Beruflich Dokumente
Kultur Dokumente
TN Densimeter Repair
One Volume
Revision 1.03
22 August 2005
BJ Services
Title
Revision 1.03
Revision 1.03
BJ Services
Services
BJ Services
BJ
Introduction
Definition of Terms
Theory of Operation
Detector Assembly
BJ Digital Transmitter
Controllers/Data
Acquisition Systems
Specifications and
Conversions
Nuclear Densimeter
Calibration
Nuclear Density
Maintenance
Appendix A
Appendix B
BJ Services Introduction
BJ Services is an oilfield service company specializing in pressure-pumping and coiled tubing
operations. A large part of the pressure pumping services include the cementing and stimulation of
wells. These services require a means to measure the density of the various slurries pumped into the well
during a given job.
Nuclear Densimeter Introduction
To this end, BJ utilizes the TN Technologies Nuclear Densimeter, which measures the density of a slurry
through radiation detection. This method of measurement works well with both proppant-laden and
cement-laden slurries. This device, however, is extremely sensitive, and the Electronic Technician, or
ET, is usually assigned the duty of ensuring the Nuclear Densimeter works properly.
Specifications
Dimensions (w/o Pipe)
Pipe Size
2 to 10 in (5.1 to 25.4 cm)
Operating Temperature
40 to 130F (4 to 54C)
Detector Output
0 to 10VDC
Power Requirements
15VDC @ 60mA minimum
Specifications
From this point, the operation of the Nuclear Densimeter, or Gauge, is discussed. To begin, the
specifications for this device are listed above. They include:
Dimensions
Pipe Size
Operating Temperature
Detector Output
Power Requirements
Pipe Size
The Nuclear Densimeter can be mounted on a wide range of pipe sizes. For BJ Services, this range is
from 2 to 10 inches. If the Gauge is removed from one pipe and mounted on another, it must be recalibrated. There are however, certain gauges that cannot legally be removed from the pipe. This topic
is discussed in Section 3, Nuclear Densimeter Theory of Operation.
Operating Temperature
Specifications list the operating temperature as 40 to 130F (4 to 54C). If the Nuclear Densimeter is
operated outside this temperature range, it will still function but its accuracy may be compromised, and
its output may become unstable, causing the density reading to fluctuate.
Detector Output
Depending on the density of the fluid circulating through the pipe, the Gauge outputs a 0 to 10VDC nonlinear signal.
Power Requirements
The Nuclear Densimeter requires 15VDC to operate. It receives this power from some type of
monitoring electronics, referred to in this course as a Transmitter.
Nuclear Densimeter/Transmitter
0-10VDC Signal
15VDC Power
Transmitter
TN Nuclear Densimeter
TN Analog Transmitter
TN Digital Transmitter
BJ Digital Transmitter
Control Systems
Control Systems
The primary function of a control system is to regulate the processes of a job. Similar to the data
acquisition systems, most control systems have the ability to power a Nuclear Densimeter. These
include:
Pendant Control System (shown above)
611C Control System (shown above)
Universal Control Module II (UCM II)
Mixing Control Module Series (MCM Series)
Automatic Cement Controller II (ACC II)
The Nuclear Densimeter provides the Operator with a density reading at the controller and, on blenders
used in stimulation applications, this density reading from the Gauge can be compared with the density
reading calculated from sand-screw rpm's for control purposes.
Stimulation Applications
125C Blender
Stimulation Applications
When used in stimulation applications, a Nuclear Densimeter is usually mounted at the following
locations:
Blender discharge line (Low Pressure)
The Treating Line (High Pressure)
Nuclear Densimeter Mounted On The Blender
A Gauge is mounted on the discharge side of a blender, so that the Operator knows the density of the
slurry as it leaves the blender tub. At this point in the process, the slurry is pumped at low-pressure,
ranging between 40-100 PSI. The advantage of the low pressure Densimeter is its rapid response to
changes in concentration. Once the slurry leaves the blender, it enters the frac pump(s). The photos
above show a low pressure Nuclear Densimeter mounted on a 125C blender discharge line.
Stimulation Applications
Cement Applications
Cementing Applications
When used in cementing applications, a Nuclear Densimeter is mounted on cement units (on-shore
cement applications), or cement skids (off-shore cement applications). For these applications, the
Nuclear Densimeter is usually powered by one of the following:
Automatic Cement Controller II (Control System)
3305 Mini Monitor (Data Acquisition System)
3600 Well Treatment Analyzer (Data Acquisition System)
The Automatic Cement Controller II
When powered by the Automatic Cement Controller II, or ACC II, the Nuclear Densimeter can be used
to provide feedback to the ACC II, in order to regulate the cement-mixing process. Additionally, it is
possible to serially link the ACC II and the 3305 Mini Monitor so that the density reading can be
transmitted to the 3305 for monitoring and recording purposes.
The 3305 Mini Monitor
In some instances, a DB-IV electronic densimeter is used to regulate the cement-mixing process. In this
case, the Nuclear Densimeter is powered by a 3305 Mini Monitor and used for monitoring and recording
purposes.
10
Review Questions
Introduction, Densimeter Repair
1. The Nuclear Densimeter can be mounted on a wide range of pipe sizes. For BJ
Services, this range is from 2 to 10 in. If the Gauge is removed from one pipe and
mounted on another, it must be ____________________.
2. Specifications list the Operating Temperature as __________ to __________F
(__________ to __________C).
3. Depending on the Density of the Fluid circulating through the pipe, the Gauge outputs
a ____________________ Non-Linear Signal.
4.
Page 1 of 2
Review Questions
Introduction, Densimeter Repair
Page 2 of 2
Definition Of Terms
Densimeter Repair
Definition Of Terms
The first step an Electronic Technician, or ET, must take toward learning Nuclear Densimeter operation
is to understand the associated terminology used by Operations personnel. This is important because,
usually, the ET isnt on location where job problems may occur. When the equipment arrives to the
yard, the ET must repair the problem, and the Operator is usually the only person who can tell the ET
exactly what happened. The Electronic Technician, however, must be capable of interpreting the
necessary information from the Operator. To achieve this goal, this section discusses terminology
associated with the Nuclear Densimeter that is used at the operations level.
Definition Of Terms
Density
Types Of Density
Bulk Density
Absolute Density
Proppant Concentration
Specific Gravity
Density Units for Various Applications
Stimulation
Cement
Sand Control
Definition Of Terms
The items listed above are terminology related to density readings.
Density
Density = =
Weight
Volume
Weight
Volume
Density
The density of a material is defined as the ratio of a materials weight to the volume that it occupies. For
example, if a 1-gallon (volume) bucket is completely filled with water, it weighs 8.34 pounds (weight).
Therefore:
Density Of Water =
= 8.34
Pounds
Gallon
= 8.34
Lbs
= 8.34 PPG
Gallon
Units Of Measurement
For BJ Services US Operations, the units of measurement for density are usually expressed in pounds
per gallon, or PPG. For International Operations, the units of measurement for density are expressed in
kilograms per cubic meter (kg/m3), or kilograms per cube.
Types Of Density
Bulk Density
14.3 PPG
Absolute Density
22.1 PPG
Types Of Density
Density can be divided into 2 distinct categories:
Bulk Density
Absolute Density
Bulk Density
Some materials, such as sand, are granular, or powdered in nature. These materials have air pockets
between the grains, or particles. The total volume that the material and the air pockets occupy is referred
to as bulk volume. Bulk density can then be defined as the ratio of a materials weight to its bulk
volume.
Absolute Density
Other materials, such as liquids, are continuous in nature. That is to say, there is no air pockets, or voids,
in the material. The volume of space that a material occupies, without any air pockets, is referred to as
the absolute volume. Absolute density can then be defined as the ratio of a materials weight to its
absolute volume.
Bulk Density Versus Absolute Density
In its natural state, 20/40 sand is a granular material. If a 1-gallon bucket is completely filled with sand,
it would weigh 14.3 Pounds, so the bulk density would be 14.3 PPG. If the sand was heated until it
melted, it would occupy a smaller space because there are no air pockets present between the grains. If a
1-gallon bucket is completely filled with the melted sand, it would weigh 22.1 pounds, so the absolute
density would be 22.1 PPG. The absolute density of 20/40 sand is greater than its bulk density because
more of the melted sand can fit in a given volume (1 gallon), than granular sand.
Absolute Density
Material
Type
Weight
(Pounds)
Volume
(Gals)
8.34 Pounds
1 Gallon
Density
(PPG)
8.34 PPG
Base Fluid
1.00 Pound
.045 Gallon
Absolute Volume, not Bulk
22.1 PPG
Absolute Density, not Bulk
20/40 Sand
9.34 Pounds
1.045 Gallons
Slurry
9.34 Pounds
1.045 Gallons
Properties Of Mixtures
When a proppant, such as 20/40 sand, is mixed with a base fluid, such as water, the entire mixture may
be thought of as continuous. That is to say, the space between the grains of sand is no longer filled with
air, but is filled with fluid. In the case of proppant laden slurries, it is important to use the absolute
volume, rather than the bulk volume of the sand when computing the total volume and density of the
entire mixture.
Proppant Concentration
Material
Type
Weight
(Pounds)
Volume
(Gals)
8.34 Pounds
1 Gallon
Density
(PPG)
8.34 PPG
Base Fluid
1.00 Pound
.045 Gallon
Absolute Volume, not Bulk
22.1 PPG
Absolute Density, not Bulk
20/40 Sand
9.34 Pounds
1.045 Gallon
Slurry
9.34 Pounds
1.045 Gallons
Proppant Concentration =
Slurry Density
1
Proppant Density
Keep in mind that the proppant concentration is in units of PSA, and all density measurements are in
units of PPG.
Specific Gravity
Specific Gravity = =
Water =
Water
Water
Materials Density
Water Density
8.34 PPG
8.34 PPG
Material
Water
Specific Gravity
The specific gravity of a material is the ratio of the materials density to the density of water, which is
8.34 PPG. Since the units, PPG, are both in the numerator and in the denominator, they cancel, which
means that specific gravity does not have any units associated with it.
Specific Gravity Of Water, Water
To obtain the specific gravity of water, Water, take the density of water, 8.34 PPG, and ratio it with itself,
to obtain a result of 1.0, as mentioned before there are no units.
20/40 Sand
20/40 Sand =
Water
22.1 PPG
8.34 PPG
Proppant Concentration
Pounds Sand Added to 1 Gallon of clean fluid, or PSA
Pounds Proppant Added to 1 Gallon of clean fluid, or PPA
Cement Applications
Density
Pounds Per Gallon, or PPG
Review Questions
Terminology, Densimeter Repair
1. The first step an Electronic Technician, or ET, must take toward learning Nuclear
Densimeter Operation is to understand the associated ____________________ used
by Operations Personnel.
2. The Density of a material is defined as the Ratio of a materials
____________________ to the ____________________ that it occupies.
3. For BJ Services U.S. Operations, the Units Of Measurement for Density are usually
expressed in ____________________. For International Operations, the Units Of
Measurement for Density are expressed in ____________________.
4.
Page 1 of 1
Theory Of Operation
Now that terminology has been covered, the ET is ready to learn how a Nuclear Densimeter Gauge
works. This section provides the ET a general overview of the operation of a Nuclear Gauge.
Main Components
Transmitter
process fluid
pipe
radiation
source holder
Radiation
Energy
Detector
Assembly
Main Components
The drawing above shows the main components of the Nuclear Densimeter, which includes the:
Radiation Source Holder
Process Fluid Pipe
Detector Assembly
Transmitter
This section discusses the components in the order listed, since the radiation energy originates at the
radiation source holder and interacts with the remaining components in this sequence.
Lead Filled
Housing
0-10VDC
Cesium 137
finished source
Radiation
Energy
Cesium 137
finished
source
shutter
Cavity
Shutter
OFF Position
ON Position
REF Position
Shutter Positions
The shutter, shown above, has three positions associated with it. These are:
The ON Position
The Off Position
The Reference, or REF Position
There are some older shutters that only have the ON and OFF Positions.
Safety Precautions
The shutter must be locked in the OFF position when:
Removing the radiation source holder from the process fluid pipe
Making repairs within close range of the radiation source holder (use long handled brushes and
scrapers for cleaning inside the pipe).
Transporting the Nuclear Densimeter
Additionally, when the shutter is in the ON position, keep others and yourself at least three feet away
from the gauge.
Process
Fluid
0-10VDC
Radiation
Energy
Detector Assembly
0-10VDC
Radiation
Energy
Detector
Assembly
Detector Assembly
The Detector Assembly consists of the following major subassemblies:
Ion Chamber
High Voltage Board
Preamplifier Board
Because there are a number of things that can be done to repair and maintain these components, both the
preamplifier board and high voltage board are discussed in detail in this manual. The ion chamber is
discussed, but is a sealed component that cannot be repaired by an Electronic Technician. A general
overview, however, will be given on all three components.
Role of the Detector Assembly
When properly powered, the ion chamber converts received radiation energy into a proportional current
signal that is sent to the preamplifier board; where it is converted and amplified to a proportional voltage
signal of 0 to 10VDC. This non-linear 0 to 10VDC voltage signal is then sent to the Transmitter through a
10-Pin connector.
Density of the Process Fluid
If the process fluid pipe is empty (density = 0.00PPG), then most of the radiation energy reaches the
detector assembly. This being the case, the voltage signal sent from the detector assembly is 10VDC.
This is referred to as the Open Pipe Voltage, or VOP. If water, with a density of 8.34 PPG, is circulated
through the process fluid pipe, the density increases from 0.00 to 8.34 PPG. Usually, water is used as the
base fluid, but other fluids such as brine or KCL may be used as well. The voltage signal generated
while water is circulating through the process fluid pipe is known as the reference voltage, or VREF. As
the density increases, the magnitude of the radiation energy reaching the Detector Assembly decreases.
As a result, the voltage signal sent from the Detector Assembly decreases as well.
Ion Chamber
Positrons
Ion Chamber
Filled with Xenon
Gas
Anode
+ +
+
+
Radiation
Energy
+
-
Cathode
Current
Signal
+
+ +
R
Electrons
Ion Pair
Ion Chamber
The Ion Chamber is a cylinder that receives radiation energy and converts it into a proportional electrical
signal. The assembly consists of a stainless steel cylinder filled with xenon gas and an insulated center
wire. A stable +1400VDC from the high voltage board is applied to the wall (canister) of the ion
chamber. The TN Technologies Densimeter is configured so that the chamber wall acts as an anode and
the wire acts as a cathode. The principle is similar to that of a Geiger Counter, however most Geiger
Counters use polarity which is reversed from the above example.
Ion Chamber Operation
Ionization is the process of an atom becoming charged due to its losing or gaining an electron. When the
radiation energy enters the ion chamber, it ionizes with the xenon gas, creating ion pairs. Each ion pair
consists of:
A Negative Ion (also known as an Electron)
A Positive Ion (also known as a Positron)
The positrons are drawn to the wall of ion chamber, while the faster moving electrons are drawn to the
wire. A charge collects on the Anode, resulting in a voltage change in the circuit. The size of this
voltage change depends on the number of electrons collected from the ionizing process. This causes a
proportional current signal to flow to the preamplifier board, where it is then converted to a voltage
signal and amplified to 0 to 10VDC.
Radiation Energy/Ionizing Relationship
If the full magnitude of the radiation energy enters ion chamber, a greater number of ion pairs are
created, and more charge collects on the anode, resulting in a larger current signal. This larger current
signal results in a larger voltage signal sent to a transmitter, ideally 10VDC, or VOP. If the magnitude of
the radiation energy entering the ion chamber is attenuated, the number of ion pairs created is less, which
results in a smaller current signal, resulting in a smaller voltage signal sent to the transmitter.
Detector Assembly
Ionization
Chamber
Lead Shield
high voltage
board
preamplifier
board
Detector Assembly
The photo above shows the detector assembly. The high voltage board is mounted above the ion
chamber. The lead shield, mounted on the top plate, blocks radiation from passing through the
signal/power connector. This shield might not be found on new units.
Transmitter
Transmitter
0-10VDC
Radiation
Energy
15VDC
Transmitter
A transmitter provides four important functions:
Linearizes the 0-10VDC density signal
Displays the density
Supplies the Nuclear Densimeter with 15VDC
Transmits the density signal to a remote monitor via frequency signals, analog signals or digital
communication.
A transmitter linearizes the voltage signal from the Detector Assembly and produces a numerical value,
which is indicative of the density for the process fluid. Additionally, it provides a display of the density
for the Operator.
Proppant Concentration
In stimulation operations, the transmitter also calculates the proppant concentration in the fluid.
Proppant concentration is measured in units of PSA, or Pounds Sand Added.
10
Transmitters
Analog Transmitter
Digital Transmitter
TN Nuclear Transmitter
Transmitters
There are a number of devices that may be utilized, in whole or part, as a Transmitter.
TN Analog Transmitter
TN Digital Transmitter
BJ Digital Transmitter
3305 Mini Monitor
3600/Isoplex36 Well Treatment Analyzer
Pendant Control System
MCM 1000 Series (Not shown)
11
process fluid
pipe
radiation
source holder
0-10VDC
Radiation
Energy
Detector
Assembly
12
Review Questions
Theory of Operation, Densimeter Repair
1. The Radiation Source Holder consists of a protective
______________________________ and a small ____________________ Finished
Source pellet. The housing has a small ____________________ which serves to
focus the radiation beam from Finished Source.
2. BJ Services Personnel ____________________ have the authorization to open the
Radiation Source Holder, or to remove a non-shuttered Source from the pipe.
3. Additionally, when the Shutter is in the ON position, stay at least
____________________ away and keep others away from the gauge.
4.
Page 1 of 2
Review Questions
Theory of Operation, Densimeter Repair
This page intentionally left blank.
Page 2 of 2
What Is Radiation?
Alpha Radiation
Beta Radiation
Gamma Radiation
X-Ray Radiation
Neutron Radiation
What Is Radiation?
In order to work safely around Nuclear Gauges, one must first understand some basic facts about
radiation. Radiation originates from atoms, which are the building blocks of all matter. Certain atoms
are at excited states and release energy in the form of radiation. This energy is transferred as either
particles or electromagnetic waves.
Types Of Ionizing Radiation
There are 5 types of Ionizing Radiation:
Alpha Radiation
Beta Radiation
Gamma Radiation
X-Ray Radiation
Neutron Radiation
Each has a unique penetrating ability that needs to be considered when protecting oneself from
Radiation.
What Is Radiation?
Alpha Radiation
Beta Radiation
Gamma Radiation
X-Ray Radiation
Neutron Radiation
Alpha Radiation
Alpha radiation occurs when the atom emits large atomic particles. These particles have very little
external penetrating power, and can be shielded with something as thin as a piece of paper. When
exposed externally to Alpha radiation, it poses no external hazard because it can be shielded by the dead
layer of skin covering the body. Alpha radiation, however, can be internally harmful if inhaled or
ingested.
Beta Radiation
Beta radiation occurs when the atom emits small, fast moving particles known as electrons. These
particles are more penetrating than Alpha particles, but are still considered to have relatively low
penetrating ability. Beta radiation can be easily shielded by materials such as cardboard or plastic. It
can, however, penetrate the dead layer of skin on the body.
Gamma Radiation
Gamma radiation occurs when electromagnetic waves are emitted from an atom as a result of radioactive
decay. This form of radiation has a high penetrating ability, and is considered an external threat.
Gamma radiation can be shielded by a dense material such as concrete or lead.
X-Ray Radiation
X-Ray radiation is similar to Gamma radiation in that it emits electromagnetic waves. X-Ray radiation,
however, is generally machine generated and is less penetrating than Gamma radiation.
Neutron Radiation
Neutron radiation results from the emission of a Neutron particle from the nuclei of an atom. This form
of radiation is extremely penetrating and poses a significant external threat.
What Is Radiation?
As
L ow
As
R easonably
A chievable
Safety Factors
The different types of ionizing radiation are harmful, but there is a very little risk associated with the
low levels of radiation of a Nuclear Densimeter. Nevertheless, in practice a person should keep his
exposure As Low As Reasonably Achievable, or ALARA. This can be done by following 3 simple
concepts:
Time
Distance
Shielding
Time
The more Time one remains in a radiation field, the larger the radiation dose. At times, especially during
emergencies, work must be performed in a strong radiation field. In this case, the work procedure should
be carefully planned outside the work area so that a minimum amount of Time is used to complete the
job. If the Time required for one man to complete the job would result in an exposure beyond prescribed
limits, then a team of workers should be employed. This would mean a small exposure for several
people instead of a large exposure for one person.
Distance
Radiation is emitted from a point source uniformly in all directions. The further one is from the
radiation source, the lower the exposure.
Shielding
A Shield is defined as a physical entity placed between the radiation source and the object to be
protected in order to reduce the radiation level at the objects location. An example would be the
radiation source holder. The radiation source is mounted within a lead-filled housing that prevents the
Radiation from traveling anywhere except in the specified direction. In this case, the physical entity is
the lead filled-housing, and the objects to be protected are BJS personnel.
Emergency Instructions
Radiation Program Management Organization
Radioactive Materials Records Management
Radioactive Materials - Employee Notices and
Instructions
Use of Densimeters Having Nuclear Gauges
Transportation Procedures
Handling Procedures
Radiation Protection Program Review
Nuclear Gauge Procedures
Labels
CAUTION
RADIOACTIVE MATERIAL
MODEL
5190
SERIAL NO.
BXXX
ISOTOPE
Cs-137
AMOUNT
EMPTY
DATE MEAS.
09/97
TAG NO.
BJ DEMO
Texas Nuclear Products
TN Technologies
DO NOT REMOVE TAG
MADE IN USA
Labels
R
A
DI
C
O
ACNTE
TI NT
VI S
TY :
:
USA DOT 7A
TYPE A
RADIOACTIVE
MATERIAL
A
C
T
C IV
E
E
O
IN
EX
D
X
DE
IN
Marking Label
13
7
II
T
R
II
R
O
RAY II Label
A
C
T
C IV
E
E
SI
U
M
SP
SP
13
7
Notify if found:
BJ SERVICES CO., USA
HOUSTON, TEXAS
AN
AN
ACNTE
TI NT
VI S
TY :
:
TR
TR
SI
U
R
A
DI
C
O
RAY II Label
Labels
To comply with the licensing agreement, every Nuclear Density Gauge must have two Radioactive
Yellow II Labels (RAY II Labels) and one Marking Label.
Radioactive Yellow II Labels (RAY II Labels)
The 2 Radiation Yellow II, RAY II, Labels must be placed on the Radiation Source Holder on opposite
sides. A RAY II Label displays the following information:
Contents (Always Cesium 137 for BJ Services)
Activity (In Gigabecquerels, GBq)
Transport Index
This activity can be obtained from the AMOUNT reading on the Radiation Source Holder Plaque. The
AMOUNT value is expressed in units of millicuries, so a unit conversion is necessary. (100mCi =
3.7GBq and 200mCi = 7.4 GBq).
Transport Index
When transporting the Nuclear Densimeter, the TRANSPORT INDEX must be filled in. This value is
determined by taking the highest radiation survey meter reading at any point 1 meter (39 inches) from
any surface of the Radiation Source Holder. The value must be less than 1.0 (no units necessary) to use
the RAY II Label. The Transport Index is written to the nearest tenth (Example: use 0.3, not 0.25).
Marking Label
The Marking Label must be placed between the RAY II Labels. A Marking Label displays the following
information:
USA DOT 7A type A Radioactive Material
Emergency phone number
Identifies BJ Services as the owner of the Nuclear Gauge
Review Questions
Radiation Safety Review, Densimeter Repair
1. Radiation originates from ____________________, which are the building blocks of
all matter.
2. When exposed externally to _________________________, it poses no external
hazard because it can be shielded by the dead layer of skin covering the body.
3.
4.
5. The more time spent around a radioactive source, and the closer the distance to the
source, a greater ____________________ results.
6. A person must physically come in contact with, and take a portion of the radioactive
material to become ____________________
7. A ____________________ is defined as a physical entity placed between the
Radiation Source and the object to be protected in order to reduce the Radiation Level
at the objects location.
8. The ______________________________, which provides information about the
Finished Source, is mounted on top of the Radiation Source Holder.
9. The 2 Radiation Yellow II, RAY II, Labels must be placed on the
_________________________ on opposite sides.
10. When transporting the Nuclear Densimeter, the ______________________________
must be filled in. This value is determined by taking the highest radiation survey
meter reading at any point 1 meter (39 inches) from any surface of the Radiation
Source Holder.
Page 1 of 2
Review Questions
Radiation Safety Review, Densimeter Repair
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Page 2 of 2
Detector Assembly
ET-205 Densimeter Repair
Radiation
Energy
Detector
Assembly
Nuclear Densimeter
The Fast Start Up (FSU) detector is an improved version of the early SGO detector. This section of the
presentation will deal with the theory of operation and maintenance of the FSU. The following will be
discussed in this section:
General theory of operation review
FSU and SGO Gauge comparisons
High Voltage and Preamplifier Board circuit detail
Calibration and adjustments
Maintenance and Troubleshooting Procedures
Note
Only personnel who have successfully completed an approved Nuclear Safety Course are permitted to
service nuclear densimeter systems.
Detector Assembly
Ionization
Chamber
High Voltage
Board
Preamplifier
Board
+ 1400 V
Radiation
Energy
High Voltage
Board
Preamplifier
Board
Ion
Chamber
+15V
GND
-15V
+15V
GND
-15V
0-10V
Gain
Power
From
Transmitter
Density
Signal To
Transmitter
Ion Chamber
Anode
+
+
+
Radiation
Energy
Current
Flow
Cathode
+
-
+
+
+ 1400 V
Ion Chamber
Gamma particles from the nuclear source striking xenon gas ions cause ionization to occur,
which results in a current flow. This extremely small current flow is converted by the
preamplifier board into a representative 0 to 10VDC density signal.
Ion Chamber
Adhesive From
Heater Wrapping
Modified Gauge
The adhesive residue in the above photo identifies this Ion Chamber as part of a former SGO assembly.
Due to the inherent sensitivity of the obsolete SGO Gauge to changes in temperature, a heater was taped
to the Ion Chamber in order to maintain a constant temperature inside the housing. Additionally, heater
resistors on the top plate kept the electronics warm. Because of this temperature sensitivity, the SGO
Gauge required long a warm up time before the density readings would stabilize, usually about an hour
or more in cold climates. Upgrading an SGO unit consists of replacing the two boards and removing the
heater.
The FSU Gauge
The improved FSU Gauge contains temperature stabilization circuitry that enables it to remain
remarkably stable over a wide range of temperatures. Additionally, the warm up time from initial
power up is dramatically reduced to 15 minutes or less.
High Voltage To Ion Chamber
There is a +1400VDC potential applied to the Ion Chamber. Although the actual measured voltage has a
100V tolerance, it must be well-regulated, because any fluctuation, no matter how slight, will cause a
corresponding change in the output signal voltage.
Insulated
Collar
U-3
-12V Regulator
From Preamplifier
Board
U-2
MC-79L
12 ACP
CR-1
CR-2
Q-1
3
2
2N3906
Blue (-15V)
White/Gray Stripe (Ground)
White/Purple Stripe
(+15V)
Oscillator
15V
Rectifier &
Voltage Doubler
Oscillator
+1400V
(To Ion Chamber)
U3A
-12V
Regulator
Fusible Resistors
10
Voltage Doubler
HV
Out
Active HV
Regulation
-12V Regulator
Oscillator Circuit
Components Q1, T1, C5, C6, R4, and R5 form an LC Hartley oscillator, utilizing positive feedback to
make up a frequency-selective network running at approximately 1.5 kHz. The two primary windings of
T1 act as the inductive portion of the sine wave oscillator. This loop is designed to have a gain of unity
at a single frequency as determined by the frequency-selective network. In this type of oscillator, sine
waves are generated essentially by a resonance phenomenon. Excitation voltage is supplied by the same
15VDC that powers the preamplifier board.
High Voltage
The AC voltage produced by the oscillator circuit is stepped up by transformer, T1, to approximately
500VAC (RMS). Half-wave rectification, via CR2, gives a DC voltage of +700VDC which is increased to
1400V using a voltage doubler circuit, consisting of C7 and CR1. Filtering is provided by an RC circuit
consisting of C8, R6, R7, C9 and C11. Active (dynamic) filtering is also provided in the feedback
circuit.
High Voltage Regulation
Regulation is developed from the voltage value derived from voltage divider R8, R11 and the regulated 12V from IC, U2. Any deviation is fed back to the oscillator for correction to its output. For this voltage
correction to occur, operational amplifier, U3A, must amplify any deviation between the voltage divider
and ground. The non-inverting buffer, U3B, feeds the error voltage to the primary supply voltage for Q1,
varying it to hold the output at a constant value. An RC circuit, consisting of R12 and C13, slows the
correction slightly in order to prevent overcorrecting, which will cause hunting.
Dynamic Filtering
Similarly, any ripple voltage is treated as deviation from the referenced voltage. Amplified ripple
voltage from the secondary is fed back through the low side of T1 to null the output ripple, thereby
providing dynamic filtering.
11
Voltage Doubler
700V
C7
CR2
+
CR1
Fig 1
X
CR1
Fig 2
12
Preamplifier Board
The preamplifier board converts the current flow from the Ion Chamber into a proportional non linear
voltage signal that represents actual density. It performs this task using a unique negative-going ramping
action, the slope of which varies in accordance with the incoming current. This ramp is then converted
into a DC voltage, inversely proportional to density.
FSU Preamplifier Board Features
Features of the FSU preamplifier board include:
Quick warm up using temperature compensation circuitry.
On-board regulation of input power supply voltage.
Output span adjustable via active gain set jumpers.
Gain fine adjust using trim pot.
13
+15V
-15V
-15V
U3
TP-8
Q5
AR6
W-3
W-2
+15
V
GND
TL026
CP
W6
W4
CO4093BC
P
Gain
Jumpers
W2 & W4 In
LF-13006N
TP-3 TP-4
TP-7
U2
W-1
Q6
W1/R35
Reset Reed
Relay
R13
TP-1
R12
R1
Input From
Ion
Chamber
RELAY
Q4
R28
AR1
C13
TP-2
TP-6
Dual MOSFET
Q4
14
Power Input
Fusible
resistors
Power Input
Fusible 10, 1/4 watt resistors are used on the preamplifier board for short-circuit protection. Because
an open resistor may be difficult to spot visually, supply voltage measurements should be taken not at the
connector, but at the test points on the board. Flame-proof resistors should be used for replacement after
the cause of the short is repaired.
15
DC Differential Amplifier
Inverting Input
Non Inverting
Input
Amplified Ion
Chamber Signal
Reference
Voltage
DC Differential Amplifier
An IC operational amplifier (op amp) has two complementary inputs, inverting and non
inverting. This makes it useful for application as a differential amplifier, which produces
an output voltage that is proportional to the difference between two ground-referenced input
voltages.
Noise Rejection and Temperature Stability
An advantage of this circuit is its ability to reject common-mode (noise) signals, where
there may be a large picked-up interference signal. The differential amplifier rejects this
interference signal, because it is common to both inputs, therefore cancelled out. An
additional benefit of this circuit is temperature stability, because any voltage changes due
to temperature variance will be seen on both legs, and therefore canceled out.
FSU Gauge Application
Because the signal from the ion chamber is coupled to the inverting input of AR4, the
output will be a negative-going voltage. The non inverting input of differential amplifier,
AR4, is referenced to a set voltage (The reference side of a dual MOSFET). When there is
no current from the ion chamber, both inputs are equal and no output is seen. As current
begins to flow (the result of radiation into the ion chamber), this balance becomes unequal
and the voltage difference amplified.
16
+7.5 V
Integration Mode
0V
-10 V
17
TP 6
AR4
+15V
Q4
U2
13
R28
-15V
C 13
14
+7.5 V
Zero Volt
Potential
330 pF
Integration Mode
0V
W1
(X2 Mult)
15
-10 V
18
TP 1
C 12
AR4
+15V
C5
R7
Q4
Zero
U2
Mult
10 M
U2
13
T2
-15V
C 13
V sig
AR1
.33 F
Gain
R
14
330 pF
R
0V
Zero Volt
Potential
W1
15
(X2 Mult)
150 k
300 k
-15 V
19
+12V
Regulator
Dual
MOSFET
Signal
Output
C13
Protection
FET / NE2
Ramp
Reset
Gain Set
Integration Review
During Integration, the voltage from MOSFET, Q4, through its source leg (Pin 7) is coupled to the
inverting input of AR4. The output is a negative-going signal at Pin 6 of AR4 that is coupled back to the
MOSFET through a resistor network and capacitor, C13. The voltage at the input of the Preamplifier is
amplified just enough to virtually cancel the change in voltage at pin 5 of Q4, so that all the current
flowing into the Preamplifier from the Ion Chamber is accumulated as charge voltage on C13. The rate
of voltage change, seen as a negative-going ramp at the output of AR4 (TP6), is proportional to the input
current from the Ion Chamber. The reference voltage for the IC is controlled by the second portion of the
dual MOSFET, thereby automatically compensating for voltage drift caused by changes in temperature.
Setting Gain
The slope, or gain, of the ramp is controlled by digital resistor network IC, U2, and by the value of C13.
The procedure for adjusting the gain will be discussed later in this presentation.
Input Protection
On early version boards, an NE-2 neon lamp is used to shunt voltage spikes and protect Q4. It is
connected from the junction of R12 and R13 to ground and triggers at approximately 50 V. This lamp
was replaced with a solid-state FET lamp on newer version boards, thereby reducing the possibility of
leakage through the neon lamp body due to impurities in glass manufacture.
Voltage Regulator
Because the 15V may not be stable, a +12V regulator IC, U5, provides VCC for Q4.
20
Ramp Integration
Ramp
Converted to
Current
Summing
Point
Ramp Input
From Preamp
NULL
Adjustment
Potentiometer
Overvoltage
Protection
21
AR4
.33 uF
C5
R7
U2
Mult
Q4
U2
T2
C 13
K1
330 pF
+10 V
T1
AR6
-10 V
T2
Reset Circuit
T2
K1
T2
T1
-15 V
22
Ramp Reset
Ramp
Input
0V
+10V
-15 V
T1
-10V
+7.5 V
Integration Mode
0V
Reset Mode
To U3C
-10 V
Voltage Limits
When the ramp voltage from the preamplifier reaches a predetermined positive or negative voltage level,
an action will occur to reset the ramp. Voltage divider resistors, R27, R32, and R33 are connected to
15VDC to form the positive and negative 10V reference for voltage comparator IC, AR6A and AR6B.
This dual-package op amp senses the ramp voltage limits and triggers a positive output whenever the
input ramp from the preamplifier is equal to the reference voltage. In order to achieve a positive output
from either ramp extreme, AR6A is configured as a non-inverting output and AR6B is an inverter. The
+10VDC reference voltage limit is connected to pin 6 of AR6A, and the
-10V limit is tied to AR6B, pin 3.
Note
Under normal operation, the ramp resets to +7.5VDC, which is set by voltage divider circuit consisting of
R30 & R31 (not shown in this drawing). The +10VDC limit is not normally activated, and will only be
seen in the event of an abnormal condition, such as a saturated preamplifier input signal.
NAND Gates
When AR6 output goes high, NAND gates will be activated. (NAND gates are inverting AND gates,
therefore both inputs must be high for the output to go low.) An RC network makes these gates act
as as Monostable Multivibrators, or One-Shots, meaning the output will be a single pulse when both
inputs are equal.
Ramp Reset
When triggered, U3A & U3B develop a single positive-going square wave pulse at T1 (TP4), the duration
of which is stretched by C16, R16 and R19 to about 50ms. This pulse turns on transistor, Q5, which in
turn energizes a relay to provide a discharge path for reset feedback capacitor, C13.
23
T2
TP 1
V sig
AR1
C5
U2
Mult
T2
Gain
From U3B
K1
+10 V
AR6
T1
-10 V
T2
T2
0V
-15 V
0V
-15 V
Pulse
Stretched
24
C 12
AR4
AR1
C5
Q4
10 Meg
T2
Gain
C 13
@ 30 msec
K1
330 pF
+10 V
AR6
0V
T1
-15 V
T1
0V
-10 V
T2
T2
-15 V
Reset Circuit
0V
T2
T2
-15 V
@ 60 msec
TP 6 Signal VR
T2
300 K
+7.5 V
Reset
K1
-15 V
0
V
Slope Determines
Output Signal
Reset Start
-10 V
25
C12, Summing
Capacitor
Q2, On During
Reset
R7, Summing
Resistor
26
TP6
C8
W1
14
13
15
Resistor Array
12
DECODER
LATCH
LATCH
LATCH
Digital 2
Digital 1
Output
Signal In
W3
W2
W6
15V
AR1
W4
15V
27
GAIN
W2 / W3
W4 / W6
X-1
X-2
X-4
X-8
W3
W3
W2
W2
W4
W6
W4
W6
28
Gain
2.0
1.87
1.76
1.6
1.5
1.5
1.31
1.24
1.0
29
R35
W1 & W2
W3
30
GND
R35
-15V
+15
V
W2
W-3
W1
R35
Gain
Jumpers
TP-1
31
In addition
to jumpers,
trim pot
R35 is
Proprietary and Confidential
Property
of BJ Services
Company
32
Gain Jumpers
Rev F Boards With Resistor Feedback
Gain:
X-1
X-2
X-4
X-7
X-8
Jumper Positions
W1
W2
W3
Out
Out
Out
Out
In
Out
In
Out
In
Out
Out
In
In
Out
In
33
Capacitor, C13
If the correct open pipe voltage cannot be obtained via jumper configurations, the value of feedback
capacitor, C13, can be changed to raise or lower the Preamplifier gain. Raising the capacitance will
decrease the gain, and vice versa.
Care When Replacing C13
It is important that latex surgical gloves be worn when handling the capacitor, as any contamination
deposited on the capacitor body will affect the performance of the gauge. It has been determined by TN
Technologies that even thoroughly washed hands will still leave trace oil and dirt deposits on the
capacitor. These contaminants can cause long term drifting and instability of the output voltage.
Additionally, the capacitor must be secured to the shield plate using non-corrosive RTV silicon
compound. Do not use acid-curing compound, as contamination can result, and do not let any compound
make contact with the capacitor leads. If contamination is suspected, the capacitor and surrounding area
can be cleaned with isopropyl alcohol. Other cleaning agents may dissolve the polystyrene body.
34
Dont Forget!
Lower the value of C13 in
Preamplifier Board to raise
gain.Raise the value to lower
the gain.
Use non-corrosive silicon seal
to secure C13 to shield, and do
not let compound touch the
leads.
Nominal value of C13 is
330pF.
Dirt and oil from your hands
can contaminate C13
Cleanliness Is Critical
Even resistances in excess of 1x1013 will have a major impact upon the output signal. The
Preamplifier Board must be kept clean and free from corrosion and moisture! This is especially true of
polystyrene gain set capacitor, C13.
Expiration Date
Because polystyrene capacitors can absorb moisture, do not use any capacitors that have been sitting on
the shelf for a long time (over a year in humid climates). It is a good idea to store the capacitors in a
sealed container, and to keep a dated inventory list.
35
36
Circuit
The Nuclear Source Simulator consists of:
2K ten-turn potentiometer
15G Resistor
8 RG174 coaxial cable
Additional components include a suitable plastic case, LED and clip leads. When building
the simulator, it is important to keep the leads as short as possible, especially the coaxial
cable.
Operation
The simulator works best with the complete assembly attached, but can be used with just
the preamplifier board, connected to 15V. To use the simulator, disconnect the 15V
connector on the preamplifier board that powers the HV board and connect the simulator
power connector in its place. Connect the coaxial lead from the simulator to the junction of
R12 & R13. Adjust the potentiometer fully CCW, apply power and slowly adjust the
potentiometer for desired output voltage at TP1 on the preamplifier board.
Note:
This simulator is a troubleshooting aid only; it is not suitable for use as a calibration device.
37
Review Questions
Detector Assembly, Densimeter Repair
1. The three main component parts of the Detector Assembly are:
1. ________________________________________
2. ________________________________________
3. _________________________________________
2. Briefly explain why the Fluke 80K-40 High Voltage Probe is designed to work only
with meters that have 10M input impedance.
3. Components Q1, T1, C5, C6, R4, and R5, on the High Voltage Board, form a
____________oscillator. This oscillator uses _______________ feedback to
maintain a constant voltage.
4. Other than radiation strength, the four variables which affect the overall gain of the
preamplifier are:
1. __________________________
2. __________________________
3. __________________________
4. __________________________
5. The original NE-2 lamp was replaced with a solid-state FET lamp on newer version
boards to reduce the possibility of _________ due to variances in glass manufacture.
6. When powered up, The preamplifier will always be in one of two modes:
1. __________________________
2. ___________________________
7. IC, U2, used as part of the RC gain set in the Preamplifier circuit, is simply a
_____________________________________________________________.
Page 1 of 2
Review Questions
Detector Assembly, Densimeter Repair
8.
9. When the voltage ramp applied to pins 5 and 2 of AR6 reaches the value set by
________________, one output will go ____________ and trigger the NAND gate U3A
and U3B.
10. Temperature stability is primarily provided by component _____________________.
Page 2 of 2
Prerequisites
None
Objective
The objective of this activity is to present a guide for locating and identifying Test Points
found on the FSU Preamplifier Board
Procedure
1. Mount FSU Nuclear Densimeter Assembly into Test Stand. Remove any test sticks
from tube.
2. Verify power supply is turned off. Connect Power/Signal Wiring Harness from J1 on
Preamplifier Board to 15V Power Supply.
3. Locate, on the FSU Preamplifier Board, The Test Point marked GND. Connect
common lead of DVM to this Test Point.
4. Turn on power.
5. Locate the following Test Points and measure the voltage at each:
+15 ________
-15 _________
TP1 (Signal Output) _________
TP6 (Ramp Signal) __________
6. Connect High Voltage Probe to DVM and measure voltage on the Ion Chamber,
through access hole in Test Stand. Record voltage ______________.
7. While measuring High Voltage, tap on High Voltage Board with insulated tool. Did
High Voltage change? ________.
8. This Activity is complete
Page 1 of 2
2. Why is it preferable to check 15V at the Test Points, rather than on the Molex
Connector?
Page 2 of 2
Prerequisites
Objective
The objective of this Activity is to demonstrate the ramping action of the Preamplifier,
and how it affects output signal voltage.
Procedure
1. Place FSU Nuclear Densimeter Assembly into Test Stand
2. Connect Power/Signal Wiring Harness from J1 on Preamplifier Board to 15V power
supply. Connect the Nuclear Signal Simulator
3. Set up oscilloscope to measure voltage and display waveform (5V/Div, DC Scale,
100mS) and connect to Preamplifier Board:
Probe to TP6
Ground clip to GND test point
4. Apply power to Densimeter
5. Adjust the Source Simulator to maximum current (fully clockwise.)
6. Observe the ramping action on TP6.
7. Observe and record the voltage at which the ramp resets:
Upper voltage ramp limit_______
Lower voltage ramp limit_______
8. Decrease the input current from the simulator. The slope of the ramp:
A. Increases
B. Decreases
C. Stays the same
Page 1 of 2
Study Questions
1. Why does the ramping action slow with reduced radiation exposure to the Ion
Chamber?
Page 2 of 2
Prerequisites
Objective
The objective of this Activity is to instruct the technician in the proper procedure to
follow when zeroing the Nuclear Densimeter.
Procedure
1. Place FSU Nuclear Densimeter Assembly into Test Stand.
2. Connect Power/Signal Wiring Harness from J1 on Preamplifier Board to 15V Power
Supply.
3. Place DVM to measure voltage at TP6
Positive lead to TP6
Negative lead to Gnd test point
4. Install jumper wire from resistor, R13 to TP6, to remove the effects of residual input
signal.
5. Apply power to Densimeter.
6. Adjust Trim Pot R28 for 0 V at TP6.
7. Leaving jumper wire in place, move meter lead to TP1.
8. Adjust Trim Pot R1 for 0 V at TP1.
9. Recheck TP6 and re adjust if necessary.
10. Remove jumper and note that voltage at TP1 does not increase significantly.
11. Power down and discharge high voltage.
12. This Activity is complete
Page 1 of 2
Study Questions
1. Can the zeroing procedure be performed without the Ion Chamber or High Voltage
Board attached? ________. Explain:
3. What will be the slope of the ramp at TP6 with a properly zeroed system.
Page 2 of 2
Prerequisites
Objective
The objective of this activity is to familiarize the ET with gain-set adjustments and
jumpers on the FSU preamplifier board.
Page 1 of 3
GAIN
W2 / W3
W4 / W6
X-1
X-2
X-4
X-8
W3
W3
W2
W2
W4
W6
W4
W6
Study Questions
1. In the above Activity, it is seen that the gain of the preamplifier can be adjusted by a
combination of jumper settings. What parameter is being changed with these jumpers?
Page 2 of 3
3. What other component value can be changed to vary the gain of the Preamplifier?
Page 3 of 3
Prerequisites
Objective
The objective of this activity is to observe and compare the operation of the three reset
pulses. By observing the time relationship between these pulses, an understanding of
their purpose should become apparent.
Procedure
1. Place FSU Nuclear Densimeter Assembly into Test Stand
2. Connect Power/Signal Wiring Harness from J1 on Preamplifier Board to 15V.
Connect the Nuclear Signal Simulator.
3. Connect Oscilloscope to Reset Test Points:
Channel A to TP6
Channel B to TP4
Ground lead to GND
4. Set up Scopemeter for waveform measurements as follows
Sensitivity: 5V/Div
Sweep: 50 mS/Div (may vary with source strength and ramp speed)
DC Volts
5. Apply power to Densimeter
6. Adjust the Nuclear Source Simulator fully clockwise.
Page 1 of 3
9. Leaving Channel B probe on TP4, move Channel A probe to TP3 and compare these
two pulses. For ease of observation, move the base line (zero point) of one channel,
thereby separating the two waveforms. Performing a waveform capture using
single sweep function will help in this effort. Sketch these two waveforms, again
showing the period relationship:
10. Move TP4 probe to TP2. Compare and sketch these two waveforms.
Page 2 of 3
Page 3 of 3
BJ Digital Transmitter
ET-205 Densimeter Repair
Inputs/Outputs
12VDC Power
0-10VDC Signal
15VDC Power
LAN
Output
Local Frequency
Output
Bus
(611C)
Inputs
The BJ Digital Transmitter requires 10.5 - 15VDC power to operate. It receives a 0-10V signal from the
Nuclear Densimeter.
Outputs
The BJ Digital Transmitter has three data outputs available:
1 - Frequency Output
1 - LAN Output
1 - Local Bus
Frequency Output
The frequency output is self powered, which means it does not require external excitation voltage for its
high level (approx 10VP-P) output signal. It is scaled so that 1000 Hz = 10 Pounds Proppant Added
(PPA), which equates to a PPU = 6000.
LAN Communication
The BJ Digital Transmitter can communicate over the BJ Local Area Network via RS-422
communication. By assigning unique ID numbers, up to three BJ Digital Transmitters can send data to a
3600, Isoplex36 or Isoplex monitor. To view this data at the 3600 and Isoplex36 Monitoring Systems,
select >TEXAS NUCLEAR DETECTOR MODULES, reached by pressing the following sequence from
the Main Menu Screen of either the 3600 or Isoplex36:
>SELECT PARAMETERS
Choose the appropriate Parameter Number
>SELECT INPUT
>LAN SYSTEM
>TEXAS NUCLEAR DETECTOR MODULES
Local Bus
The two-wire Local Bus line is designed to transmit data only to the 611C Controller.
Proprietary and Confidential Property of BJ Services Company
BJ Density
Transmitter
611C Installation
The above photos show a BJ Digital Transmitter in a typical 611C installation. Notice the location of the
transmitter. It is usually mounted in the lower, right hand, slot.
Rear View
Power/Signal
Connector
Contrast
Control
Contrast Control
The contrast control is a 10-turn potentiometer, located on the rear of the BJ Digital Transmitter. This
potentiometer adjusts the contrast of the display, which changes with the angle of view. If power for the
BJ Digital Transmitter is turned on, but nothing appears on the screen, check to insure that the contrast
control is properly adjusted.
Power/Signal Connector
Power and signals are routed through this single multi-pin connector.
Keypads
Main
Screen
Numerical
Keypads
Reference
Key
Specific
Gravity
Key
Fluid
Weight
Key
Carrier
Specific
Gravity
Key
10
Span
Key
11
Volts In
Key
12
Arrow
Keys
Arrow Key(s)
The Arrow Keys are used for two purposes:
Change Viewing Options on the Main Screen
Choose a Selection when in Test Mode
Change Viewing Options On The Main Screen
From the Main Screen, the two arrow keys allow the Operator to view the following parameters:
Density, in PPG
Proppant Concentration, in PPA
Both Density in PPG, and Proppant Concentration in PPA
Both Density in kg/m3, and Proppant Concentration in kgPA (Metric Units)
Density, in kg/m3 (Metric Units)
Proppant Concentration, in kgPA (Metric Units)
Choose a Selection When In Test Mode
In the Test Mode, the arrow keys scroll through various test choices.
13
Self Test
14
Exit Key
15
Clear
16
Data Entry
17
18
BJ Digital Module
19
Resistor
Install
Jumper
REFDWG: 41696
20
Change to
1k
9.09k
Resistor
Added
REFDWG: 41696
21
15V Supply
REFDWG: 41709
22
15V
Power
Supply
Board
+5V
Regulator
(Behind Panel)
8V Power
Supply
REFDWG: 41692
23
12V IN
12V
Vicor Power
Supply
Trimmed To
8V
8V Out
LM7805
5V
Regulator
LM7805
5V
Regulator
12V IN
15V
DC/DC
Converter
5V Logic
5V
To
68VAC
Inverter LCD Back Light
24
Power Diagram
Vicor
Converter
(PS1)
Connector
J1
REFDWG: 41697
Input Power
Primary +12VDC power is supplied through Connector J1. The power input portion of multi-function
connector J1 is:
Pin A = +12VDC
Pin B = +12VDC
Pin C = Ground
Pin D = Ground
UCM II Power Supply Requirements
Because the logic and backlight input circuits operate at 5VDC, and there are no other voltage
requirements, the UCM-II module is designed to operate more efficiently with +8VDC input to the
regulators. This voltage is typically supplied by a Vicor power supply (+12VDC supply, trimmed to
+8VDC), and is found externally mounted on multiple-module setups such as the Hydration Unit.
BJ Density Transmitter Power Requirements
Because the 15VDC Converter in the BJ Density Transmitter requires +12V input and the unit is
designed to be functional in a stand alone mode, the +8VDC power supply is installed inside the
Transmitter housing, and identified as PS1. This converter supplies power to the two 5V regulators
which operate the following:
Logic and main PC board circuits
68VAC Inverter for Backlight power
Because the 5VDC regulators only have to drop 3 Volts, power lost to heat is lowered.
In addition to power, the converter provides isolation for the circuit.
12V Vicor Converter Set To 8V
The nominal +12V DC-DC Converter is set to 8VDC via trim resistor R3. The Vicor Converter input also
sends +12VDC to the 15V DC/DC Converter on PC2 through Connector, P1, Pins 1 (+12V) and 2
(GND).
Proprietary and Confidential Property of BJ Services Company
25
+5V
Regulator
(VR1)
To Contrast
Control
68VAC
Inverter
(VR2)
REFDWG: 41696
26
Serial Communication
Standard 3600
LAN Connection
Tx
Rx
Rx Tx
/Tx
Standard LAN
Node Connection
/Rx GND
Local Bus
Line to 611C
JP5
TX
/TX
GND
RX
/RX
5
JP4
1
REFDWG: 41697
Serial Communication
Serial communication over the Local Area Network (LAN) is possible with the BJ Digital Transmitter.
To enable communication to occur, an ID number must be entered at the Transmitter and that same ID
entered at the 3600/Isolplex36. Additionally, a Local Bus line provides one-way serial communication
to a 611C Blender Console. An ID number is not necessary for communication with the Local Bus line.
TIP
When wiring or servicing the LAN system, keep in mind that it is a null modem configuration. TX from
3600 is sent to the RX at the Module.
27
Review Questions
BJ Digital Transmitter, Densimeter Repair
1. The nominal +12V DC-DC Converter used to power the BJ Digital Transmitter is set
to ___V via trim resistor _____.
2. The power supply voltages found in the BJ Digital Transmitter are:
_________________________________
_________________________________
_________________________________
3. The BJ Digital Transmitter has ______ Serial Ports. State the purpose of each.
4. What would be the observed symptom if +5V to the contrast were lost?
5. Describe the function of each of the 5V regulators, VR1 on the PC board and VR1 on
the front panel.
Page 1 of 1
Sensor Cable
Lead Filled Housing
Containing Cesium-137
Source
NUC DENSITY
Energy
Beam
Ion Chamber
Detector And
Preamplifier
3305
J-Box
Pin B Signal In
Pin C -15V
Pin D Common
Pin E +15 V
Pin G Shield
F
K
C
E
D
Bulkhead Connector
Front View
Densimeter Wiring
The J-box Nuclear Density Connector uses the standard BJS-specified connector PT02E-18-11P.
Nuclear Density
Interface J-Box
Energy
Beam
Ion Chamber
Detector And
Preamplifier
3600 Interface
The 3600 can accept up to two Density Inputs, but each input can only read a maximum voltage of
5VDC. Because of this limitation, a Nuclear Density Interface J-box, consisting of an adjustable voltage
divider network, is required in order to keep the input voltage below its limit.
Density Inputs
1 and 2
Density Input
Two inputs are specific to Nuclear Densimeter. Even though the density connectors are different, the
input circuitry is identical to the six Analog Inputs. The 3600 program firmware corrects the non-linear
characteristics of the Nuclear Densimeter.
Pin B Signal In
Pin C -15V
Pin D Common
Pin E +15 V
Pin G Shield
G
H
B
C
F
E
D
Densimeter Wiring
Shown above is the 3600 WTA pin configuration for Density #1 and #2 Inputs. In addition to slope
correction, these two inputs provide the 15VDC required to operate the densimeter.
NOTE
The 3600 density input connector is different from the connector used on the Nuclear Densimeter. It is
adapted to the standard BJ connector via the dDensity Interface J-box.
13.3k
5k
J2-B
J1-B
J1-C
J1-D
J1-E
10k
-15V
COM
+15 V
To Densimeter
J2-C
J2-D
J2-E
To 3600 Density Input
<1>
<2>
USING
(EXIT)
F1
F2
F3
F4
Select Source
The Pendant has two Nuclear Densimeter input choices:
High Pressure
Low Pressure.
To make the selection, use the numeric keypad to select <1> or <2>.
<1> REFERNCE
= 0.00
= 0.00
= 0.00
<4> SPAN
= 0.00
= 0.00
(EXIT)
F1
F2
F3
F4
Calibration Procedure
The Nuclear Densimeter setup on the Pendant consists of the following operator entries:
Reference, zeroing on base fluid.
Base ASG, specific gravity of the base fluid (water is 1.00).
Prop CSG, specific gravity of the proppant (20/40 sand is 2.65).
Span, the calibration number found on the Gauge housing.
The raw voltage input from the densimeter is displayed on this screen, and is a handy test point to ensure
voltage data is being sent from the Nuclear Densimeter. With current firmware, the value displayed will
be one-half of actual input voltage.
10
BASE ASG
= 0.00
NEW VALUE
Fresh Water
1.00
= 0.00
(EXIT)
F1
F2
F3
F4
11
PROPPANT CSG
= 0.0
NEW VALUE
Sand Typically
2.65
= 0.00
(EXIT)
F1
F2
F3
F4
12
Setting Span
CALIBRATE LOW PRESSURE PSA
SPAN
= 0.0
NEW VALUE
= 0.00
(EXIT)
F1
F2
F3
F4
Span
The Span number for the densimeter to be used is entered via the numeric keypad. This span number is
generally found on the Nuclear Densimeter housing. If unknown, a calibration procedure should be
performed by the Electronic Technician.
13
REFERENCE
= 0.0
NEW VALUE
= 0.00
Enters Detector
Voltage as Zero
PSA
(AUTO)
F1
F2
F3
(EXIT)
F4
Reference Entry
Auto (F1) key is pressed to automatically enter the current Gauge voltage as Zero PSA. This key should
only be pressed while on pad fluid (ie. No proppant).
14
DENSITY1
Pendant Density
Input
OPTO ISOLATED I/O
DENSITY2
CLOCK
ENABLE
DATA OUT
DATA IN
HIGH SPEED ANALOG-TODIGITAL CONVERTER
15
16
Voltage Divider
17
Review Questions
Monitors & Controllers, Densimeter Repair
1. Using dedicated 15V supplies in the Pendant Controller isolates the signal and
power ground of the Nuclear Density Gauge from the Pendant _______ ground, to
eliminate the possibility of _____________and reduce the chance of processor errors
caused by Gauge or cable failures.
2. The 3600 WTA density interface J-box is used to lower the _____________voltage
from the Nuclear Density Gauge.
3. Discuss the two main differences between the 3305 and 3600 Density Inputs:
Page 1 of 1
Introduction
With BJ Services acquisition of various Oilfield Service Companies throughout the years, the
problem of Standardization has become a major concern. The Instrumentation Engineering
Department has made an effort to incorporate the Plug N Play concept, so that if a district borrows
a Nuclear Densimeter or any other piece of instrumentation, re-wiring and re-scaling will not be
necessary in order to make it to work with their equipment.
Standardization Is The Goal
In an effort to implement the Plug N Play concept with each Nuclear Densimeter, regardless of
company origin, the ET should become familiar with the differences that may be found in Nuclear
Densimeters, and make it a point to convert any densimeter that does not meet BJ specifications.
This section provides the information necessary to convert nonstandard Nuclear Densimeter to BJ
Specifications, thus ensuring uniformity within the Company.
Specifications
Conversion
Connector Specifications
Generic Detector Assy
MS3102E-18-1P P/N 174140
BJS Detector
PT02E-18-11P BJS P/N 43291X
Conversion
When converting a generic Nuclear Densimeter to BJ Specification, the following steps should be
taken:
Replace the connector mounted on the Detector Assembly with the BJ Connector, P/N 43291X.
Verify that the connector at the Transmitter is P/N 35817X, using the pin configuration listed
on the next page.
Replace the cable with P/N 35818X.
On Detector Assembly, install potentiometer on Preamplifier Board @ W1 for gain
adjustment..
Adjust the Preamplifier Gain between the range of +9 to +10 Volts with Open Pipe, using
procedure found in the Maintenance section of this manual.
Obtain a Span Number using the calibration procedure found in the Calibration section of this
manual.
Using indelible marker, write the Span Number on Nuclear Densimeter housing. A water proof
tag may also be used to attach the Span Number.
Pin B Signal In
Pin C -15V
Pin D Common
Pin E +15 V
Pin G Shield
F
K
C
E
D
Bulkhead Connector
Front View
Pin B Signal In
Pin C -15V
Pin D Common
Pin E +15 V
Pin G Shield
G
H
B
C
F
D
BJ SERVICES COMPANY
TECHNICAL SERVICES
Subject:
Revision:
1.
Date:
Page:
of
Introduction
Portions of the following procedure were reprinted from Procedure Number 10006-tp,
Rev N/C. It outlines the calibration procedure using Calcium Bromide and a 3305
Mini Monitor. Substituting a 3600 Well Treatment Analyzer for the 3305 will yield
similar results.
2.
Material Requirements
3.
Prerequisite
This procedure should only be performed by personnel that have been certified
in use and handling, safety and servicing of the nuclear gauges or under the
supervision of someone who has been certified by TN Technologies. Perform
an in-process inspection of the assembly and verify that a lock and a set of keys
were included with the unit.
Inspect the pipe saddles to insure that the
detector/source assembly is secure and that the nuts are welded. Following is a
procedure that is recommended to establish a Cal Factor (SPAN Number) for the
nuclear gauge.
After calibration, the Calibration Record Form is to be completed by the Electronic
Technician who performed the calibration. The Densimeter should be completely
checked out after calibration to verify that it is fully operational. If any difficulties are
encountered during calibration, the problems should be recorded on the Calibration
Record Form and Technical Services should be contacted for assistance. The
completed form should be retained by the Electronic Technician, for future reference.
BJ SERVICES COMPANY
TECHNICAL SERVICES
Subject:
Revision:
4.
Date:
Page:
of
Procedure
1. Plug the down end of the pipe of the gauge with a pipe plug or use a smooth
rubber mat in a container to capture the Calcium Bromide after use.
2. Connect cables to the 3305 monitor, J-Box, power, and the gauge.
3. Apply power to the 3305 monitor and J-Box. Allow 15 minutes for electronics to
thermally stabilize.
4. Go to the Calibration menu for Nuclear Density. Select option 1 for Reference
Voltage. The lower right hand portion of screen will display volts input. With the
shutter closed (if so equipped) Volts Input should read near zero.
5. Unlock the shutter and slide it to the On position. Monitor the voltage displayed
on the 3305. With the pipe open to air it should read approx. 9.95 0.15 VDC.
If the assembly reads in excess of 10.55 VDC, the gain on the preamp of the
gauge may need to be adjusted. Record this voltage on the Calibration Record
Form.
6. Fill the pipe with water just above the top clamp where the detector and source
are mounted. Monitor the voltage and verify that it drops to approximately the
voltage noted, based on pipe size. Record this voltage on the Calibration
Record Form.
8
2.55 VDC
6
3.4 VDC
5"
4.3 VDC
4
5.4 VDC
3
6.6 VDC
2
7.9 VDC
7. Verify that the Base ASG has a value of 1.00. Reference the water voltage by
pressing the F3 key (AUTO).
BJ SERVICES COMPANY
TECHNICAL SERVICES
Subject:
Revision:
Date:
Page:
of
to
to
to
to
to
to
7.5
9.5
12.0
16.0
25.0
45.0
Empty the pipe and dry it out as much as possible. Using the hydrometer from
the kit, float it in the Calcium Bromide solution. After it settles, obtain a density
reading, then remove the hydrometer. On the side of the hydrometer is a scale
in SGU readings. Multiply the density reading by 8.34 to obtain a PPG value and
record this value on the Calibration Record Form. After obtaining the PPG
number, fill the pipe with the Calcium Bromide solution just above the top
mounting brackets then, go to option 3 (SPAN) and adjust the initial reading up
or down until the correct PPG is displayed on the 3305. Document the final
SPAN number on the Calibration Record Form and on the gauge.
10. Drain and capture the Calcium Bromide for future use.
11. Rinse the pipe thoroughly and dry it out.
12. Add water again and verify that the PPG reading on the 3305 monitor comes up
to 8.34 0.1 PPG.
13. Empty the pipe. Slide the shutter to the OFF position and use the lock to
secure the device.
14. Document all the information on the Calibration Record Form.
Detector Assembly
Detector Assembly
Some of the more common problems related to the Nuclear Densimeter include:
No density reading (The Nuclear Densimeter is locked up)
Erratic and unstable density readings
Density spikes
Density consistently high or low from actual
The possible causes of these problems are explained in this section, as well as suggested solutions.
Detector Assembly Calibration
Many of the problems mentioned above may be avoided if the Detector assembly is calibrated at routine
intervals. The calibration procedure is discussed in this section as well.
Calibration/Repair Materials
Materials List
A primary list of items needed to service the Detector Assembly includes:
3/16 Allen Socket Wrench, to remove lid
7/16 Deep Socket w/ Ratchet Wrench, to loosen the rubber grommet
2 Large 90 Allen Wrenches, for prying out electronics
4 Adjustable Wrench
Small Phillips Head Screwdriver and Small Flat Head Screwdriver
Clean White Eraser, to clean contacts
Trichlorethane 1,1,1 or Commercial Grade Everclear (95% ethyl alcohol)
Silicon Dielectric Grease, to lubricate the O-ring
Digital Voltmeter with 4 digit display (Fluke Model 8050-01 or equivalent)
High Voltage Probe
Test Clip Leads
Rubber Mallet
DC Power Supply (12V @1A)
Small Adjustment Screwdriver (tweaker)
Insulated mat
IDET Densimeter Training Video, TV-201
If repairs are to be made to boards, or if the open pipe voltage (gain) is to be set, additional tools include:
Soldering Iron and rosin-core Solder
Desoldering tool or Solder Wick
Assortment of polystyrene capacitors
Hemostats or needle nose pliers
Non-corrosive, non-flowing Silicon Seal
Latex surgical gloves
Oscillator, Q1
C7
Voltage Regulation
Fusible Resistors
-12V Regulator
Output, TP1
Ramp Reset/Hold TP
Nylon Insulator
Nylon Guide/Insulator
A nylon guide is used in the housing assembly to properly align the Ion Chamber with the radiation
beam, and to help prevent movement. The guide also provides electrical insulation of the Ion Chambers
high voltage. The guide is pressed into a bracket in the housing of the Gauge and has an indention on
one end that will mate with a pin welded onto the center of the Ion Chamber. When servicing the
assembly, care must be taken to prevent the guide from becoming dislodged. It should fit tightly in its
holder, as any play will allow the Ion Chamber to move and cause an erratic signal output when
vibration is present. Inspect the guide for wear and damage. If it is slightly loose, a small amount of
silicon seal applied to the base of the guide may prevent movement. Greater movement will usually
require replacement of the guide. Also, inspect the Ion Chamber tip for integrity. If the tip is damaged
or has fallen off, the guide may no longer prevent movement of the can. The tip can be replaced by TN
Technologies.
FSU Connectors
15V To High
Voltage Board
Connector J1
15V Input
& Signal Output
10
Density Spikes
20.0 PPA
20.0 PPA
20.0 PPA
20.0 PPA
11
20.0 PPA
20.0 PPA
20.0 PPA
12
2 PPA
13
Fluid Volume
If the flow meters are not accurately measuring base fluid, proppant totals will not be correct. Therefore,
the first step that should be taken when discrepancies in proppant volume are reported should be to verify
that the flow meter pulses per barrel (ppus) are correctly set. This can be done by taking strap volume
measurements of the fluid tanks before and after the job, and comparing the results with clean flow meter
totals. If volumes dont match, the next step should be to verify that the correct ppus are programmed
into the system and that no problem exists with the flow meter itself. If no problems are found, and the
error is small, a change in ppus can be made in order to correct the problem. Increasing ppus will
increase volume and vice versa. This holds true for Mass, Magnetic, Turbine, Encoders and 60-Tooth
Gear assemblies.
Proppant Volume from Encoders
Unlike flow meters, encoders do not give a direct volumetric measurement, therefore other factors, such
as auger wear and the resulting loss of product delivery must also be considered. Because there is no
delay, the density calculated from the encoders is called instant density.
Span Number
The low-pressure densimeter on a blender is typically used as a reference for the instant density
calculated from the sand augers. This procedure verifies that the screws are delivering the correct
proppant volume. Because adjustments to the sand auger ppus are made to keep instant density in line
with the nuclear densimeter, the Operator should keep in mind that theTransmitters span number has
an inverse effect on proppant delivery. For example, increasing the span number will give a higher
nuclear density reading, therefore the auger ppus (instant density) will have to be lowered so as to bring
the density reading down.
14
Preamplifier Zeroing
For best accuracy, no voltage should be seen at the output of the preamplifier with no received radiation
at the Ion Chamber. A zeroing adjustment of the preamplifier board can be performed with or without
the Ion Chamber or high voltage board connected.
Background Radiation Must Be Negated
Because it is constantly exposed to natural background radiation while out of its shielded enclosure, the
preamplifier input must be disabled prior to zeroing the unit. Even if the Ion Chamber is not connected,
stray noise pickup at the input will often prevent an accurate zeroing of the board. For this reason, the
input must be shorted to the output of the ramp generator.
Zeroing Procedure
Now that the necessary precautions have been taken, the zeroing procedure for the preamplifier board
can now performed:
Place a jumper from TP6 to input resistor R13 (or the junction of R12 and R13).
Adjust R28 for 0 V volts at TP6. TN Technologies now recommends this voltage be set slightly
negative in order to ensure no reset pulse is seen at the output, TP1.
Leaving the jumper in place, adjust the NULL potentiometer, R1, for 0 V volts at TP1.
Recheck the voltage at TP6 and repeat the above procedure if necessary.
NOTE
A Zeroing procedure must be performed whenever a board or component is replaced on the Gauge.
15
16
Test Sticks
Test Sticks
BJ Services has test sticks available for simulating various proppant and slurry weights. These sticks
display the approximate weight marked on the end, but are not designed to be used as a calibration tool.
They are ideal as a quick check to determine if the system is functioning, and to look for intermittent
problems. To use the sticks, calibrate the Gauge in the usual manner, ensuring it is zeroed on water.
Remove fluid from the pipe and install the acrylic test stick. Observe the marked density (nominal 1.6
PSA). Remove the acrylic stick and install the magnesium stick. Note that the density increases to the
value marked (nominal 13.2 PSA). The density reading should remain constant unless the stick is
disturbed.
The part numbers and costs are as follows:
35172-1
2 Acrylic. $106.00
35172-2
2 Aluminum.$106.00
35172-3
2 Magnesium...$150.00
34955-1
3 Acrylic..$205.00
34955-3
3 Magnesium...$298.00
39721-1
4 Acrylic..$395.00
39721-3
4 Magnesium...$420.00
TIP
When servicing a high pressure Nuclear Densimeter not having a shutter, a magnesium test stick can be
inserted in the pup joint to reduce exposure to radiation from the source.
17
Preventive Maintenance
18
Review Questions
Densimeter Gauge Maintenance, Densimeter Repair
1.
2.
List some causes, other than the Densimeter, that could cause inaccurate sand totals
3.
A zeoring procedure should always be performed with the Ion Chamber and High
Voltage connected.
A. True
B. False
4.
Test Sticks are suitable for use in calibration of the Nuclear Densimeter.
A. True
B. False
Page 1 of 1
Tables
Densimeter Repair
Density (lbs/gal)
21.08
21.25
21.25
20.84
21.33
21.25
22.08
29.58
30.45
22.08
22.08
22.75
27.08
22.08
26.25
26.25
26.33
21.67
22.08
21.08
21.42
21.08
21.67
21.67
21.42
29.08
26.42
Sand Sizes
The sizes of the particles are often expressed as a number, which corresponds to the mesh screen size of a
sieve. The screen size indicates the number of openings in the mesh screen per inch. For example, a # 40
sieve has 40 openings per inch in the screen mesh. Particles that can sift through that mesh are said to be
"40 mesh" size.
Below is a list of mesh sizes and the size of the mesh opening in millimeters (1/1000 of a meter) or microns
(1/1,000,000) of a meter. Of coarse there is a correlation between the size of the mesh opening and the
particle size of the sifted powder. As the opening becomes smaller, so will be resulting particle size. Most
of the particles of a sifted powder will have approximately the size as the mesh opening.
Mesh Opening Size
Mesh Size Number
10
20
30
40
50
60
70
80
100
millimeters
2.00
0.84
0.59
0.42
0.297
0.250
0.210
0.177
0.149
microns
2000
840
590
420
297
250
210
177
149
The USP 24/NF19 uses descriptive terms to define granular fineness. The table below shows the correlation
their classification.
Description Term
Very Coarse
Coarse
Moderately Coarse
Fine
Very Fine
Sieve Distribution API specifications place the following limitations on sieve distribution for proppants
suitable for use in a fracture:
at least 90% of material must fall between the two mesh sizes
no more than 10% of the material may be coarser than the largest mesh size
no more than 0.1% of the material may be coarser than the next largest mesh size (e.g. for 20/40,
up to 10% of the proppant may be between 16 and 20 mesh, but no more than 0.1% can exceed 16
mesh)
no more than 1% of material is permitted to fall onto the pan
For gravel pack media, the suggested distribution is more tightly constrained:
at least 96% of material must fall between the two mesh sizes
no more than 2% of material is permitted to be finer than the specified size
no more than 0.1% of the material may be coarser than the next largest mesh size (e.g. for 20/40
media, no more than 0.1% can exceed 16 mesh, and no more than 2 percent may pass through the
40 mesh screen, and no more than 4% can be outside the range of 20/40.)
Appendix B
Electrical Drawings