatively, the core sample diameter may be 1.48”-1.52” (3.76 – 3.86 cm) with alternate internal components installed. The diameters of the cores used for testing should be as consistent as possible to insure a longer life for the core holder tube.

1. Ensure that no confining pressure is applied to the core holder. 2. Remove only the plumbing lines from the bottom of the core holder. 3. Unscrew the end plug from the bottom of the core holder. 4. Insert the core first and then the spacers to achieve the total length required for the

tester. 5. Reinsert the end plug and screw it into the bottom of the core holder. Be sure the end

plug butts firmly against the core (or spacers). Note: The end plug MUST fit firmly against the core (or spacers) or the Core

Holder Tube will not seal correctly.

6. Re-attach the plumbing lines on the bottom of the core holder. Note: When spacers are used, the bottom flush does not actually flush the bottom

face of the core, but rather the spacers.


Loading a Drilling Fluid Drilling fluid may be transferred from the fluid preparation cart tank to a piston accumulator via the fluid transfer pump.

1. Designate an accumulator pair for drilling fluid recirculation, and evacuate both accumulators. Refer to the “Unloading a Drilling Fluid” section of this manual. It is recommended that drilling fluids be loaded in the AB pair, and fluids designated to be recirculated across the core face be loaded into the next pair, from left to right. The first fluid to be used should be loaded into accumulators A and B, the second fluid to be used should be loaded into accumulators C and D, and the last fluid to be used should be loaded into accumulators E and F.

2. Select “Close all Valves” in the flow path drop list above the appropriate accumulator pair on the Fluid Recirculation software screen.

3. Clean the fluid preparation cart tank, close the side drain valve and load the drilling fluid into the tank.

4. Select an air pressure of 20 PSI, and set the fluid transfer pump control valve to the “ON” position. The pump may cycle a few times and stop.

5. Place a container below the bleed valve at the rear of the instrument, and open the valve. The fluid transfer pump should begin to cycle.

6. Once any air or fluids left in the fluid transfer pump and fill lines are displaced, close the bleed valve.

7. Select a pressure of 100 PSI on the fluid transfer pump air regulator. 8. In the “Fluid Recirculation” software screen, select “Fill A”, “Fill C” or “Fill E”,

depending on the accumulator pair being used from the flow path drop list above the appropriate accumulator pair.

9. Select “VENT” on the recirculation oil fill tank control valve. 10. The fluid transfer pump should begin pumping fluid into the accumulator. 11. Observe the pressure indicator for the accumulator on the “Plot” tab. Once the

pressure has reached the same pressure as the oil fill tank (approximately 0 PSI), the piston has reached the end of its travel in the downward direction.

12. Select “Close all Valves” from the flow path drop list above the accumulator pair. 13. Select “Adjust Initial Volume” from the flow path drop list above the accumulator

pair. 14. Select “Constant Flow” in the drop list for the fluid recirculation pump. 15. Select a flow rate of 100 mL/min in the flow rate set point for the fluid recirculation

pump. 16. Press the “Run” button, and observe the pressures for each accumulator in the pair

being used. If the pressure exceeds 100 PSI, reduce the flow rate, to prevent the pressure relief valve at the right side of the lower-right cone and seat valve manifold from opening at its relief pressure of 150 PSI.

17. Once the accumulator volumes have equalized, the pump will stop automatically. 18. Select “Close All Valves” in the drop list above the accumulator pair being used.

Note: Before heating any fluids stored in an accumulator pair, select the

“Accumulator Heating” flow path, to allow the oil and drilling fluid to expand during heating.


Filling the Sand Injection Accumulator The sand injection accumulator can be filled prior to a test, so that the solution is heated prior to injection. To fill the sand injection accumulator, use the following procedure:

1. Loosen the fittings at the top and bottom and remove the accumulator from the instrument.

2. Unscrew the cap from the bottom of the accumulator, aim the top fitting at a waste container, and press the piston as far into the accumulator as possible, using the core extraction rod.

Caution: Any oil stored in the top of the accumulator will be expelled under

pressure through the top fitting.

3. Fill a container or syringe with the sand and a carrier fluid. In general, viscosified carrier fluids tend to deliver a more uniform gravel pack than fluids with a low viscosity. Use the following chart as a general guideline to determine the volumetric requirement. It is recommended that the entire volume of the sand injection accumulator be filled, so that the maximum ratio of carrier fluid to sand is used.

Slot Width (in) Slot Height (in) Sand Volume (mL) Liquid Volume

(mL) 0.75 0.5 20 35 0.75 0.25 15 40 0.75 0.125 13 42 1.0 0.5 25 30 1.0 0.25 17 38 1.0 0.125 15 40

4. Ensure that the sand is mixed well into the solution, before filling the accumulator.

Do not pour the sand directly into the accumulator, before adding the carrier fluid. This may cause the carrier fluid to be injected, leaving the sand behind in the accumulator.

5. Replace the bottom cap, ensure that the sand injection accumulator isolation valve is closed, and re-install the accumulator.

6. Bleed the air from the oil supply to the accumulator. a. Place the handle of the three-way valve next to the accumulator in the

downward position. b. Open PumpWorks. c. From PumpWorks, open the fill and deliver valves of Pump 2, Cylinder A,

simultaneously. d. Set the pressure regulator at the top of the confining oil fill tank to 50 PSI. e. Loosen the cap on the side of the tee connection at the top of the accumulator,

and catch any oil that is expelled with a cloth or paper towel. f. Tighten the fitting, once oil flows from the loose fitting, with no air bubbles.


Injecting Sand (Simulated Gravel Pack) Sand may be injected into the flow slot at the core face, during a test. The following procedure assumes the sand injector accumulator is loaded with sand and a carrier fluid, the core sample is installed and is ready for sand placement.

1. Ensure the sample injection pump and fluid recirculation pumps are stopped. 2. Close valves 17 and 22. 3. Ensure that the pressure in the fluid recirculation loop is equal to the pressure at the

core face. a. Close valves 19, 20 and 21. b. Select “Close All Recirculation Valves” on the “Fluid Recirculation” screen. c. Select “Pressurize A” from the “AB Flow Path” drop list. d. Enter the desired pressure in the fluid recirculation pump pressure set point

entry box, and press the “Run” button next to the pump. e. The pump should automatically adjust the pressure in accumulator A.

4. Open a flow path between the sand injection accumulator and a fluid recirculation accumulator. (eg. Open valves 21 and 27 and ensure that valve 25 is in a position that shows a green flow path between the bottom and right ports, in order to accept the carrier fluid into accumulator A.)

5. Open valve 27. 6. Place the sand injection screen filter valve handle in the outward position, to place the

screen filter in the fluid flow path. 7. Open the sand injection accumulator isolation valve beneath the sand injection

accumulator. 8. Place the sand injection / screen placement three-way selection valve handle in the

downward position, for sand injection. 9. Select “Constant Rate” in the “Sand Injection Mode” drop list on the “Permeameter”

screen. 10. Enter a flow rate set point of 50 mL/min in the lower-left field below the sand

injection/screen placement pump on the “Permeameter” screen. 11. On the “Plot” tab of the “Fluid Recirculation” screen, enable the “Sand Injection

Pressure” channel, so that pressure can be monitored during sand injection. 12. Ensure that the confining oil fill tank is pressurized to 50 PSI. 13. From PumpWorks, set the safety pressure for Pump 2, Cylinder A to 250 PSI above

the pressure at the core face. 14. Press the left “Run” button, located near the bottom of the sand injection / screen

placement pump on the “Permeameter” screen. 15. The pump will begin injecting oil into the accumulator, displacing the piston, sand

and carrier fluid. 16. Observe the sand injection pump pressure on the graph. It will cycle each time the 11

mL of oil is displaced from the cylinder, and the cylinder is refilled. When the pressure climbs above the safety pressure, the pump will automatically stop. This indicates that the piston in the accumulator has stopped moving.

17. To ensure that the entire volume of sand and carrier fluid was displaced, count the

number of pump cycles, indicated by a rise and decrease in the sand injection pump


pressure on the graph. Each cycle represents approximately 11mL of fluid displacement. Thus, for a complete injection, approximately 4-5 cycles are required.

Dynamic Screen Placement A screen sample may be dynamically pressed against the core face or into the gravel pack during a test, to simulate well bore conditions. The screen may be lowered by placing the three-way valve handle next to the sand injection accumulator in the upward position. This allows the sand injection / screen placement pump cylinder to deliver oil to the hydraulic piston inside the head of the core holder. It is recommended that “Constant Pressure” be selected from the “Sand Injection Mode” drop list on the “Permeameter” screen, so that the piston overbalance pressure can be precisely controlled. Required Screen Dimensions

A screen sample must be cut to match the template found in the following drawings, located in the “Drawings” section of this manual: 1” Core Holder (0.75” Slot) - 6100-2390 SCREEN TEMPLATE, .625 X 1.6 1.5” Core Holder (1.0” Slot) - 6100-2391 SCREEN TEMPLATE, .875 X 1.6 Preparing the screen for a test

A screen sample may be installed in the screen holder, using automotive RTV sealant. The screen must be cut to the required dimensions for the appropriate screen holder, before insertion. A series of spacers is available, which must be placed behind the screen sample. Use a combination of spacers that positions the screen sample flush with the end of the screen holder. Seal the edges of the screen with a fine bead of sealant. Avoid using excess sealant, to preserve a clear flow path through the screen.

Figure 103 - Screen Holder


Operating a Test without a Screen

For a test without a gravel pack simulation, use of a screen sample may not be desired. In this case, an adapter is provided that does not require a screen to be glued in place. The adapter and hydraulic piston are shown below.

Figure 104 - Hydraulic Piston without Screen Holder


Changing the Screen Adapter

To change the screen adapter, use the following procedure:

1. Disconnect the plumbing to the top of the core holder head assembly and remove it by rotating the collar counterclockwise. Once the threads are disengaged, pull upward to disengage the piston o-rings from the core holder.

Figure 105 - Core Holder Head Assembly

2. Remove the fittings from the top of the assembly, and pull the piston assembly out of

the cap, as shown below.

Figure 106 - Removing the Piston Assembly

3. Remove the screen adapter retaining screw from the top of the piston.


4. Install the new adapter, using the screen adapter retaining screw at the top of the piston.

5. Re-install the fittings, and re-install the core holder head assembly onto the core holder.

Setting the Maximum Slot Height

The maximum slot height can be reduced, by inserting the supplied spacer rings above the screen placement piston. The maximum slot height is 0.5”, but the addition of spacers will effectively limit the piston travel. It is recommended that the pressure to the screen placement piston be regulated during heating, to prevent thermal expansion of the oil from causing the piston to actuate prematurely. This is accomplished by placing the three-way valve handle next to the sand injection accumulator in the upward position. This allows the sand injection / screen placement pump cylinder to deliver oil to the hydraulic piston inside the head of the core holder. It is recommended that “Constant Pressure” be selected from the “Sand Injection Mode” drop list on the “Permeameter” screen, so that the hydraulic pressure on the piston pressure can be precisely controlled during heating of the sample.

Nitrogen Permeability Measurement Nitrogen permeability measurement is performed in the same manner as a liquid permeability measurement, except that the Nitrogen flow controller is used to deliver Nitrogen to the core holder. Nitrogen can be applied at a constant pressure, or constant flow rate, depending on the software selection. Refer to the online help files or the “Primary Software Functionality” section of this manual for more details. Filling the Nitrogen Humidifier

The Nitrogen humidifier may be filled with water, using the following procedure:

1. Remove pressure from the system. 2. Disconnect the plumbing from the top of the humidifier. 3. Remove the humidifier lid, using a spanner rod. 4. Ensure that the drain valve at the bottom of the humidifier is closed. 5. Partially fill the humidifier by pouring water into the top of the vessel. Do not

overfill the vessel. 6. Replace the humidifier lid using a spanner rod and reconnect the plumbing.


Starting a Permeability Test After the core is inserted into the core holder with the appropriate spacers, verify that all of the plumbing lines are re-connected to the core holder. Fill as many fluid containers as are necessary for the test. Only fluids with low viscosity may be placed in fluid containers 1-4 (i.e. fluids less than 10cP, such as brines or acids). The fluid loaded into container #1 should be the least hazardous and easiest to dispose of fluid. Viscous materials such as muds must be loaded into the accumulators (designated as fluid containers A, B and C) in order to be pumped. Any muds pumped should either be solids-free, or should be pumped using the fluid recirculation system. Note: The use of inhibitors in acid solutions is highly recommended.

Note: The fluid in container #1 is used to push the piston in the accumulators

(fluids A, B and C). Therefore, sufficient fluid must be placed in fluid container #1 to equal the volume to be used in the test as well as to provide enough fluid volume for pumping up the piston in the accumulator.

1. To fill an accumulator with a viscous fluid, perform the following steps:

a. Disconnect all plumbing lines from the top of the accumulator. b. Remove the top of the accumulator. c. Open the valve at the bottom of the accumulator and place a container

underneath the outlet to catch the liquid. Note: The fluid in the accumulator will be the last fluid from Fluid #1 that was

used to pump up the accumulator. Be careful handling the fluid.

d. Manually push the piston to the bottom of the accumulator. e. Close the valve. f. Fill the accumulator with the desired fluid. g. Replace the top and re-connect all lines.

2. Prime the pump by manually operating the pump from the software. Select the desired fluid and set a flow rate. The pump will then self prime.

3. Apply confining pressure to maintain a pressure of 300-500 PSI greater than the chemical injection pressure. (Also see notes on Confining Pressure below.)

4. It may be desirable to fill the fluid lines of the system with a fluid other than water. Typically, after a test, the lines will be left filled with water from the flushes. However, if the core being tested is sensitive to water, the lines will need to be flushed with another fluid.

5. Set the Back Pressure Regulator Control regulator to the desired pressure (typically 100 PSI).

6. Load the fluid recirculation system by following the “Loading a Drilling Fluid” section.


7. Begin heating, if desired, by entering the set point into the oven temperature control on the “Permeameter” software screen and pressing the green button on the front of the control panel. The red button stops the heaters. An “Enable Heaters” on the software must also be selected, for a non-zero temperature set point.

8. Close the oven doors and activate the oven seal actuator by pressing one of the green buttons on the oven door.

9. Verify that a container is on the balance to receive any leak-off fluids. 10. Tare the balance. 11. Select the desired flow path and begin flow using the computer control software.

Recirculating Fluids Drilling or cleaning fluids may be recirculated across the core face during a test, using any of the three fluid recirculation accumulator pairs. The following procedure allows drilling fluid to be recirculated, without reaching the core face. Refer to the “Dynamic Mud-Off” section of this manual for details on recirculating fluids across the core face.

1. Load a fluid into the desired recirculation accumulator pair, prior to starting the test. (Refer to the “Loading a Drilling Fluid” section of this manual.)

2. Close valves 19 and 21. 3. Open valve 20. 4. Select a working volume for the appropriate accumulator pair in the “Calibration”

software screen. 5. Select “Deliver from X, Receive to Y” from the drop list above the accumulator pair,

where “X” is the accumulator with more fluid in it, and “Y” is the accumulator with less fluid in it. The software will automatically configure the valves.

6. Select “Constant Flow” from the drop list next to the fluid recirculation pump. 7. Select the desired flow rate for the fluid recirculation pump. 8. Select the desired operating pressure, by setting the back pressure regulator control

pump. 9. Start the back pressure regulator control pump, and the fluid recirculation pump.


Dynamic Mud-Off To recirculate fluids across the face of the core and perform a dynamic mud-off test, perform the following procedure.

1. Follow the “Recirculating Fluids” procedure to set the fluid recirculation loop pressure and flow rate.

2. Allow the accumulators to reciprocate at least once, to ensure that the software volume calculations are correct.

3. Select the desired back pressure on the permeameter back pressure regulator. 4. Stop the sample fluid delivery pump. 5. Tare the balance. 6. Select “Mud-Off” from the flow path selection drop list on the “Permeameter”

software screen. 7. Filtrate will be collected on the balance, and can be monitored from the on-screen

plot.

Static Mud-Off For a static mud-off test, perform the same procedure as for dynamic mud-off, except that the fluid recirculation pump must be used in constant pressure mode. It is also important that the fluid recirculation loop back pressure regulator be set to a higher pressure than the set point for the fluid recirculation pump, to prevent pressure loss through the regulator. Conversely, a valve configuration can be selected that does not allow oil to return to the back pressure regulator.

Test Clean-up Note: Test clean up (steps 1, 2, and 7) can begin immediately after the test is

completed if the operator does not wish to preserve the core. If the operator wishes to preserve the core, water flushes should not begin until after the core is removed.

1. Using the control software, turn the fluid pump off. 2. Turn the heaters off by pressing the red button on the front of the control panel. 3. Open the oven doors and turn the cooling valve on. 4. Allow the system to cool to below 200ºF (93ºC) before continuing. 5. Remove the backpressure by setting the back pressure regulator control pump to zero. 6. Remove the confining pressure by setting the confining pressure control pump to

zero. 7. Remove core by following the Unloading the Core Sample procedure below. 8. Flush all the permeameter lines using the Water Valve on the front of the instrument.

Using the Water Valve on the front of the instrument will allow a more rapid clean up than the 50 mL/min maximum flow rate provided by the pump. Flow water through


all the various flow paths to insure each line is flushed. Be sure to flush all lines to minimize the risk of corrosion and clogging due to precipitation.

9. Clean the piston accumulators thoroughly. 10. Clean the fluid recirculation system thoroughly by following the Cleaning the Fluid

Recirculation System procedure below. 11. Wipe up all spills from the bottom tray.

Unloading a Drilling Fluid To unload (evacuate) a drilling fluid from an accumulator pair, use the following procedure. 1. Pressurize the recirculation oil fill tank using the recirculation oil fill tank controls on

the lower-right front panel of the instrument. Set the air pressure regulator to 80 PSI, and select “Pressurize.”

2. Ensure that the fluid transfer pump control is set to the OFF position. 3. Select a path for the fluid to go, once it is removed from the accumulators, using the

return valve on the lower-right front panel. The fluid can be diverted to the fluid preparation cart, or to a drain on the right side of the instrument. Optionally, the fluid can be removed from the bleed valve at the back of the instrument, as well. To remove fluid from the bleed valve at the back of the instrument, select “OFF” at the return valve, place a container below the bleed valve outlet, and slowly open the valve.

4. From the Fluid Recirculation screen in the software, select “Evacuate Both” under the “XX Flow Path” drop list, where “XX” is the accumulator pair being used (“AB”, “CD” or “EF”).

5. Observe the pressure indicators for both accumulators on the “Plot” tab. Once the pressures have stopped climbing, and reach the same pressure as the oil fill tank (approximately 80 PSI), the pistons have reached the end of their travel in the upward direction.

6. The fluid recirculation accumulator pair can now be cleaned. Refer to the “Cleaning the Fluid Recirculation System” section of this manual.

Cleaning the Fluid Recirculation System The fluid recirculation system may be cleaned using soap and water, loaded from the fluid preparation cart tank. For drilling fluids containing solids, it is recommended that the system also be flushed with a viscous fluid, capable of carrying solids from the accumulators.

1. Unload the fluid from each piston accumulator. Refer to the “Unloading a Drilling Fluid” section of this manual.

2. If solids are present in the system, flush the fluid transfer pump, using a viscosified solution.

a. Fill the fluid preparation tank with a viscosified cleaning fluid. b. Set the return valve on the lower-right panel to the “OFF” position.


c. Close all fluid recirculation valves, using the “Close All Fluid Recirculation Valves” selection in the “General Flow Path” drop list.

d. Place a container beneath the bleed valve at the rear of the instrument. e. Set the fluid transfer pump controls to 20 PSI, and place the fluid transfer

pump control valve in the “ON” position. f. Open the bleed valve at the rear of the instrument. g. Close the drain valve on the lower-right panel of the instrument. h. Close the both valves at the bottom of the fluid preparation cart. i. Set the water valve on the lower-right panel to the “PUMP/DRAIN” position. j. If the pump does not begin to cycle, gradually increase the pump pressure. k. Allow water to flush through the fluid transfer pump and fill manifold. l. Close the bleed valve at the rear of the instrument.

3. If solids are present in the system, flush each accumulator with the viscosified solution, loaded into the fluid preparation tank in the previous step.

a. Fill each accumulator pair with the cleaning solution. Refer to the “Loading a Drilling Fluid” section of this manual.

b. Recirculate the cleaning fluid across the face of the core holder at 400 mL/min. Refer to the “Recirculating Drilling Fluid” section of this manual.

c. Recirculate the fluid through valve 20 by opening valve 20 and closing valves 19 and 21.

d. Unload the cleaning fluid. Refer to the “Unloading a Drilling Fluid” section of this manual.

e. Drain the fluid preparation tank. 4. Fill the fluid preparation tank with soap and water, and repeat the entire process, until

only soap and water are received into the fluid preparation tank. If desired, heat the accumulators to 100-150ºF while cleaning with soap and water.

5. Repeat the process again with clean tap water.

Unloading the Core Sample

1. Insure that there is no fluid pressure on the system and that the confining pressure has been completely removed from the core sample.

Note: Fluid pressure must be removed before the confining pressure is removed.

2. Remove the two plumbing lines from the adjustable end plug located at the bottom of the core holder.

3. Unscrew the end plug from the core holder. 4. Unscrew the top cap from the core holder, to provide direct access to the top of the

core sample. 5. Using the core extractor rod, gently push the core sample out of the core holder.

Note: Do not force the core sample out of the core holder. Damage may occur to

the seals within the core holder if the core sample is forced.


Notes on Confining Pressure Confining pressure is applied to the core by applying hydraulic pressure into the cavity surrounding the rubber Hassler sleeve and core. When pressure is applied, the tube compresses around the core and effectively seals the outer surface of the core so that fluids injected at the ends of the core must pass through it rather than bypass it. The Chandler Model 9000 Drilling Fluids Simulator uses a digitally-controlled pump to apply this confining pressure. There is a gauge on the front panel of the instrument which displays the confining pressure. The confining pressure set point (Refer to the “Description of Primary Software Functions” section of this manual, or the online help files) must be adjusted via software to provide the necessary confining pressure. When the Core Holder is heated, expansion of the oil will cause pressure to increase. Therefore, the software will automatically disable the heaters when the confining pressure pump is stopped, to prevent an overpressure condition. When cooling the system, the confining pressure pump should also be left running, to compensate for any decrease in pressure, due to cooling of the confining oil. Note: Generally it is desirable to maintain a confining pressure that is 300-500

PSI greater than the chemical injection pressure.

SECTION 3 – MAINTENANCE 3-1

Section 3 - Maintenance Core Holder Assembly / Disassembly

The core holder may be disassembled, in order to replace the sleeve, rearrange the pressure tap configuration, or change the sleeve size. Several o-ring seals are also located inside the core holder assembly that may be replaced as needed.

1. Disconnect the two fixed plumbing lines from the bottom of the core holder. Leave the plumbing lines that are wrapped around the mounting collar attached.

2. Disconnect the plumbing lines from the top of the core holder. The screen actuator assembly at the top of the core holder may be removed by rotating the collar counterclockwise. Once the threads are disengaged, pull upward to disengage the piston o-rings from the core holder. Refer to the “Changing the Screen Adapter” section of this manual for illustrations.

3. Evacuate the confining oil. Refer to the “Evacuating the Confining Oil” section of this manual.

4. Pull the rotation pin and rotate the core holder to an inclined position, as shown below.

Figure 107 – Core Holder Assembly Rotation

5. Disconnect the plumbing from the bottom of the core holder. 6. Remove the thermocouple from the bottom of the core holder and set it aside. 7. Remove the adjustable end pug from the core holder.

3-2 SECTION 3 – MAINTENANCE

8. Use the core extraction rod to remove any spacers or core samples that are in the core holder.

Figure 108 - Removing Spacers with the Core Extraction Rod

9. Using a spanner rod, rotate the bottom cap counterclockwise, until the internal core

holder assembly can be extracted (pulled) from the core holder housing.

Figure 109 - Internal Core Holder Assembly

10. Remove the pressure tap hose clamps, using the supplied pliers. 11. Loosen the sleeve stiffening rods, by rotating the jam nut at the base of each rod

counterclockwise.

Figure 110 - Sleeve Stiffening Rods


12. Slide the locking tabs at the base of the sleeve stiffening rods outward and pull the core sleeve assembly out of the end plug assembly.

Figure 111 - Core Sleeve Assembly Removal

13. Use the supplied spanner wrench to remove the brass sleeve retaining ring from the

base of the core holder sleeve to remove the sleeve from the base.

Figure 112 - Brass Ring Removal


14. Loosen the hose clamp at the end of the core sleeve and remove the insert from the end of the core sleeve.

Figure 113 - Sleeve Insert Removal

15. Before replacing the sleeve, select a pair of pressure ports along the length of the core

sleeve to monitor during a permeability test. Use the supplied cutting tool to punch through the membrane, if necessary.

Figure 114 - Pressure Tap Cutting Tool


16. Install the sleeve into the base using the brass ring and metal insert, as shown below.

Figure 115 - Core Sleeve Installation

17. Slide the hose clamp over the core sleeve, and press the adapter into the end of the

core sleeve. Use lithium grease to lubricate the sleeve for ease of insertion. If necessary, cut a slight chamfer into the inside edge of the sleeve with a sharp knife.

Figure 116 - Installing the Sleeve Adapter


18. Install the pressure taps. Plug any unused holes in the sleeve with the supplied plugs.

Figure 117 - Pressure Tap Installation

19. Install the core sleeve assembly into the end cap assembly.

Figure 118 - Installing the Core Sleeve Assembly

20. Slide the locking tabs inward, and re-install the sleeve stiffening rods.

Figure 119 - Sleeve Stiffening Rods


21. Align the ports on the core holder bottom assembly with the slot at the top of the sleeve, so that the confining oil pressurization port will rest at the bottom, if the assembly is held horizontally, while the slot is oriented vertically.

22. Re-install the internal core holder assembly, making sure the confining oil pressurization port is facing outward from the oven assembly, and the flow slot is aligned precisely with the mud recirculation ports.

23. Rotate the core holder to its upright position, loosen the bottom assembly and readjust the alignment of the flow slot, if necessary. The screen holder assembly will not be able to fit into the slot, unless the alignment is accurate.

24. Reinstall the top cap assembly and ensure that the screen holder assembly will fit into the flow slot. Loosen the core holder bottom cap and rotate the core sleeve from the top, using a wrench handle or large flat blade screwdriver, if necessary.

25. Fill the core holder with confining oil. Refer to the “Filling the Confining Oil” section of this manual.

26. Reconnect the plumbing lines to the core holder.

Back Pressure Regulator Diaphragm Replacement The back pressure regulator diaphragms can be replaced, if they become damaged. Teflon and Viton diaphragms are provided for each back pressure regulator. Viton can be used for precise control at differential pressures up to 1500 PSI. For higher differential pressures, a Teflon diaphragm must be used, at the expense of less precise pressure control at low flow rates. It is recommended that a Viton diaphragm be used for the core holder back pressure regulator and a Teflon diaphragm be used for the fluid recirculation system back pressure regulator.

Figure 120 - Back Pressure Regulators

1. Remove pressure from the system, and disconnect the plumbing lines to the regulator. 2. Remove the regulator from the oven assembly, by removing the screws in the

mounting bracket. 3. Place the mounting collar in a vice, and remove the two large hex screws from the

mounting collar. 4. The two halves of the regulator can be removed from the mounting collar by hand.

Tap on the regulator lightly with a rubber mallet or screwdriver handle to free the regulator from the collar, if necessary.


5. Remove and inspect the diaphragm. Teflon diaphragms require an o-ring for proper sealing.

Figure 121 - Teflon Diaphragm and O-Ring

6. Replace the diaphragm, and reassemble the regulator. Tighten each mounting collar

screw as evenly as possible. Turn one screw 90 degrees, then turn the other screw 90 degrees. Repeat until the screws are tightened securely.

Figure 122 - Installed Teflon Diaphragm and O Ring

7. Re-install the regulator and reconnect the plumbing lines.


Filling the Confining Oil To fill the confining oil, use the following procedure.

1. Ensure that the confining oil fill tank is full. 2. Install all three spacers in the core sleeve, and install the adjustable end plug. 3. Disconnect the two fixed plumbing lines from the bottom of the core holder. Leave

the plumbing lines that are wrapped around the mounting collar attached. 4. Disconnect the plumbing lines from the top of the core holder. The screen actuator

assembly at the top of the core holder may be removed by rotating the collar counterclockwise. Once the threads are disengaged, pull upward to disengage the piston o-rings from the core holder.

5. Pull the rotation pin and rotate the core holder to an inclined position, as shown below.

Figure 123 – Core Holder Assembly Rotation


6. Remove the 1/8” plug from the end of the core holder assembly and install the supplied flexible hose. Open the recirculation oil fill tank lid and place the free end of the hose in the tank. This will allow any overflow oil to be delivered to the tank, preventing a potential oil spill once the core holder is filled.

Figure 124 - 1/16" and 1/8" Confining Oil Plugs

7. Open the Quizix PumpWorks software and open the fill and deliver valves for Pump

2, Cylinder B. 8. Set the confining oil reservoir pressure to 50 psi. 9. The pump will begin to displace the air in the system with oil. The confining oil

cavity is approximately 1 Liter for a 1 inch core sleeve, and 850 mL for a 1.5 inch core sleeve. If the Core Holder is completely empty, the total fill time will be approximately 30 minutes. When the air is completely bled from the system, close the confining oil pump deliver valve, and replace the plug in the end of the core holder assembly.

10. Loosen the topmost 1/16” plug at the end of the core holder. 11. Open the deliver valve on the confining oil pump, and watch the loose 1/16” plug for

oil. Once the air bubbles are bled from the port, tighten the plug.


Evacuating the Confining Oil The confining oil may be evacuated from the core holder, ONCE THE SYSTEM HAS COOLED BELOW 104°F (40°C). To create a partial vacuum on the confining oil, open PumpWorks, and select “Auto-Op, Control Sequencer Operation.” Select “Evacuate Confining Oil” and press Start, on the screen that appears. Reduce the confining oil fill tank pressure to 0 PSI. Once a partial vacuum is achieved, the confining oil can be drained (if desired) by rotating the core holder to a horizontal position, and removing the topmost 1/16” plug from the bottom of the core holder. The pump will remove most of the oil from the core holder within 45 minutes.

Figure 125 - 1/16" and 1/8" Confining Oil Plugs

Note: The Confining Oil Pump is not rated to temperatures above 104°F (40°C).

Failure to allow the Core Holder to cool before evacuating the oil through the pump may cause damage to occur!


Oil Filter Replacement An oil filter is located near the mud recirculation pump, which helps to protect the pump and valves, effectively prolonging the life of each. To replace the oil filter, drain the oil from the system and remove with a standard automotive strap wrench.

Cone and Seat Valve Service Pneumatically actuated, software-controlled cone and seat valves are used throughout the fluid recirculation system, to select the desired fluid flow path. These valves are designed to handle particle-laden fluids, and are rated for pressures up to the maximum system pressure of 5,000 PSI. The cone and seat valves are equipped with air actuators, mounted on the rear of the instrument, and contain easily replaceable internal components.

Figure 126 - Cone and Seat Valve

Replacing a Valve Seat (Ring)

To replace a valve seat, remove the gland from the front of the manifold or valve body. Extract the seat (ring) with a small screwdriver and carefully replace it, ensuring that it is inserted fully into the valve body and does not fall over before reinstalling and tightening the gland.


Replacing a Valve Cone (Stem)

1. Remove air pressure from the system, and disconnect the air lines from the valve

actuator. 2. Loosen the jam nut at the back of the valve body (inside the oven) and rotate the air

actuator counterclockwise from the back of the oven, until it is free to pull out of the valve body.

Figure 127 - Valve Actuator Removal

3. Pull the assembly out of the back of the oven.

Figure 128 - Air Actuator and Valve Stem Assembly


4. Remove the four (4) stainless steel screws from the air actuator, and slide the mounting collar off to expose the internal assembly. Place the assembly on a table, as shown below.

Figure 129 - Internal Valve Stem Assembly

5. Press the valve stem in as far as possible, to retract the air actuator. 6. Make note of the total valve stem height from the table. 7. Loosen the jam nut at the base of the valve stem and unscrew the valve stem. 8. Replace the valve stem and tighten the jam nut, ensuring that the valve stem height is

the same as before. 9. Re-assemble the valve and tighten the packing. 10. Reconnect the air lines and apply air pressure to the system.


Adjusting the Valve Packing

A weep hole is located on the side of each valve, and at the rear, on the valve stem assembly. Should fluid begin to leak out of the side weep hole, the front packing may need tightening. Tighten the gland from the front of the manifold or valve body. Ensure that the valve is open before tightening the gland. Be careful not to over tighten. Should fluid begin to leak from the back of the valve, the rear packing can be tightened as follows.

1. Remove the 4 stainless steel screws from the valve actuator, so that the actuator is free to rotate.

Figure 130 - Loosening the Air Actuator Screws

2. Loosen the jam nut at the back of the valve body (inside the oven). 3. Tighten the packing gland, by rotating the gland body by placing a wrench on the

gland body behind the jam nut, and rotating counterclockwise. 4. Tighten the jam nut. 5. Realign the valve actuator, so that the text is horizontal. 6. Tighten the four (4) stainless steel screws on the air actuator.

Cartridge Valve Replacement / Repair To replace a valve, perform the following steps:

1. Press down on the orange ring and remove the tubing from the valve. 2. Using the thin wrench provided with the Model 9000, remove the valve. 3. If the valve is leaking, the two o-rings and two backup o-rings on the exterior of the

valve can be replaced. 4. Replace the valve using the thin wrench and re-attach the tubing.


Replacing the 4-Way Valve Rotor The 4-way valve keeps the flow direction constant while recirculating fluids across the core face. As fluids are reciprocated back and forth between accumulators, the 4-way valve is automatically configured to achieve a constant flow direction, via software. The valve is equipped with replaceable internal components, and is easily serviced from the front of the instrument.

Figure 131 - 4-Way Valve

The 4-way valve rotor can be accessed by removing the four (4) screws from the front of the 4-way valve assembly. The rotor can be pulled from the stem assembly and replaced. Be sure to match the original rotor orientation when replacing the rotor.

Figure 132 - 4-Way Valve Rotor

When replacing the screws at the front of the valve assembly, tighten each screw 90 degrees and repeat until the screws are tight.


Re-Installing Software and Drivers The software comes pre-installed on the 9000 PC. However, if problems are encountered or a new computer is obtained and the software must be installed, the following procedures should be used. Network Settings

The Model 9000 PC is shipped with Network settings pre-configured. Should it become necessary to re-configure the settings, or install the software on a different PC, the following procedure should be used.

1. Open the Network Connections Window 2. From the start menu, right-click on My Computer, and select Explore, as shown

below.

Figure 133: Start Menu


3. Click on My Computer, Control Panel and Network Connections, as shown below.

Figure 134: Network Connections

4. Identify the Model 9000 Network Connection. Many computers will have multiple

network connections shown in the right-side of the Network Connections window, but only one is used to communicate with the Model 9000 hardware. The proper connection must be configured to work properly with the updated software. To identify which connection is used for the Model 9000 hardware, use the following procedure.

a. Turn the Model 9000 ON. b. Wait 30 seconds. c. Make a note of any icons in the right that do not have a red “x” next to them

and do not show the text “Network cable unplugged”. d. Turn the Model 9000 OFF. e. Observe the Network Connections window. One of the icons, should now

have a red “x” next to it, and will include the text “Network cable unplugged,” as shown below.


Figure 135: Identifying the Network Connection

5. Double-Click on the icon that appears with a red “x.” If more than one icon appears

with a red “x,” select the one that changed when the Model 9000 power was turned OFF.

6. Ensure that “NWLink IPX/SPX/NetBIOS Compatible Transport Protocol” is installed and enabled, using the following procedure.

7. In the window that appears, select the “General” tab (default). 8. In the list below the text “This connection uses the following items:,” look for

“NWLink IPX/SPX/NetBIOS Compatible Transport Protocol.” If this item appears in the list, ensure that the box next to it is checked, as shown below.


Figure 136: IPX/SPX/NetBIOS Compatible Transport Protocol

9. If the item appears in the list, proceed to the next step. If the item does not appear in

the list, perform the following procedure.

a. Click on the “Install...” button. b. Select Protocol, and click the “Add...” button, in the window shown below.

Figure 137:Adding a Protocol


10. Select the “NWLink IPX/SPX/NetBIOS Compatible Transport Protocol” item, and click the “OK” button.

11. Change the IP Address and Subnet mask for the network connection, using the following procedure.

12. In the General tab of the window shown below, highlight “Internet Protocol (TCP/IP)”, and click on the “Properties” button.

Figure 138: Selecting TCP/IP Properties

13. In the General tab of the window that appears, select “Use the following IP

address” and enter an IP address of “10.1.1.1” and a subnet mask of “255.0.0.0.” The default gateway should be left blank, as shown below.


Figure 139: TCP/IP Settings

14. Click the “OK” button on the window shown above, and on the previous window.

Quizix PumpWorks

The Model 9000 PC is shipped with PumpWorks pre-installed. Should it become necessary to re-install PumpWorks, the following procedure should be used.

1. Insert the Quizix PumpWorks CD. 2. Run “Setup.exe”. 3. Follow the prompts that appear on-screen. 4. Select the default installation parameters for all settings.

9000DACS and 9000Utils

The Model 9000 PC is shipped with 9000DACS pre-installed. Should it become necessary to re-install 9000DACS, the following procedure should be used.

1. Insert the 9000DACS CD. 2. Run “Setup.exe”. 3. Follow the prompts that appear on-screen.


4. Select the default installation parameters for all settings. The 9000Utils installer will run automatically, during installation of the 9000DACS program.

Comtrol Devicemaster RTS 8-Port Serial Hub

Should it become necessary to re-install the driver for the serial hub, the following procedures should be used. Please follow the procedure for network settings, before attempting to install the drivers. To REMOVE the driver, use the following procedure.

1. Under “Control Panel”, select “System”.

Figure 140: Control Panel

2. In the dialog that appears, select the “Hardware” tab and “Device Manager.”


Figure 141: System Properties

3. Under “Multi-port serial adapters,” right-click on “DeviceMaster RTS 8 Port.”

In the menu that appears, select “Uninstall.”


Figure 142: Device Manager

4. Reboot the PC.

To INSTALL the driver, use the following procedure.

1. Insert the 9000DACS installation disk. 2. Ensure that the Model 9000 is turned on and the Ethernet cable is connected

between the PC and the instrument. 3. Under “Control Panel,” select “Add Hardware.”



4. In the dialog that appears, select “Next.”


Figure 144: Add Hardware Wizard

5. Select “Yes, I have already connected the hardware” and press “Next.”

Figure 145: Add Hardware Wizard Dialog


6. Select “Add a new hardware device” and press “Next.”


7. In the dialog that appears, select “Install the hardware that I manually select

from a list (Advanced),” and press “Next.”



8. Select “Multi-port serial adapters” and press “Next.”



9. In the dialog that appears, select “Have Disk…”


10. In the dialog that appears, select “Browse…”

Figure 150: Install from Disk Dialog

11. In the dialog that appears, browse to the 9000 DACS installation CD, and look

for the “Drivers\Comtrol” folder. Select any file in the folder, and press “Open.”


Figure 151: Locate File Dialog

12. Select “OK.”

Figure 152: Install from Disk Dialog

13. Select “Comtrol Corporation” and “DeviceMaster RTS 8 Port.”



14. In the following dialog, select “Continue Anyway.”

Figure 154: Hardware Installation Dialog

15. In the following dialog, select “Continue Anyway.”


Figure 155: Software Installation Dialog

16. Select “Finish.”



17. Repeat the following procedure eight (8) times, as the dialogs appear.

a. In the dialog that appears, select “No, not this time” and press “Next.”

Figure 157: Found New Hardware Dialog


b. In the dialog that appears, select “Install from a list or specific location (Advanced),” and press “Next.”


c. In the following dialog, select “Search for the best drivers in these

locations” and “Include this location in the search.” Do not select “Search removable media (floppy, CD-ROM…).” If the path to the Comtrol drivers is already selected, press “Next.” Otherwise, select “Browse” and select the “\Drivers\Comtrol” folder on the 9000DACS CD.



d. In the dialog that appears, select “Continue Anyway.”

Figure 160: Hardware Installation Dialog

e. In the dialog that appears, select “Finish.” This process will repeat

automatically for all 8 serial ports connected to the hub.



18. To complete the setup, use the following procedure.

a. Under “Control Panel,” select “System.”



b. In the dialog that appears, select the “Hardware” tab and “Device

Manager.”


Figure 163: System Properties

c. Under “Multi-port serial adapters,” right-click on “DeviceMaster RTS

8 Port.”


Figure 164: Device Manager

d. In the menu that appears, select “Properties.”


Figure 165: Properties Menu

e. Under “Network Connections”, select “MAC Mode,” and enter the

MAC address of the hub. The MAC address is printed on the bottom of the hub, which should be visible inside the rear electrical enclosure.


Figure 166: Network Connections Tab


Figure 167: MAC Address Label Location

f. Select the “Port Settings” tab. Select the first serial port listed (e.g.

COM7), and select “Properties”.


Figure 168: Port Settings Tab

g. In the dialog that appears, select “RS232, None, 0 sec, Block Plug-N-

Play search for attached serial device. Apply these settings to all ports, COM7 and Renumber all subsequent ports relative to this port.” Select “OK” and close all remaining open dialogs.


Figure 169: COM Port Properties Dialog

WatView Software

The Model 9000 PC is shipped with WatView pre-installed. Should it become necessary to re-install WatView, the following procedure should be used.

1. Insert the WatView CD. 2. Run “Setup.exe.” 3. Follow the prompts that appear on-screen. 4. Select the default installation parameters for all settings.


Maintenance Schedule The maintenance schedule will vary with each component. Please refer to the Component Instructions included with your instrument.

MAINTENANCE SCHEDULE Model 9000 Drilling Fluids Simulator

COMPONENT EACH TEST MONTHLY 3 MONTHS 6 MONTHS ANNUALTransducers Calibrate

Hastelloy Fluid Path Filters

Check. Clean if dirty.

Filters Check, replace if dirty

Piston Accumulator O-Rings

Inspect drilling fluid for oil contamination. Replace seals if needed.

Pressure Relief Valves

Check

This maintenance schedule applies to normal usage of one test per day. Detailed procedures for these operations are contained in your manual. Per API Specifications Where Applicable

SECTION 4 – TROUBLESHOOTING GUIDE 4-1

Section 4 - Troubleshooting Guide Potential Problems and Solutions

Problem Solution

Poor Water Supply Check filters to be sure they are not plugged. Check water supply to be sure it is in the “ON” position.

Valves Not Opening / closing Check to see that sufficient air pressure exists – at least 80 PSI. Check the valve itself to ensure that it is functioning. Check that the software is properly communicating with the Model 9000 and the correct flow path is selected.

Leaks Cartridge Valves - If the leak exists by the valves, the o-rings in the valves should be changed. Cone and Seat Valves – If the leak exists behind a valve, tighten or replace the packing.

Confining Pressure Bleeding Off Core Holder Hassler Sleeve may be ruptured. Fluids Not Pumping Check to insure that all lines are primed.

Check fluid inlet filters. Check the pump for any problems. Check PumpWorks Status for errors.

No Power Check, and replace if necessary, the two main fuses in the control box (see electrical schematic).

Connection Lost to Computer Check all cables to insure that they are properly connected. Check power to the Model 9000. Check the two fuses in the power supply.

Heaters Not Functioning Check for alarms in the Alarm Monitor Screen. Check all thermocouple connections. Check thermocouple wiring.

Back Pressure Irregular The diaphragm in the backpressure regulator may be fouled or worn – clean or replace.

Alarm Scanner Communication Error

Check software serial port assignment. Check serial cable. Check status of serial hub in Windows Device Manager. Reinstall serial hub driver if necessary.

Temperature Controller Communication Error

Check software serial port assignment. Check serial cable. Check status of serial hub in Windows Device Manager. Reinstall serial hub driver if necessary.

Nitrogen Flow Controller not Functioning

Check software serial port assignment. Check status of serial hub in Windows Device Manager. Reinstall serial hub driver, if necessary.

Balance Communication Error Check software serial port assignment. Check serial cable. Check front panel of balance for proper display.

4-2 SECTION 4 – TROUBLESHOOTING GUIDE

Problem Solution Restore factory default settings on balance (see balance manual). Check status of serial hub in Windows Device Manager. Reinstall serial hub driver, if necessary.

SECTION 5 – REPLACEMENT PARTS 5-1

Section 5 – Replacement Parts

Part Number Description 6100-0172 Rotor,4-W Slurry Valve 6100-1506 Spreader Sleeve 6100-2012 Diaphragm, Teflon, Pressure Regulator 6100-2028 Plug,1.5"Core Length Adjustment 6100-2029 Gland, Core Adjusting 6100-2046 Collar,4.75-Stub Acme-8 6100-2047 Plug, Coreholder, Adj. End 6100-2048 Housing-Coreholder 6100-2060 Sleeve Adapter,1.5,Slip 6100-2084 Insert, Tube, 1" Core 6100-2086-HC Spacer,3",1" Core, HC 6100-2087-HC Spacer,2",1" Core, HC 6100-2088-HC Spacer,1",1" Core, HC 6100-2089-HC Spacer,3",1.5" Core, HC 6100-2090-HC Spacer,2",1.5" Core, HC 6100-2091-HC Spacer,1",1.5" Core, HC 6100-2145 Modified, Fitting Coreflow 6100-2160 Rod, Core Extractor 6100-2177 Retainer,1.5 Flanged Sleeve 6100-2184 Spanner, Coreholder Flange 6100-2285 Assembly, Tap Nipple with .063 Tubing 6100-2308 Adapter,Flanged,Sleeve,1"Slot x 1.5"Core 6100-2311 Sleeve, Flanged 1x 8.77 Molded Taps 6100-2312 Tube,Coreholder,1.5" 6100-2316 Plug Screen Actuator 6100-2321 Retaining Collar 6100-2323 Cap, Bottom, Coreholder 6100-2328 Gland Nut,.5-20 6100-2329 Stem, Piston Actuator 6100-2330 Piston, Screen Actuator 6100-2332 Adapter,Flanged,Sleeve,.75 Slot x 1"Core 6100-2335 Ring,1"Sleeve Retaining, Notched 6100-2337 Insert, Retaining Ring 6100-2346 Plug,1.5"Core Length Adjustment 6100-2347 Tool, Tap Cutting 6100-2348 Insert, Flow Dist,1" Slot 6100-2349 Insert, Flow Dist,.75"Slot 6100-2350 Spacer,Piston,Back-Up,2D x .2 6100-2351 Spacer,Piston,Back-Up,2D x .1 6100-2352 Spacer,Piston,Back-Up,2D x .3 6100-3040 Valve, Repair Kit 6100-3099 Kit, Valve Repair Tool 6100-3157 Rod,Spanner,0.312 x 0.375 x 6

5-2 SECTION 5 – REPLACEMENT PARTS

Part Number Description 6100-3162 Rod,Spanner,0.250 x 0.187 x 4 6990-0001-HT Valve, Hastelloy C-LD 9000-0172 Rotor,4-W Slurry Valve 9000-0204 Thrust Washer,.377 x .7 x .05 9000-0214 Spring,Rotor,Valve,4-Way 9000-0218 Screw,Set,Drive,Valve,4-Way C00596 Oring,Viton,AS010-75 C07852 Filter, Element 2 Micron C08565 Oring,Viton,AS230-90 C09272 Ring,Backup,Viton,8-010 C09354 Oring,Viton,AS133-70 C09587 Oring,Viton,AS151-75 C09589 Oring,Viton,AS132-75 C09699 Ring,Retaining,2.00,302 SST C09701 Ring,Retaining,3.25,302 SST C09724 Filter, Element 20 Micron C09782 Retainer, External.WS75-SO2 C09814 Ferrule, 1/16, Hip C09815 Gland, 1/16, Hip C09869 Bottle, Wide Mouth,Poly,32 C09999 Spanner, 2" C10035 Filter, Element 15 Micron C10042 Bottle, Wide Mouth,64oz C10084 Plug,1/16, HIP C10293 Ring,Rtng,Ext,WS-175 C10338 Oring,Viton,AS236-75 C10460 Nut, Gland Peek 1/4-28 x .125 C10461 Ferrule,Peek,0.125 C11327 Oring,Viton,AS-010-75 C11532 Oring,Viton,AS240-V75 C11533 Oring,Viton,AS235-V75 C11534 Oring,Viton,AS244-V75 C11632 Ring,Viton,Parback,8-133-V90 C11649 Packing Set, HIP C11651 Lens Ring, Hip Valve C11653 Stem Assembly, Hip Valve C11688 Clip, Spring Hose,0.5 C11689 Screw,Shoulder,SST,1/4 x .375,Slot P-1765 Oil,White,Mineral,9nf,28.2g P-1944 Reducer,SST,1/8T x 1/4OD P-2291 Oring,Buna,AS121-70 P-3217 Grease,Lithium,White,16oz

SECTION 6 – DRAWINGS AND SCHEMATICS 6-1

Section 6 – Drawings and Schematics

Drawing Number Description 6100-2182-XX Accumulator Assembly 6100-2280-XX Assembly, Back Pressure Regulator 6100-2343 Assembly, Core Holder Pressure Vessel 6100-2344-ACCESS Kit, 1.0" Core Adapter For 6100-2343 6100-2345-ACCESS Kit, 1.5" Core Adapter For 6100-2343 6100-2390 Screen Template, 0.625” x 1.6” 6100-2391 Screen Template, 0.875” x 1.6” 6990-0001-XX Valve, Hastelloy C-LD 9000-0020 Plumbing Schematic 9000-0021 Plumbing Schematic (Detail) 9000-0024 Valve Assembly, Cone and Seat 9000-0025 Manifold Valve Assembly, Cone and Seat 9000-0034 Electrical Schematic 9000-0035 Electrical Schematic 9000-0110 Fluid Recirculation Accumulator Assembly 9000-0169 Rotary Valve Assembly 9000-0252 Assembly, Sand Injector Vessel 9000-0288 Assembly, Filter/Valve 9000-PNEU Pneumatic Connections

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