HDI 2522 4-inch Choke Position Indicator User s Manual Rev 2 New 2522 Indicator Gauge Linear Potentiometer w/open Housing 2200 Indicator Gauge Linear Potentiometer
TABLE OF CONTENTS HDI 2522 4-inch Indicator Contents 1.0 Systems General Information... 4 1.1 General Information:... 4 1.2 Unpacking and Inspection:... 4 1.3 Precautionary Information:... 4 1.4 Personnel Qualifications:... 4 2.0 Systems Description... 5 2.1 Systems Description:... 5 2.2 System Components:... 5 2.2.1 Choke Position Display... 5 2.2.2 Choke Position Potentiometers... 5 2.2.3 Cables... 5 2.3 System Capacities... 6 2.3.1 Choke Position Indicators... 6 2.4 System Options:... 6 2.4.1 Remote Display... 6 2.4.2 4-20 ma Output... 6 2.4.3 0-1 VDC Output... 6 2.4.4 Intrinsic Safety Certifications... 6 3.0 Installation... 7 3.1 Control Head and Sensors... 7 3.2 Cables... 7 3.2 Mounting Hardware... 7 3.3 Choke Position Sensor Assembly and Standard Installation... 7 3.3.1 General Assembly... 7 3.3.2 Choke Position Display... 9 3.3.3. Cables... 9 4.0 Info... 10 4.1 Choke Positioning Systems... 10 5.0 Calibration... 10 5.1 Choke Position System... 10 2
HDI 2522 4-inch Indicator 5.1.1 Setting Closed Position Level... 11 5.1.2 Setting Open Position Level... 11 6.0 MAINTENANCE... 12 6.1 Choke Position System... 12 6.2 Choke Position Systems Battery Replacement... 12 6.3 Tools Required for Field Repair or Annual Service:... 13 7.0 Warranty... 13 APPENDIX A... 15 APPENDIX B... 16 3
1.0 Systems General Information HDI 2522 4-inch Indicator 1.1 General Information: This manual describes the installation, operation, and maintenance of the HDI 2522 Choke Position Indicator System. Included in this manual are all the necessary procedures to install and maintain this Choke Position Indicator System properly. 1.2 Unpacking and Inspection: Upon receipt of the equipment, the customer should make sure that all items are accounted for on the packing list. If any items are missing, immediately inform the freight forwarder. Inspect all items for damage. If any items are damaged immediately inform the freight forwarder and HDI Instruments. 1.3 Precautionary Information: The customer should verify that all directions on the packages are followed during unpacking and handling. Caution: If the return spring is preinstalled on the linear potentiometer shaft (if purchased), the user should use caution to prevent damage to the potentiometer shaft. The fully compressed spring has enough force to shear the holding clip and launch the potentiometer stem from the housing, destroying the unit. There is enough force when compressed that the linear shaft can be pulled from the internal body. If damaged, the linear potentiometer must be replaced since this is an oil-filled sealed unit and cannot be repaired. 1.4 Personnel Qualifications: This equipment requires minimal experience to handle, install and maintain. HDI offers technical training on our premises at customer request. 4
2.0 Systems Description HDI 2522 4-inch Indicator 2.1 Systems Description: The HDI 2522 System is an Electronic Choke Position Indicator System. The system consists of three primary components as detailed in Section 2.2. An electronic potentiometer is housed inside a stainless steel housing and is adjustable to ensure the sensor is located properly to detect travel movement of the choke. HDI has several different housing configurations that have been designed to adapt to the most commonly used chokes: Shaffer/NOV, Cameron, Swaco, Control Flow, Cortec. HDI can assist the customer in the design for a specific application. The electronic bar graph display indicates choke position from closed to open, where 100% if fully Open. 2.2 System Components: 2.2.1 Choke Position Display The display is a liquid crystal display (LCD), which includes a four digit numerical display (for accuracy) and a bar-graph representation (for trend). 2.2.2 Choke Position Potentiometers As noted above, HDI has designed several different sensor housings to be compatible to various choke styles to reduce onsite customization and to simplify installation after removing the existing pneumatic sensors. General dimensional drawings or photos are available upon request to ensure compatibility. 2.2.3 Cables All interconnecting cables supplied by HDI or can be adapted to use junction box for open termination. Wiring details are provided later in this manual. 5
2.3 System Capacities HDI 2522 4-inch Indicator 2.3.1 Choke Position Indicators HDI s Choke Position Indicators will display from 0 to 100 percent and will be respective to the customer s choke body orientation for an open or close position. By default, the display is configured to represent the open state of the choke and 100% represents fully open. 2.4 System Options: HDI offers the following options to the customer at an additional cost. 2.4.1 Remote Display Remote displays may be provided to allow secondary indicators at an alternate location at the customer s request. 2.4.2 4-20 ma Output HDI offers as an option, a signal current loop providing a 4-20 ma remote output that may be used for chart recorder inputs, data logging or to PLC systems for remote graphical representation. This is a factory installed option and does not require calibration. The customer is required to provide a 24 Vdc current loop and related barrier for zone installation. 2.4.3 0-1 VDC Output HDI offers as an option, a signal providing a 0-1 Vdc remote output that may be used for chart recorder inputs and / or data logging. This is a factory installed option and does not require calibration. 2.4.4 Intrinsic Safety Certifications The HDI 2522 was designed based on HDI s experience and current products to meet safety concerns to be intrinsically safe rated; however, this product does not have any current IS Certificates. IECEX and IS certificates are pending at this time. 6
3.0 Installation HDI 2522 4-inch Indicator 3.1 Control Head and Sensors The control head and sensors are to be mounted by the customer at the locations deemed most suitable for such equipment. The system potentiometer assembly comes from the factory as a complete assembly and only requires mounting of the sensor housing using standard practices for such installations. 3.2 Cables All cable lengths from the control panel to the sensors shall be supplied by the customer. This is so that HDI can provide prefabricated cables for a quick and simple plug and play installation. HDI s systems may differ from other similar position indicators on the market. HDI s cables will have a male (pin) and female (socket) connectors that easily allow cables to be added to extend cable lengths. 3.2 Mounting Hardware Sensor integration to the choke bodies will generally use the existing bolts from the pneumatic sensors once removed. The HDI sensor assembly will be complete with all necessary hardware or adaptive stems as required. For example, both Swaco Rotary and Cameron s M3D Sensors will include a choke specific adaptive stem. Custom fit ups are available as options by HDI. 3.3 Choke Position Sensor Assembly and Standard Installation 3.3.1 General Assembly The Choke Position Potentiometer and mounting brackets are provided to replace an existing pneumatic regulator choke position system presently in use. This assembly is designed to mount in the original choke position enclosure utilizing the existing hole patterns and mounting hardware. The customer should remove the existing choke position assembly and install the new stainless steel housing and potentiometer assembly with mounting brackets with the existing mounting hardware. 7
Bracket Style Linear Housing: HDI 2522 4-inch Indicator Using a 1 ¾ wrench, loosen the potentiometer nuts on both sides of the bracket to allow the customer to adjust the sensor depth. With the choke body in the fully closed position, adjust the cylinder potentiometer assembly to allow for a 1/8 to 1/4" compression of the shaft. Hand tighten the potentiometer nuts to secure the potentiometer from movement. Slowly function the choke while observing the potentiometer to prevent it from bottoming out inside the cylinder housing. Once confirmed that there are no issues, tighten the nuts and then proceed to calibration Standard Linear Potentiometer Housing Loosen the potentiometer brass mounting brackets to allow for adjustment. With the choke body in the fully closed position, adjust the cylinder potentiometer assembly to allow 1/8 to 1/4" compression of the shaft into the potentiometer housing and tighten the bolts on the brass mounting brackets. Observe the choke bodies and sensor while opening the choke to make sure the potentiometer does not bottom out inside the cylinder housing. Rotary Potentiometer HDI provides an adaptive shaft (for a Swaco application) that must be threaded into the existing choke shaft via the adjustment stud. The customer will note on the face of the rotary potentiometer a Dead Spot marked in red. The remaining section is the working zone of the potentiometer. The potentiometer is left loose at this point for a future adjustment to the HDI provided bolt which is threaded into the choke stem. Orientation to clockwise and counter-clockwise operation is critical to avoid crossing into the dead span of the potentiometer, which will cause a spike or erratic reading on the LCD. Once the orientation of the rotary potentiometer matches clockwise and Counterclock-wise orientation, gently tighten the set screw on the brass mounting block to secure the potentiometer assembly from rotating during operation. An instructional video of this installation is available on the HDI website. 8
HDI 2522 4-inch Indicator 3.3.2 Choke Position Display The LCD gauge is designed to be a direct drop in replacement for all similar 4-inch round position indicators to include the bolt hole pattern to secure the gauge. The only noticeable difference is that the HDI unit may require one to two inches of additional clearance once installed into the control panel. In the event there is any interference with hydraulic plumbing, the interconnect cable can be configured with a 90 degree elbow to offset any cable clearance. Remove the lock nuts, drop the gauge in the appropriate hole and replace the lock nuts and secure the gauge. Do not overtighten. 3.3.3. Cables The system comes complete with cable and connectors made to the customer s specifications. Simply route the cable from the transducer to the gauge, connect the cables to the transducer and gauge, and tighten the collars. Note the pin terminator side attaches to the LCD display. 9
4.0 Info HDI 2522 4-inch Indicator 4.1 Choke Positioning Systems The LCD (Control head) has a 3.6 V E606 (replaceable) battery pack that supplies power to the LCD via the power cable. The Control Head then supplies the excitation to the Sensor and measures the ohm resistances generated during the extension or compression of the potentiometer. The information is then converted to be displayed on the LCD as a numeric digit readout with a corresponding bar graph. The choke position indicator does not require any warm up period. Note: HDI sensors are typically 2 or 5K potentiometers, but are compatible with client specific potentiometers up to a 25K unit. Turning the system off when not in use will greatly extend battery life. 5.0 Calibration 5.1 Choke Position System This device is field calibrated directly from the front membrane panel. Calibration is required for the first time install and anytime the main processor board or the potentiometer sensor is field repaired or replaced. See table below for descriptions of the button functions. Mode Select Button UP ARROW 100% Calibration Select Button DOWN ARROW 0% Calibration Select Button Enter Select Button Selects calibration. Allows for calibration at open choke position. Allows for calibration at closed choke position. Enters Mode and Calibration Selections Power ON/OFF Power on/off switch. 10
HDI 2522 4-inch Indicator Power ON: Press the Power button once (Unit performs self-test, all display segments turn on) Power OFF: Press the Power button once. 5.1.1 Setting Closed Position Level 1. Once the installation is complete the choke should be closed completely. 2. Apply power to device by pressing the POWER button. 3. Choke Position Indicator will perform a short self-test during which time all LCD segments will be active. 4. After the self-test is complete, the display will be in the run/active mode. (RUN indicator will appear at the lower left side of the LCD display). 5. Check to verify the Choke is completely CLOSED, press the MODE button. (RUN indicator will turn OFF). 6. Press the Down button. (Unit is now in calibration mode) 7. The down arrow and a four digit number will appear at the top of the LCD display. 8. Press the Enter button. (This function causes the gauge to accept (store) the low / closed set point position, unit returns to RUN mode). 9. The closed position level is now set, and the three digit display should read 000.0 5.1.2 Setting Open Position Level 1. Function the Choke to the fully Open position. 2. Once in the Open position, press MODE button. (RUN indicator will turn OFF) 3. Press UP button. (Now in calibration mode) 4. The up arrow and a four digit number will appear at the top of the LCD display. 5. Press the Enter button. (This function causes the gauge to accept the high / open set point position, unit returns to RUN mode). 6. The Open position level is now set, and the three digit display should read 100.0 11
HDI 2522 4-inch Indicator 7. The unit is now fully calibrated. 6.0 MAINTENANCE 6.1 Choke Position System Generally, this system should only require calibration every 2 years, when the power pack is replaced, or if there are any change in system wiring or if a repair is completed. It is suggested that a visual inspection be performed from time to time, perhaps every 6 months to ensure the stem has not been bent. The sensor box when mounted has some play in the mounting pattern allowing alignment of the unit to avoid putting any bind on the stem while in operation. This may need some adjustment. The customer should also periodically check the cables for any visual damage or cuts that will allow water or moisture into the cable causing interference and erroneous results. 6.2 Choke Position Systems Battery Replacement Remove the cable from the back side of the case, along with the 3/8 locknuts that are securing the gauge to the panel. Using a 7/64 Allen wrench, remove the machine screws from the front of the unit to gain access to the electronics. Remove the front trim ring and the membrane panel with the gasket. Disconnect the battery lead from the main processor board. Remove 3 of the 5 PCB screws. See photo. 12
HDI 2522 4-inch Indicator Remove the battery retainer plate then proceed to remove the battery, desiccant pack, corrosion inhibitor and humidity indicator. Insert the new battery in the case. Replace the desiccant pack, corrosion inhibitor and humidity indicator and install the retainer clip. It is recommended that the system be tested at this time to ensure everything is working before closing up the gauge. Connect the battery to the main processor board and connect the interconnect cable to the gauge and have the choke functioned to calibrate the unit per Section 5. If the system operates properly, finish assembling the unit in the reverse order. The power pack is covered under a one year warranty from date of shipment and will generally last 14-18 months when continuously running. When not in use, it is suggested to power off the unit to extend battery life. 6.3 Tools Required for Field Repair or Annual Service: 1. Screwdriver, Phillips (small) 2. Allen wrench, 7/64 3. Socket Wrench, 3/8 7.0 Warranty HDI Instruments, LLC. (HDI) warrants this product for a period of one year from the date of shipment. HDI s manufactured products to the extent that HDI will replace those parts having defects in material or workmanship when used for the purpose or specification HDI recommends for Normal Oilfield Usage. HDI shall not honor the Warranty if any evidence of tampering, misuse or intrusion is indicated except by an HDI authorized technician or agent. HDI will replace or repair, as it deems necessary, any products covered by this warranty, after HDI's examination discloses to its satisfaction, that in fact the products are defective and an adjustment is required. If an adjustment is required, the amount of the adjustment is the net sales price of the defective product. No allowances shall be made for labor or expenses of repairing defective products or damage resulting from same. All products accepted under the provisions of 13
HDI 2522 4-inch Indicator this warranty shall be shipped prepaid to HDI and returned to the customer prepaid by HDI. This is to include all applicable custom clearance fees, etc. for inbound international shipments. All products not accepted under the provisions of this warranty shall be shipped prepaid to HDI and returned freight collect. HDI shall not be responsible for repair or replacement of products, resulting from improper handling, storage, installation, misuse, negligence, or use in a manner contrary to the recommendations of HDI. HDI warrants only the products that it sells of Other Manufacturers to the extent of their warranties. All warranty claims shall be made in writing to the nearest HDI office or authorized factory representative. HDI makes no other warranty of any kind, expressed or implied, and all implied warranties of merchantability or fitness for a particular purpose which exceed HDI's afore-stated obligation are hereby disclaimed by HDI and excluded from this warranty. This Warranty is non transferable and HDI shall not be liable for any damage, injury, loss to property or persons resulting from the use of any HDI's products or equipment whether such damage, injury or loss results from, or is caused by: manner of use, defects in materials or workmanship or otherwise. Only exception: when the purchase is made from a known supply house, the end user should be identified. 14
APPENDIX A HDI 2522 4-inch Indicator WIRING INFORMATION: Sensor Wiring: Linear Potentiometer Device Markings Connector Processor Board Color Code 1 A P BLACK 2 B S WHITE 3 C G GREEN Rotary Potentiometer w/ stem facing user Connector Processor Board Color Code Left A P BLACK Middle B S WHITE Right C G GREEN 4-20mA Output Connector A B C D E Function Code 4-20 + 4-20 - Not Used Not Used Grnd Color Black White Red Green Shield 0-1 Vdc Output 5-pin Connector A B C D E Function Code N/A N/A Signal + Signal - Grnd Color Black White Red Green Shield 15
HDI 2522 4-inch Indicator APPENDIX B 16
HDI 2522 4-inch Indicator 17
HDI 2522 4-inch Indicator 18
HDI 2522 4-inch Indicator Client Maintenance Notes 19
ISO 9001:2008 Office Phone - 713.688.8555 After Hours Support, Primary: 713.446.2212 After Hours Support, Secondary: 713.819.6103 4130 Directors Row Houston, TX 77092