Model SS2100 1.25” Sapphire Pressure ... - Spartek Systems

Model SS2100 1.25” Sapphire

Pressure/Temperature Recorder

Operations Manual

10011125

________________________________________________________________________ Model SS2100 1.25” Sapphire Pressure/Temperature Recorder Page 2/50

Document Revision History Revision Name Date Comment

01 K. Johnson May 13, 2005 First Draft

02 A. Sielmann July 11, 2005 Revise and Update

03 S. Snelgrove January 26, 2006 Updated Lubrication Practices

04 S. Giordano May 22, 2007 Updated Back-Up ring information. Removed Nitrile references

05 B. Schellenberg May 12, 2010 Updated accuracy to 0.024% FS

Disclaimer Spartek Systems makes every effort to ensure the accuracy of the content of this manual. We would certainly welcome any suggestions as to how we can improve the content for any future manuals. This manual may be updated periodically which will be reflected in the above Document Revision History. Spartek Systems declines any liability that may arise out of inaccuracies in this document. We thank you for choosing Spartek Systems as your equipment provider of choice.


Table of Contents

Model SS2100 1.25” Sapphire Pressure/Temperature Recorder ........................ 1

Table of Contents.................................................................................................. 3

1. Introduction .................................................................................................... 5

2. Preparing the Recorder for Operation ........................................................... 6

2.1. Accessories Required to Operate a Recorder ........................................... 6

3. Installing Spartek Systems Field Software .................................................... 7

4. Connecting the Recorder to a Computer ....................................................... 7

5. Program Modes of the SS2100 ................................................................... 10

5.1. General Program Information................................................................... 11

5.2. Programming the Gauge for Memory Mode............................................. 13

5.3. Programming the Gauge for Surface Read Out Mode............................. 13

6. Pre-Job Check Out ...................................................................................... 14

6.1. Gauge Test Procedure............................................................................. 14

6.2. Battery Test Procedure ............................................................................ 15

7. Assembling the Gauge for Deployment ....................................................... 16

7.1. Grease and Lubrication............................................................................ 17

7.2. Sealing Procedure.................................................................................... 17

8. Dismantling the Gauge After a Job.............................................................. 22

8.1. Removing the Battery Housing ................................................................ 22

9. Recovering Data from the Gauge ................................................................ 23

10. Removing O-Rings and Back-Up Rings................................................... 23

10.1. Seal Removal Tools ............................................................................. 23


10.2. Seal Removal Procedure...................................................................... 24

11. Filter Removal and Replacement ............................................................. 26

12. Replacing O-Rings and Back-Up Rings ................................................... 27

12.1. Seal Configurations .............................................................................. 29

12.2. Seal Replacement Procedure............................................................... 30

13. Product Specifications.............................................................................. 33

13.1. Standard Calibration Temperatures ..................................................... 34

14. Mechanical Dimensional Drawing ............................................................ 36

15. Spare Parts .............................................................................................. 40

15.1. Seal Material Types.............................................................................. 40

15.2. Redress Kits ......................................................................................... 41

15.3. Battery Housing Seals .......................................................................... 42

15.4. Bull Nose/Crossover Seals ................................................................... 42

15.5. Crossovers............................................................................................ 43

16. Battery Packs ........................................................................................... 43

16.1. Battery Housings .................................................................................. 44

17. Battery Pack Handling.............................................................................. 45

17.1. Battery Safety ....................................................................................... 45

17.2. Battery Storage..................................................................................... 45

17.3. Test Battery .......................................................................................... 46

17.4. Reusing Battery Packs ......................................................................... 47

17.5. Power Profiling...................................................................................... 47

18. References............................................................................................... 49

19. Contact Information.................................................................................. 50


1. Introduction General System Overview The Sapphire Gauge records elapsed time, pressure, and temperature data in an internal memory. Temperature data is measured by a Resistive Temperature Device (RTD), and is ten times more accurate than a gauge not equipped with “Rapid” RTD technology. This data can be used for a more accurate well bore temperature curve. These gauges can be powered by lithium batteries below ground or from the surface using a wireline power supply. Sapphire gauges can be programmed to sample at a user determined rate. This rate can be either fixed or variable. To program this gauge for operation requires the use of a computer. The gauge is connected to the computer via a Program Interface Box. The user communicates to the gauge through the use of Spartek Systems Field Software.

The SS2100 Sapphire Pressure/Temperature Recorder The SS2100 Sapphire Recorder is a member of the SS2000 family of gauges available for pressure and temperature data evaluation. This manual is for the SS2100 Model Number 1139 F1. This model is offered in six different pressure values, ranging from 750 psi to 15 000 psi. All of these gauges can withstand temperatures up to 170°C (338°F), although not all of them are calibrated to this temperature as a standard practice. The overall diameter of the gauge is 1.25”. This gauge requires a minimum of 3V to operate. This can be provided by a 2 “C” Cell battery pack for low temperature applications (165°C/329°F or below). For high temperature applications (greater than 165°C/329°F), a 3 “C” Cell battery pack is recommended. The standard memory storage capacity is 666 666 data points. Each gauge is manufactured and calibrated at our facilities in Sylvan Lake, Alberta.


2. Preparing the Recorder for Operation 2.1. Accessories Required to Operate a Recorder

Included with each set of recorders are some essential accessories required to ensure proper functioning before deployment. These items include: Item Quantity Part Number Note Carrying Case 1 10011118 Thread Protector (Male) 2 10002891 Bull Nose 1 10000100 Crossover 1 Alternate † Spartek Systems PC Software 1 Alternate ‡ Program Interface Box 1 Alternate § SS2100 Operations Manual 1 10011125 External 12V Power Supply 1 10001540 ** Test Battery Pack 1 10009861 ††

1.25” Sapphire QC Assembly 2 Alternate ‡‡

Electronics Housing 2 Alternate §§ Battery Housing 2 Alternate *** Battery Pack 2 Alternate †††

† One type of this item will be included – Standard or NPT. See the Mechanical Drawing in Section 14. ‡ One version of software will be included. § One type of this item will be included – RS232 or USB. See Section 4. ** This item will only be included with an RS232 Interface Box. See Section 4. †† This item is used for surface testing. See Section 17.3 for more information. ‡‡ One type of this item will be included based on the required pressure rating. See Section 13.1. §§ One type of this item will be included based on the threads required for the battery housing. See Section 16.1. *** One type of this item will be included based on the size of the battery pack. See Section 16.1. ††† The battery type will be determined by the customer when ordering based on characteristics of the application such as the temperature and/or the duration of the task being performed. See Section 16.


Figure 1 – SS2100 Gauge Assembly and Accessory Equipment

3. Installing Spartek Systems Field Software The first step for ensuring a successful survey is to communicate with the gauge. This is done using Spartek Systems proprietary software. Spartek Software must be installed before the gauge can be programmed. To install the software, insert the CD into the computer and the Demo Shield Installer will guide the user through the installation. This software allows the user to program a gauge, retrieve data after a job, graph the results for analysis, and to run diagnostic tests on the gauge before deployment. It features an On-Line Help System explaining how to use the software and contains contact information. Software is also available for download from the Spartek Systems website at http://www.sparteksystems.com. Upon registration and approval from Spartek, a username and password are assigned providing access to software downloads.

4. Connecting the Recorder to a Computer This gauge interfaces with a computer using a Program Interface Box. There are two types of Interface Boxes: RS232 and USB. Each box has different characteristics and different setup configurations. The chart below provides a comparison.

Interface Box Power Depassivation Connector Standard Temp / High Temp Part Number

RS232 (Single) 12V/Battery 165°C or less 7 Pin ST/HT 10002588 RS232 (Dual) 12V/Battery 165°C or less 7 Pin/11 Pin ST/HT 10002392

USB USB Port 165°C or less 7 Pin HT Only 10010527

* For higher temperature packs, use the SS1008 200°C Depassivation Box. See Section 17.


Figure 2 – An SS1000 Dual RS232 Interface Box and an SS1009 USB Interface Box

USB Interface Configuration To connect the gauge to an SS1009 USB Interface Box, remove the battery housing from the gauge to expose the connector. Connect the 7 pin silver connector on the Program Interface Box to the pressure gauge. Next, connect the black USB connector on the Interface Box to the USB port on the computer as shown in Figure 3a. Power supplied by the USB port on the computer will power both the box and the gauge so no additional power source is necessary.

Figure 3a – Gauge connected to computer using a USB Interface Box

RS232 Interface Configuration


To connect the gauge to an SS1000 RS232 Program Interface Box, ensure that the battery housing has been removed from the gauge to expose the connector at the top of the electronics housing. Connect the small 7 pin silver connector on the Program Interface Box to the gauge. Next, connect the black 9 pin ‘D’ shell connector on the Interface Box to the serial port on the computer. Once the cabling is complete, ensure that the switch labeled ST/HT (Standard Temp/High Temp) on the Interface Box is set to HT. Finally, to supply power to the instrument, connect a Spartek Systems battery pack or plug in a 12V external power supply to the interface box. See Figures 3b and 3c. Note: A 200°C battery pack cannot be used to power an RS232 Interface Box. Use a lower temperature pack. See Section 16.

Do Not Plug In A 12V Power Supply & A Battery Pack At The Same Time

Figure 3b – Gauge connected to computer using an RS232 Interface Box (Battery)


Figure 3c – Gauge connected to computer using an RS232 Interface Box (12V)

Communication Using Either Interface Box Once power is applied and a gauge is connected, note that the LEDs flash rapidly several times. This is a quick diagnostic check indicating that the processor in the gauge has initialized and the gauge is ready to accept commands from the computer. For the next step the user must launch Spartek Systems Field PC Software to program the gauge.

5. Program Modes of the SS2100 The SS2100 has two modes of operation: Memory Mode and Surface Readout Mode (SRO).

Memory Mode In Memory Mode, the gauge records time, pressure, and temperature data to the gauge memory which can be recovered when the gauge is retrieved from below the surface. Data can be uploaded for analysis when the gauge is connected to a computer using Spartek Systems PC software and a Program Interface Box. Data will remain in the gauge memory until it is reprogrammed for another survey.

Surface Read Out Mode


In addition to recording time, pressure, and temperature data to the gauge memory, a gauge equipped with SRO will also transmit this data to the surface while still below ground. This requires the use of a surface recovery unit commonly known as an SRO Box (SS6001). The SRO Box acts as a receiver from the gauge. It displays gauge data and stores it in a memory of its own, in addition to the data being stored on the gauge. Gauges run using SRO do not require the use of a battery pack since the SRO Box provides power to the gauge via the wireline cable. The sample rate of the SRO Box is controlled by the user, but the sample rate of the gauge cannot be changed while the gauge is recording. Spartek Systems recommends that the sample rate of the SRO Box be slower than the sample rate of the gauge to ensure that data transmission runs efficiently. If a computer is available on site, data can be viewed on a graph using the Live Acquire feature of the software by connecting the SRO Box to the computer.

Surface Readout is not the default mode of operation for this type of gauge. Gauges must be converted to SRO Mode by the user through Spartek Systems PC Software. See Section 5.3.

5.1. General Program Information

Program Rates For the SS2100 there are two different program rates available for sample acquisition: Fixed Rate and Variable Rate.

Fixed Rate This method programs the gauge to take a sample at a constant or fixed rate until the memory is full, the battery runs out, or power is disconnected.

Variable Rate

This type of program allows the user to custom design multiple sample rates during a single survey. This allows the gauge to be deployed at a given time with one sample rate, and to sample at a different rate at a predetermined point in the future.

The Variable Rate is more practical for applications where battery life is of concern. The gauge can begin taking samples at a moderate rate and then change to a faster rate at a specified time instead of constantly sampling at the faster rate, in order to conserve power.

In the event that the Variable program sequence is completed before the gauge is retrieved or the battery pack runs out, the


gauge will still continue to accumulate samples. At this point the gauge will continue recording at a default rate of 30 seconds until the memory is full, power is disconnected, or the battery runs out.

Note: Programming the gauge for either rate will erase any samples currently stored in memory. If data on the gauge has not been recovered prior to reprogramming, it will be lost.

See Section 9 for details regarding data recovery.

Default Program Rates A gauge programmed for either mode will start recording samples at a default rate of 5 seconds for the first minute (12 samples) once power is applied. This default rate is built into in all Spartek pressure recorders in order to provide functionality feedback once a battery pack is connected. The user programmed sequence will begin after this initial default rate. If no program is downloaded into the gauge, a default Fixed sample rate of 30 seconds will be enabled.

Sample Rate Calculation In order to design a program that will perform as the user intends, it is important to understand how the gauge calculates which rate to acquire samples at, especially for multiple (Variable) rate programs. When connecting a battery pack, look for a small LED located inside the plastic top of the pack. This LED will flash upon power connection to indicate that the processor is active. After the initial rapid flash, a more prolonged on/off period will occur. This is a visual display of the gauge taking a sample and storing it in memory. The LED will flash a total of 5 times to give the user a clear indication that the gauge is actually running, flashing once for each of the first five samples. The five sample flashes will occur at one of two rates. If the gauge has just been programmed or if the gauge has zero samples stored in its memory, the flashes will occur every five seconds using the five second default rate outlined in the Default Section. If the gauge has more than twelve samples stored in memory, the LED will flash at the Fixed or Variable rate programmed in the gauge. If the gauge is programmed using a Fixed rate, the gauge will sample at the programmed Fixed rate. If the gauge is programmed using a Variable rate, the gauge will determine how many samples are already stored in memory and


compare this to the number of samples that each program step will require. With this information, the gauge will determine what the sample rate should be (based on the program sequence) and resume sampling at the corresponding rate. The LED will flash at this rate.

5.2. Programming the Gauge for Memory Mode The programming process is explained in detail in the On-Line Help system which is available through Spartek Systems Field Software. Once the software has been installed and opened, click on the tab labeled Help and view the section labeled Running the Software to learn how to program a gauge for Memory Mode. Once the gauge is programmed, check the verification sheet to make sure the program has validated that the gauge is ready for operation. Click the button labeled Update Data on the Data Acquisition page of the software and notice that the number of samples has been erased and now reads zero samples. Spartek Systems preprograms each gauge with a 30 second Fixed sample rate unless otherwise requested by a customer. Memory Mode is compatible with both Fixed and Variable Rates.

5.3. Programming the Gauge for Surface Read Out Mode The gauge must be programmed to operate in SRO Mode to enable the gauge to transmit data back to the surface recovery unit at a user determined, preprogrammed interval.

Note: The SRO Box will display pressure data from the transducer, and temperature data from the external RTD probe.


Figure 4 – SS6001 Surface Recovery Unit (SRO Box) The SRO programming process is explained in detail in the On-Line Help which is available through Spartek Software. Once the software has been installed and opened, click on the tab labeled Help and view the section labeled SRO to learn how to program the gauge for SRO Mode. Once the gauge is programmed, check the verification sheet to make sure the program has validated that the gauge is ready for operation. Click the button labeled Update Data on the Data Acquisition page and notice that the number of samples has been erased and now reads zero samples. The gauge has now been successfully programmed. Before deployment, the gauge and the battery pack should be tested in order to determine that all features of the gauge are functioning correctly.

Gauges programmed for SRO can operate in a Fixed Rate Mode only.

6. Pre-Job Check Out In order to isolate any potential problems, the Pre-Job Check Out is divided into two steps. A gauge test will make certain that the gauge is operating properly. Once this is established, the battery pack should be tested to minimize the possibility of failure due to battery issues.

6.1. Gauge Test Procedure This simple test will ensure that the gauge records accurate samples, interfaces with the software, and properly uploads stored data. This test should be done on a work bench before arrival at a job site. For RS232 Interface Boxes, connect the gauge to a computer using a 12V power supply as explained in Section 4. For USB communication, simply connect the gauge to a computer as explained in the same section. Open Spartek PC Software and use the Sample to Terminal feature to record data into the gauge memory. Set the sample rate to 10 seconds and use the Continuous Samples function to begin acquiring data. Let the gauge run for about five minutes before terminating sample acquisition. Click Update Data and note the number of samples recorded. Five minutes of sampling at a 10 second sample rate should yield approximately thirty samples. Upload the data following the instructions explained in the Data Acquisition section of the On-Line Help.


Following the On-Line Help instructions should open up a graph and display the samples recorded by the gauge. The samples should be steady in both pressure and temperature and read room temperature and pressure values. The number of samples on the graph should be equal to the number displayed on the main page of the software under the Num of Samples field. If the values of pressure and temperature are within the expected range and the gauge records the correct number of samples, the gauge can be considered to be working correctly.

6.2. Battery Test Procedure This test will make certain that the battery supplies enough power to enable the gauge to record accurate samples, interface with the software, and properly upload stored data. This test will also make sure that the gauge executes the correct program sequence. Note: this test does not determine whether or not a pack is suitable for a downhole application. Spartek Systems recommends only new packs be used for a given application. See Section 17.4 for more information.

Be sure not to use a 200°C (392°F) battery pack for the following procedure. Use a lower temperature pack or the red test battery pack.

First, program the gauge in memory mode for a 10 second Fixed sample rate as explained in Section 5, then disconnect the gauge from the computer.

Connect the battery to be tested directly to the gauge with no Interface Box. Inside the plastic top of the battery pack, there is a small LED that will flash upon power connection. This indicates that the processor is active. After the initial rapid flash, a more prolonged on/off period will occur. This is a visual display of the gauge taking a sample and storing it in memory. The LED will flash a total of 5 times to give the user assurance that the gauge is actually running. The five sample flashes will occur at five second intervals. Let the gauge continue running for about five minutes. This will give the gauge time to complete the default five second sample rate for the first minute, as well as time to begin the ten second Fixed Rate program that will commence after the default period ends.


After five minutes the battery can be removed to discontinue sample acquisition. Connect the gauge to both the Program Interface Box and to the computer as explained above. Click Update Data and note the number of samples recorded. Five minutes of sampling at a 10 second sample rate should yield approximately thirty samples. To upload the data, refer to the Data Acquisition and Data Manipulation features of the On-Line Help. Following the On-Line Help instructions should open up a graph and display the samples recorded by the gauge. The samples should be steady in both pressure and temperature, and read approximately zero psi and room temperature values. If the values of pressure and temperature are within the expected range and the gauge has recorded the correct number of samples, the battery pack can be considered to be working correctly. The gauge can now be erased and reprogrammed for the rate desired for the specific application at hand. Note: This test only ensures that the battery pack is suitable for bench testing of the gauge. Use a new battery pack for any downhole applications. A new pack should also be tested before deployment using the procedure described above.

7. Assembling the Gauge for Deployment New gauges, for either rental or purchase, are sent with new seals ready for deployment. Gauges are not shipped fully assembled since the batteries are not connected and the battery housings are not in place. Gauges are therefore shipped in a semi complete state.

For these reasons, the following procedure will begin by explaining how to lubricate the seals followed by how to install the battery and battery housing. This section will end with how to seal the gauge.

The assembly procedure requires the use of two standard 1 1/16” (1.0625”) wrenches in addition to the parts listed in Section 2.

For seal removal and replacement procedures see Sections 10 and 12.


7.1. Grease and Lubrication Once all of the seals have been installed, it is necessary to lubricate the sealing area to prevent damage when restoring the battery housing. To do this, two products are required.

Products High temperature/high pressure grease is to be used for O-Ring and Back-Up surfaces. Proper o-ring lubrication reduces the risk of damaged during installation and the effort required to closed the joint. For thread lubrication, a high temperature anti-seize compound will provide the protection necessary for high temperature downhole applications. Thread lubrication greatly reduces the risk of thread galling, common when threading stainless steels into one another. Spartek Systems recommends Lubriplate 461 for elastomers and Fastorq 70+ as a thread lubricant. Another useful product is ID Red. ID Red is a fast evaporating industrial degreaser that can be used to remove any contaminants from O-Ring seats or simply to clean the tool for general maintenance.

These products are available for purchase from Spartek Systems. The chart below shows the Spartek item numbers for the products mentioned above, as well as tools used for product application.

Item Quantity Part Number

Lubriplate 461 O-Ring Lubricant 1 10012768 Fastorq 70+ Moly Paste 1 10013669 Zep ID Red Industrial Degreaser 1 10001028 Brush 2 10004099 Spartek Systems PG2 Grease 250mL 10001321


Figure 5 - Lubrication Products and Accessories

Application Apply Lubriplate 461 Grease to the O-Rings on the end of the electronics housing using a brush as shown in Figure 6 steps 1 and 2. Using a clean brush, apply Fastorq 70+ to the threads as shown in steps 3 and 4.

Figure 6 – Lubricating O-Rings with grease and threads with anti-seize

1. 2.

3. 4.


Do not over-grease. Too much grease will attract debris that can potentially damage the seal and cause flooding. A perfectly greased O-Ring will look moist and shiny. Apply Lubriplate 461 grease to the O-Ring on the pressure sub as well. Fastorq 70+ is not necessary for the threads of the sub, but its application may make disassembly easier.

Figure 7 – Greasing the O-Ring on the Pressure Sub

7.2. Sealing Procedure With the O-Rings greased and the filter in place, the next step is to seal the gauge. The seal procedure involves attaching the bull nose, the battery, and the battery housing, and then tightening the two joints.

Installing the Bull Nose Ensure that the seals have been replaced and lubricated before attaching the bull nose. Thread the bull nose on as shown in Figure 8. Hand tighten the bull nose up to the housing to prepare it for final seal.


Figure 8 – Attaching a Bull nose

Installing the Battery Housing The battery pack and the battery housing should not be connected and sealed until the gauges are scheduled for deployment within a few hours. This step should not be completed until the gauge is ready to begin sampling. Connecting the battery will begin the program on the gauge and the battery life will begin depletion. Take this into account before attaching the battery to the gauge and sealing the battery housing joint. When the battery is connected, notice the LED flashing, shown in Step 3 of Figure 9. This indicates that the gauge is working.


Figure 9 – Installing the Battery Pack and Housing Place the battery housing over the battery and hand tighten the battery housing up to the electronics housing to prepare it for final seal.

Final Seal Tightening the joints can be done in one of two methods to achieve the correct force required to make a firm seal: by hand or by wrench. Spartek recommends hand tightening of the joints for this gauge. This will provide enough torque to effectively seal this gauge. If the customer so desires, these joints can be tightened with a 1 1/16” (1.0625”) wrench. Keep in mind the low amount of torque achieved through hand tightening is all that is required. The tightening procedure is shown in Figure 10. Spartek Systems recommends a torque spec of no more than 25 ft-lbs for both the bull nose the battery housing joints. Use the wrench to firm up the joints only. Do not over tighten. Excessive force will damage the seal glands.


Figure 10 – Attaching and sealing Bull Nose, Battery Pack, and Battery Housing The gauge is now assembled and ready for deployment. If two gauges are to be run in tandem, they can be connected together at this time. A complete gauge will look like the image shown in Figure 11.

Figure 11 – One Full Gauge with a Bull Nose

8. Dismantling the Gauge After a Job

8.1. Removing the Battery Housing The process of opening up the gauge is the reverse of the assembly above. Loosen the battery housing with two standard 1 1/16” wrenches and cautiously unscrew the housing by hand monitoring the ease of which it is loosening. If undo force is required there may be pressure inside the gauge or the threads may be seized. Alternate the housing back and forth loosening and tightening the gauge but proceed slowly and carefully for safety reasons and to avoid damaging the threads.


Do not stand in line with the gauge when dismantling. If there has been a pressure build up inside the gauge, make sure the battery housing will not cause injury if it were to be ejected.

9. Recovering Data from the Gauge Connect the gauge, Program Interface Box, battery, and computer as explained in Section 4 and refer to the On-Line Help system to recover data from the gauge. Use the Data Acquisition feature to upload data and the Data Manipulation feature to view graphs of the recorded information. Data will be saved in a file on the computer during Acquisition and can be viewed at any time without repeating the Acquisition step by using the Analyze Data or View Data functions of the software. Both of these are listed under the Data Manipulation tab. Make sure the plots presented on the graph are what the user is expecting before reprogramming the gauge. Be sure to retrieve the data before reprogramming the gauge. The process of programming the gauge will erase recorded data, and there is no recovering data thereafter. The gauge has successfully completed its task and is now ready for a new job. Before reassembling the gauge, the seals should be replaced.

10. Removing O-Rings and Back-Up Rings 10.1. Seal Removal Tools

The following tools are required to change the seals of Spartek gauges:

Item Quantity Part Number Side Cutters 1 10000426

O-Ring Removal Tool (Plastic) 1 10010354 O-Ring Removal Tool (Brass) 1 10011116

Wax String 1 10000360


Figure 12 – Types of O-Ring Removal Tools - Plastic and Metal

10.2. Seal Removal Procedure Take care not to damage the O-Ring seats during this procedure.

Sweet / Sour Seal Removal If an O-Ring Removal Tool is unavailable, use something plastic or a blunt metal object made of a metal type that is softer than stainless steel to prevent scratching of the O-Ring seat during removal. During seal removal, the O-Rings and Back-Up Rings require different procedures. O-Rings are single use while split PEEK Back-Ups can be reused.

PEEK Back-Ups can be reused. Do not cut or discard PEEK Back-Ups.

Use the O-Ring Removal Tool to lift up the O-Ring to provide enough room to slide the cutters underneath it and cut it as shown in Figure 14.

Figure 14 - Removing O-Rings


To remove a PEEK Back-Up Ring, position the split between the thumbs. Press on one side of it with one thumb and spread apart with the other. Bend the Back-Up over the threads for removal.

Figure 15 – PEEK Back-Up Removal PEEK is flexible but it can deform or break if stretched. Gently bend the Back-Up into its original shape if this occurs.

Figure 16 – Deformed PEEK Back-Up Ring


11. Filter Removal and Replacement The pressure sensing system of the SS2100 does not use a bellows system, so fluid can directly contact the transducer diaphragm. The diaphragm is highly sensitive, so a mesh filter is in place to prevent any solids from reaching the transducer diaphragm. To protect the diaphragm, PG2 grease is used to fill the void in the transducer cavity. The grease acts as an inhibitor preventing any well fluid or H2S gas from directly contacting the diaphragm.

Maintaining this system consists of cleaning the transducer cavity to remove any old contaminants and replacing the grease. The transducer cavity should be cleaned and the filter replaced after each well application.

Filter Removal The filter is located beneath the bull nose (or crossover). Removal of the filter may require the use of a !” wrench. Using ID Red or another fast evaporating industrial degreaser, remove any contaminants or excess grease from the transducer cavity in the manner shown in Figure 17.

The diaphragm of the transducer is extremely sensitive and should never be touched, poked, or tampered with.

Figure 17 – Filter Removal Procedure


Once the cavity is clean, inspect the diaphragm for damage. If any aberrations are observed, contact a representative of Spartek Systems.

Filter Replacement Once cleaned, PG2 grease can be applied using a clean syringe. Fill the grease up to the top of the threads of the cavity shown in Figure 18.

Figure 18 – Greasing and Replacing the Filter If the recommended syringe is used the sensor can not be damaged. If some other applicator is used, be cautious not to damage the sensor. Tighten the filter using a 0.75” wrench and wipe away any excess grease.

12. Replacing O-Rings and Back-Up Rings The SS2100 uses 212 O-Rings and Backups. These are located in three places, two of which are field replaceable joints. The replaceable seals are located at the joints of the pressure sub/bull nose & the battery housing/electronics housing. The electronics housing/pressure sub joint is to be serviced at Spartek Systems. See Figure 19.


Figure 19 - SS2100 Gauge Sections and Field Joints

The electronics housing/pressure sub joint is a permanent joint and should not be opened in the field. The battery housing section uses two O-Rings and two Back-Ups while the pressure sub section uses an additional one O-Ring. This equates to a total of three field-replaceable O-Rings and two field-replaceable Back-Ups per gauge.

O-Rings O-Rings need to be inspected before assembling the gauge. Inspect all O-Rings for any cuts, tears, flattening, or other damage. If any signs of deterioration are observed, change the O-Rings before deployment.

It is recommended to change all field replaceable seals prior to deployment.

Back-Up Rings PEEK Back-Ups have a split in them for placement purposes, while Elastomer Back-Ups do not (Viton, Nitrile). Both PEEK and Viton Back-Up Rings have a concave side and a flat side as shown in Figure 20. Always align the concave side towards the O-Ring to create a firm seal.


Figure 20 - The Concave Side of a Back-Up Ring

12.1. Seal Configurations There are multiple seal configurations used on each gauge depending on the type of seal that is required. The quantity and position of the seal components will determine the type of seal configuration for each joint. Two different O-Ring configurations used on the SS2100: the Standard Seal and the Simple Seal. Each configuration is used in a specific location. Both sweet and sour environments use the same arrangements for each section.

Standard Seal Configuration The battery housing joint uses a Standard Seal Configuration. This arrangement consists of alternating two O-Rings and two Back-Ups with the first Back-Up positioned closest to the threads. See Figure 21.

Figure 21 – Standard Seal Configuration for Non-Sour and Sour Applications


Simple Seal Configuration The pressure sub/bull nose joint uses a Simple Seal Configuration which is one O-Ring in place without a Back-Up Ring. See Figure 22.

Figure 22 – Simple Seal Configuration

12.2. Seal Replacement Procedure

All O-Ring seats should be cleaned prior to new installation using a fast evaporating industrial degreaser such as ID Red. If this will not remove the debris, use a soft bristle brush. Be careful not to damage the seats.

For seal replacement, the use of hot water and/or grease may aid installation. These practices are acceptable, but they are not necessary for all seal types. For Chemraz O-Rings in particular, these recommendations will help tremendously.

Helpful Installation Tips • Place the O-Rings in hot water for 2-3 minutes to ease installation • Grease the O-Rings prior to installation • Use waxed string to GENTLY install the O-Rings • Inspect each O-Ring for any damage incurred during installation • Put O-Rings on before Back-Up Rings

Sweet Seal Replacement Use wax string or Teflon wire to ease the journey of the O-Ring over the threads. Place the string through the component and slide it down as shown in Figure 23.


Figure 23 – O-Ring Placement Procedure (Sweet)

Sour Seal Replacement To begin, clean the O-Ring seats using a fast evaporating industrial degreaser. Place the O-Ring over one edge of the threads and gently stretch it over the other side. This may require some force.

Do not stretch the O-Ring excessively by using a tool to wedge under the O-Ring or pry it over the threads. This could damage both the O-Ring and/or the threads. Roll the O-Ring down the threads using fingers as shown in Figure 24, or use wax string if necessary.

Figure 24 – O-Ring Placement Procedure (Sour)


With the O-Rings in place, the next step is to put on the Back-Ups. PEEK Back-Ups can be put on by spreading the split with the fingers and thumbs and snapping it into place, shown in Figure 25. When placing the Back-Up Ring, ensure that the concave side is facing the O-Ring. The seal configurations for the connections on the bull nose and the electronics housing are different. The position of the Back-Up Ring will determine the type of seal configuration on the joint.

Be sure to align the seals in the correct Seal Configuration.

Figure 25 – Replacing Back-Up Rings Repeat the O-Ring replacement procedure for seal replacement on the other end of the gauge. A finished gauge will look like the image shown in Figure 26.


Figure 26 – Gauge with Seals Replaced The gauge is now ready for a new job. Be sure to lubricate the O-Rings and threads as explained in Section 7.1 before attaching the bull nose, battery, and battery housing, and sealing the gauge.

Spartek Systems does not recommend reusing O-Rings and only the O-Rings suggested should be used for pressure applications.

Item numbers for these replacement parts are located in Section 15.

13. Product Specifications The following chart includes information on the capabilities of the SS2100 1.25” Sapphire Pressure/Temperature Recorder.

SS2100 Product Specifications Pressure

Sensor Type Sapphire Pressure Range (psi) 750 1500 3 000 6 000 10 000 15 000 Accuracy 0.024 % Full Scale Resolution 0.0003% Full Scale Drift < 3 psi/Year

Temperature Sensor Type External RTD Class one Range *-20ºC to 170ºC / -4ºF to 332ºF Accuracy +/- 1ºC / 1.8ºF Resolution Drift

0.001 ºC / 0.0018ºF < 1.0ºC / 1.8ºF per year

Power Requirement at 170ºC Source Lithium Battery Pack Battery Life Battery pack size & temperature dependent Voltage (minimum) 3 VDC Current - Sleep 0.10 mA Current - Sample 4.50 mA

Data Acquisition Channels Pressure/ Temperature/RTD Temperature/Time


Sample Rate (fastest) 1 sample/sec Memory Capacity 666 666 (standard) Housing Material 17-4 PH or 718-NACE Diameter 1.25” [3.175 cm] Length Varies - Dependent on Configuration Seal Configuration Field Joint 3 x 212 O-Ring, 2 x 212 Back-Up Communications RS232 and USB Compatible Software Compatibility Windows 98/NT/2000/XP Surface Read Out Capable Yes *All gauges are available for use at 170°C but most low pressure gauges are calibrated to lower temperatures as a standard. These can be calibrated to 170°C upon request. For a list of the pressure ranges and their standard calibration temperatures see Page 33.

13.1. Standard Calibration Temperatures Gauges are classified into three general ranges: low pressure (750 and 1500 psi), medium pressure (3K and 6K) and high pressure (10K, and 15K). In addition to the increase in pressure below the surface, these gauges typically see an increase in temperature as well. It is uncommon for low and medium pressure gauges to be run in applications that reach 170°C. For this reason, these gauges are calibrated for a temperature range that is more likely to be encountered in order to maximize the precision of the calibration at the most relevant temperature range. This is akin to running a 6K gauge for an application that is around 6K instead of running a 15K gauge for the same 6K application. The resolution is improved by using a gauge – and calibration – that more closely resembles the conditions that the gauge will encounter. The standard calibration temperatures for Spartek Sapphire Gauges are listed below.

Maximum Pressure Rating Standard Calibration Temperature Range 750 psi 0°C - 80°C (32°F - 176°F)

1500 psi 0°C - 100°C (32°F - 212°F) 3000 psi 0°C - 120°C (32°F - 248°F) 6000psi 20°C - 150°C (68°F - 302°F)

10 000 psi 20°C - 170°C (68°F - 338°F) 15 000psi 20°C - 170°C (68°F - 338°F)


It is important to note that all of these gauges have the ability to be calibrated and run at 170°C. This would be considered a special request and should be specified upon the placement of an order.


14. Mechanical Dimensional Drawing





15. Spare Parts

15.1. Seal Material Types The charts below show the characteristics of the various seals used on SS2100 gauges. The materials are listed in ascending order with the most durable components listed as the last entry of each chart.

O-Rings

Material Type Temperature Range Minimum Maximum

Pressure Maximum

H2S Content

Viton 90Duro -18°C (0°F) 150°C (300°F) 20 000 psi 0%

AFLAS 7182B 90Duro 5°C (40°F) 215°C (420°F) 20 000 psi <7% @ >150°C or <20% @ <150°C

Chemraz 526 95Duro -18°C (0°F) 232°C (450°F) 20 000 psi >7% @ >150°C or >20% @ <150°C

Back-Up Rings

Material Type Temperature Range Minimum Maximum

Pressure Maximum

H2S Content

PEEK -30°C (-20°F) 204°C (400°F) 20 000 psi >7% @ >150°C or >20% @ <150°C

H2S Content H2S or hydrogen sulphide is an extremely destructive sour gas that breaks down the seals of downhole gauges. Some materials are more resistant to H2S than others, so to better understand the correct O-Ring for a specific application will require some information regarding seal tolerances to H2S. Seals experience stress due to heat, pressure, and the presence of H2S. As indicated in the chart, most of the seals can withstand 15 000 psi leaving temperature and H2S as the most noticeable differences between the types of seals. Viton CANNOT withstand any H2S content but AFLAS, Chemraz, and PEEK can. These seals can withstand a higher concentration of H2S at low temperatures but the amount of H2S these seals can withstand is less at higher temperatures. These seal components are available in prepackaged Redress Kits or as individual parts.


CO2 and Other Gaseous Environments Viton and Nitrile should not be used in gaseous environments. This includes carbon dioxide, nitrogen, methane etc. AFLAS, Chemraz, and PEEK can be used in gaseous environments.

15.2. Redress Kits Seal replacement for the SS2100 is offered in prepackaged configurations known as Redress Kits. Redress Kits are a convenient way to replace the seals of one particular gauge joint. There is one size of kit used on the SS2100, used on the only field replaceable joint - the battery housing/electronics housing seal. This joint uses a 212 Redress Kit. The bull nose/crossover joint is a single O-Ring so it is not included in the Redress Kits. Seal replacement part numbers for this joint will follow the Redress Kit Section. There are three different classifications of environments this gauge will encounter based largely on the content of H2S.

Redress Kits are differentiated based on the content of H2S at specific temperature ranges as explained below.

Sweet / Sour Medium / Sour High • Sweet = 0% H2S • Sour Medium = <7% @ >149°C or <20% @ <149°C H2S • Sour High = >7% @ >149°C or >20% @ <149°C H2S

There are three types of Redress Kits to accommodate these different environments. The parts of a Redress Kit can be ordered individually, or as a complete package and replaced in the field if necessary.

Each Redress Kit contains a piece of wax string to aid in seal replacement procedures.

Each Redress Kit will service one joint, on one gauge, one time.


15.3. Battery Housing Seals The seals on the battery housing joint need to be replaced after every application. The item numbers for the Redress Kits and also the item numbers for individual parts are listed below. 10007268 Sweet Applications 15K/170°C

Part Number Description Quantity 10001626 O-Ring 2-212 Viton 90Duro 2 10008696 Back-Up 8-212 PEEK 2

10010504 Low Sour Content Applications 15K/170°C

Part Number Description Quantity 10008985 O-Ring 2-212 AFLAS 7182B 90Duro 2 10008696 Back-Up 8-212 PEEK 2

10009363 High Sour Content Applications 15K/170°C

Part Number Description Quantity 10010355 O-Ring 2-212 Chemraz 526 95Duro 2 10008696 Back-Up 8-212 PEEK 2

These kits are meant to replace the seals located on the top of the electronics housing. The other O-Rings on the SS2100 are not field replaceable and must be replaced at Spartek Systems.

15.4. Bull Nose/Crossover Seals The O-Ring located at this seal is a field joint. However, it requires inspection after each application not replacement. Change this seal only when it appears to be damaged.

O-Rings Part Number Description Quantity

10001626 O-Ring 2-212 Viton 90Duro 1 10008985 O-Ring 2-212 AFLAS 7182B 90Duro 1 10010355 O-Ring 2-212 Chemraz 526 95Duro 1

Be sure to choose the correct seal material for the application at hand.

This seal is available in three materials to suit any type of environment, but it should be noted that this is not a pressure seal. Spartek Systems sends gauges to customers using a Viton O-Ring for this joint unless otherwise requested by a customer.


15.5. Crossovers The SS2100 currently has two types of crossovers available, each used for a specific field application. The NPT crossover is used for gauge carrier applications. The other more common type is the Standard Wireline Crossover which is used for all other applications. The chart below compares the two types of crossovers.

Type Thread Seal Type Diameter Length Part

Number

Wireline 9/16" (0.5625") 18 UNC Simple 1.25” 3" 10000101

NPT "” (0.25”) 18 NPT Single 1.27” 3" 10003732 As indicated in the chart, the two crossovers have different threads, different diameters and different seal requirements. The threads of the two crossovers are different because of the threads they are intended to mate with. Standard Wireline crossovers are meant to joint two gauges together, whereas NPT crossovers are used to connect a gauge to a gauge carrier device. The NPT version of crossover has a diameter of 1.27” because it is also used for the SS5000 series of Quartz gauges which have a diameter of 1.27”. With regards to sealing, for standard wireline use a single O-Ring is all that is required. It acts mainly to hold the bull nose or crossover on, whereas a gauge carrier application the focus is more differential pressure oriented. For this reason, a Back-Up Ring is recommended for NPT crossover use.

16. Battery Packs The following chart details the various battery packs available for the SS2100. These packs are suitable for powering the gauge downhole. All packs listed are “C” Cell non-locking packs.

Part Number Cells Max Temp Capacity Voltage

10002415 2 85°C (185°F) 6.0Ah 7.2V 10002201 3 85°C (185°F) 6.0Ah 10.8V 10002537 4 85°C (185°F) 12.0Ah 7.2V 10002416 2 165°C (329°F) 5.0Ah 7.8V 10002351 3 165°C (329°F) 5.0Ah 11.7V 10011010 4 165°C (329°F) 10.0Ah 7.8V 10002527 3 200°C (392°F) 4.0Ah 10.8V


A two cell pack will provide enough voltage to run the gauge for most applications. A four cell pack can be used to extend the capacity for more lengthy applications. A three cell pack has a higher voltage rating but a capacity similar to that of a two cell pack. This extra voltage is unnecessary for most applications since a two cell pack provides adequate voltage. However, a three cell pack will provide more resistance to passivation at higher temperatures. For this reason, it is the pack recommended for the 200°C (392°F) temperature range. See Section 17.2 for more about passivation.

Locking Connectors and Spacers Spartek Systems currently offers battery packs of two varieties: locking and non-locking. Locking connectors provide additional insurance that a battery will maintain connection during an application.

The SS2100 is to be run using battery packs with non-locking connectors only.

16.1. Battery Housings Battery housings are commonly referred to by the number of cells they can hold. Therefore, a three cell housing can hold a three cell battery.

Care should be taken to order mating hardware and batteries for this gauge specifically in regards to length.

The following chart outlines the housings available and their associated packs. Housings are available in two material types: 17-4 Stainless Steel for sweet service applications and 718 Inconel for sour service.

Part Number Material Description Thread Overall

Length Use with

Battery Type 10000053 17-4 2 Cell ACME 10004157 718 Inconel 2 Cell ACME *10000093 718 Inconel 2 Cell 60°

8.470” 10002415 10002416

10003270 17-4 3 Cell ACME *10005848 17-4 3 Cell 60° 10002693 718 Inconel 3 Cell ACME *10000097 718 Inconel 3 Cell 60°

10.625” 10002201 10002351 10002527

10003315 17-4 4 Cell ACME 10003314 718 Inconel 4 Cell ACME

12.650” 10002537 10011010


*Note: ACME threads are the most common threads used. These will be the default threads unless otherwise specified. All of the battery housings for the SS2100 are the same as those used for the following other gauges: SS2004, SS2006, SS2700, SS2302, SS2500, SS2532, SS2552, SS2703, SS2732, SS5030, SS5061 and the SS5064. Battery housings for this gauge cannot be used with gauge types other than those listed. Battery housings from gauge types other than those listed above cannot be use with the SS2100.

17. Battery Pack Handling

17.1. Battery Safety The SS2100 utilizes Lithium batteries as a power source. This power source has proven itself over the years to be safe but the potential hazards that do exist must be recognized. The temperature rating of the cells is the maximum temperature the cell can withstand. Do not heat any battery pack beyond the temperature rating written on the pack. Each of the high temperature cells contains a fuse to protect it against damage due to a short circuit. These fuses are not field-replaceable and the batteries should not be tampered with under any circumstances. Some useful references are available in Section 18 including information about Safety and handling procedures, as well as MSDS sheets for lithium cells.

17.2. Battery Storage

Passivation Lithium batteries suffer from a characteristic known as passivation. Passivation is a chemical reaction that occurs when a lithium battery is inactive. A buildup of Lithium Chloride (LiCl) on the surface of the anode prevents lithium from discharging when a load is applied to the cell. This layer acts as a barrier and provides the cell with a long shelf life. However, if the cell is stored in a warm environment and no load current is pulled from the cell for an extended period, the layer can thicken and inhibit current flow when the cell is put to use. This means a sudden demand for current will create a drop in the voltage for a period of time affecting the current drawn by the gauge.


In order reduce the passivation layer formed in the battery, it must undergo a de-passivation process. To de-passify a battery, a large load must be applied to reduce it to a functional level. The load button on the RS232 Program Interface Box will provide a sufficient load to burn off this layer for cells with a temperature rating of 165°C (329°F) or less. Applying the load for about one minute will bring the battery voltage back up to acceptable levels greater than 5 volts. To depassify batteries with a temperature rating of 200°C (392°F) will require the use of an SS1008 200°C (392°F) Depassivation Box.

Figure 27 – SS1008 Depassivation Box The SS1008 Depassivation Box was designed for use with 200°C (392°F) battery packs only. Do not use the SS1008 with battery packs that are rated to temperatures less than 200°C (392°F). For more information about passivation and 200°C (392°F) battery packs see the SS1008 manual, included with the rental or purchase of 200°C (392°F) battery packs.

17.3. Test Battery Included with the rental or purchase of gauges to be run using 200°C (392°F) packs is a test battery. This test battery is supplied in order to perform bench testing at room temperature for either powering the gauge directly or for powering the Interface Box should AC power not be available. Use the test battery for any surface communication. Spartek Systems has increased the diameter of the pack to ensure that it will not fit into the battery housing, preventing this pack from being used improperly. It is also a bright red color. See Figure 28.


Figure 28 – 85°C (185°F) Test Battery

This pack is rated to 85°C (185°F) and will not be suitable to power this gauge below surface.

Using this pack at temperatures above 85°C (185°F) will cause the battery to explode. Do not use the test battery to power the gauge below ground.

17.4. Reusing Battery Packs There is no way to measure the capacity of a used battery pack. Therefore, it is not possible to know how much life is left on a used pack. The only way to track the life of a given pack is to log the current draw and the duration of the job(s) in which it was used. This is not a very accurate method of tracking and it has many opportunities for failure. If just one application is not recorded, the remaining Amp hours are questionable. This being the case, Spartek Systems recommends that a new battery pack be used for each downhole application.

17.5. Power Profiling The SS2100 is designed to maximize battery life by consuming as little power as possible. There are three levels of power management for each sample recorded: Deep Power Down (Sleep) Mode, Warm-Up Mode, and Acquisition Mode. The Sleep Mode consumes very little energy because most of the electronics are turned off. The gauge wakes up every second to update the counter and to see if it is time to take a sample. If it is time to take a sample the processor turns on the electronics to allow a small stabilization period known as the Warm-Up Mode. Finally the gauge will take a sample from the transducer. This process will take approximately one second and is considered the Acquisition Mode. Each sample taken from the battery will require a power budget from the battery. By taking into consideration how many samples are taken and at what intervals it is possible to determine how long a battery will last.


Spartek Systems Field Software calculates this and presents the user with a power profile for any survey entered. Refer to the On-Line Help for more information under the Power Profile Section. When profiling a survey, make sure the battery capacity equals or exceeds the profile computed by the software. The calculations made by the PC software are conservative and are based on current consumptions at the maximum rated temperature of the gauge.


18. References For Material Safety Data Sheets for Thionyl Chloride Lithium Cells or a useful safety guide to battery handling and storage http://www.greatbatch.com/cp/products/safety/default.asp For a 24-Hour Emergency Response telephone number 1-(800) 424-9300 For information regarding passivation of Lithium Batteries http://www.greatbatch.com/cp/products/lithium/passivation.asp For an overview on how passivation works http://www.spectrumbatteries.com/Prod_in/passivation_information.htm For Brochures and information on products offered by Spartek Systems http://www.sparteksystems.com/


19. Contact Information

Head Office: Spartek Systems #1 Thevenaz Ind. Trail Sylvan Lake, Alberta, Canada T4S-2J6 Tel: (403) 887-2443 Fax: (403) 887-4050 E-mail: [email protected] Regional Office Information is located at www.sparteksystems.com

Model SS2100 1.25” Sapphire Pressure ... - Spartek Systems

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