Gauge Assembly and Maintenance by Scott A. Ager 9-10-08
Gauge Sections
Gauge Sections Sensor Section (M006) Bull Nose (C010) OWR Section (Gauge S/N) Attaches to Shock Mitigater Data Readout Section (C011) Battery Section (B006)
Gauge Sections - Shock Mitigater - Used to reduce the vibration when the gun fires. Attaches to the gun or gauge carrier. - Sensor Section - Contains the two pressure ports. Attaches to the Shock Mitigater. - OWR Section - Contains the OWR Electronics. - NOTE: NEVER OPEN THIS SECTION! There are NO User Serviceable Parts inside.
Gauge Sections - Battery Section - Contains the Battery Fixture and Battery Pack. NEVER unscrew this section until AFTER the data is downloaded! - Data Readout Section - Unscrew THIS SECTION to download the Gauge Data. - Bull Nose Section - You can remove this and attach another gauge at this point.
Gauge Grease
Grease Uses - O-Rings - Pressure Port - Sensor Section - Gauge Section Threads - Battery Section and OWR Section - Large Stub Acme Threads - Bull Nose and Sensor Section - IES Shock Mitigater
Types of Grease Blue Glacier FM Grease Pressure Ports O-Rings inside the Battery Section and OWR Section Shaft of the Shock Mitigater NON-METAL anti-seize grease (black color) Threads inside the Battery Section and OWR Section (next to the O-Rings) COPPER Anti-seize grease (dark copper color) Large Stub Acme Threads on the Bull Nose, Sensor Section, and Shock Mitigater
Blue Glacier FM Grease Designed for high pressure, high temperature applications. Sticky characteristic resists washing out Resists gumming Synthetic (food grade) grease
Gauge Section O-Ring Grease Blue Glacier FM grease Battery Section and OWR Section ONLY use Blue Glacier FM grease, for ALL O-Rings located inside the gauge sections (Battery Section and OWR Section).
Gauge Section O-Ring Grease Blue Glacier FM grease OWR Section ONLY use Blue Glacier FM grease, for O-Rings located inside the OWR section.
Pressure Port Grease Sensor Section For the pressure ports, ONLY use Blue Glacier FM grease.
Shock Mitigater Grease IMPORTANT: ONLY use Blue FM Glacier grease on the shaft of the Shock Mitigater assembly.
Internal Thread Grease Battery Section and OWR Section Use ONLY the NON-METAL anti-seize i grease (black k color) ) on the threads of the Battery Section and OWR Section (located next to the high pressure O-ring seals inside the gauge sections). NOTE: DO NOT use COPPER anti-seize grease on the threads located next to the high pressure O-ring seals (inside the gauge g sections). Note: Copper Anti-Seize grease contains small metal shavings that can scratch the O-Ring surface.
Large Stub Acme Thread Grease Shock Mitigatert Bull Nose Sensor Section Use the COPPER Anti-seize grease (dark copper color) for the Large stub acme threads. These threads are located on the Bull Nose, the Shock Mitigater, and the Sensor Section. Be sure to put grease on the small O-rings located next to the threads. NOTE: DO NOT use this grease on the Gauge Section threads located next to the high pressure O-ring seals (inside the gauge sections).
Gauge O-Rings Sizes and Materials
Select the Correct O-Ring Material for your Application There are two recommend O-rings materials used with the gauge, VITON and AFLAS. Use VITON O-Rings for Formate Fluids < 8 ph Use AFLAS O-Rings for Formate Fluids >8pH ph, if the gauge will be downhole for more then 24 hours Use PEEK Backup Rings for ALL applications. Be SURE to let us know what type of O-Ring material you need for your application.
Gauge Section O-Rings Sizes The Large diameter O Rings used in the OWR Section and The Large diameter O-Rings used in the OWR Section and Battery Section are #2-125, 75A (Viton or Aflas). One PEEK backup ring is used for each large O-Ring.
Gauge Section O-Rings Sizes The Small diameter O Rings used in the OWR Section The Small diameter O-Rings used in the OWR Section (internal) are #2-018, 75A (Viton or Aflas). Two PEEK backup rings are used for each small O-Ring.
Gauge and Shock Mitigater (Stub Acme Thread) O-Rings Sizes The O-Rings used next to the LARGE STUB ACHE THREADS on the Bull Nose Section, Sensor Section, and the Shock Mitigater, are #5-964, 90A (Viton or Aflas). Four O-Rings are used for each section, two per O-Ring groove. NOTE: No backup rings are used.
Gauge O-Ring Removal and Installation Procedures
O-Ring Removal To remove the O-Ring, use a wooden dowel or pinch the O- Ring between your fingers, to get under the O-Ring. Clean off the old grease with a lint-free cloth or paper p towel. You MAY need to use a solvent to remove dirty grease.
O-Ring Removal NO!!! NO!!! DO NOT use a metal instrument to remove the O Ring It DO NOT use a metal instrument to remove the O-Ring. It could scratch the metal surface, causing a seal failure and possible high pressure leak, damaging the Gauge.
O-Ring Installation When installing O-Rings, ALWAYS use a plastic O-Ring sleeve or plastic wrap over the threads, to protect the new O-Rings from nicks, scratches and dirt, during installation.
O-Ring Installation 1. Slide the O-Rings and PEEK backup rings over the plastic wrap. This protects the O-Ring surface from nicks and scratches. 2. NOTE: Install the O-Ring and backup ring pair, closest to the threads, FIRST.
O-Ring Installation NOTE: One side of the large PEEK backup ring has a concave groove. This surface MUST face the O-Ring.
O-Ring Installation For the Large O-Rings in the Battery Section and the OWR Section, use only ONE PEEK backup ring with every O-Ring.
O-Ring Installation The PEEK Backup Ring goes on the Threaded side The O-Ring goes on the High Pressure side IMPORTANT NOTE: The PEEK backup ring MUST be positioned on the Threaded side, and the O-Ring MUST be positioned on the High Pressure side.
O-Ring Grease Use NON-METAL anti-seize grease (black color) on the threads. ALWAYS grease the O-Rings, inside surface, and threads BEFORE assembling the gauge sections. Use Blue FM Glacier grease on the O- Rings.
Gauge Assembly
Gauge Assembly - BE SURE the Gauge Threads and Grease are completely CLEAN! If there is ANY foreign debris or material on the threads when you assemble the gauge together, the threads will be DAMAGED! If the threads before dirty, you will need to clean them completely with a solvent. - Position the gauge sections in the vertical position, when you assemble the gauge section. This will help prevent CROSS THREADING from occurring. - Assemble the gauge sections together by hand, ONLY! This will allow you to feel is there is something wrong with the threads. IF YOU FEEL any resistance or grinding, immediately unscrew the sections and check the threads with your bare fingers for any rough surfaces. If found, you will need to have the threads repaired. The gauge is stainless steel and the threads can be easily damaged, if care is not taken.
Gauge Assembly - NEVER, EVER use a wrench to tighten the sections!!! Doing so will stretch the stainless steel threads, possibly damaging them! The O- RINGS in each gauge section, will keep the gauge from coming apart. - Hand tighten the Data Readout Section to the Battery Section - Hand tighten the Battery Section to the OWR Section - Hand tighten the OWR Section to the Sensor Section - Use the ½ Wrenches supplied to loosen the gauge sections. - Use the ½ Wrenches supplied to ONLY tighten: - The Bull Nose to the Data Readout Section - The Sensor Section to the Shock Mitigater - The Shock Mitigater to the GUN or GAUGE CARRIER - NOTE: If you over tighten the gauge threads, you may damage them.
Gauge Assembly Screw the gauge sections together, in the vertical position, and by hand ONLY! NEVER use a wrench to NEVER use a wrench to tighten the gauge sections together!
Gauge Assembly NOTE: ONLY use the ½ Wrenches supplied, to LOOSEN the gauge sections.
Gauge Assembly Shock Mitigater Bull Nose Sensor Section Use the ½ Wrenches supplied, to ONLY tighten Large Stub Acme Threads of the Bull Nose, Sensor Section, and Shock Mitigater
Thread Protection
Thread Protection ALWAYS use the Thread protectors and Red end caps to help prevent the threads and O-Rings from getting dirty. It will also protect the threads from physical damage.
Thread Protection ALWAYS put Thread Protectors on the threads to keep the threads and O-Rings clean, and to protect the threads from damage!
Thread Protection Be sure the threads and O-Rings are completely free of ANY debris. The stainless steel sections can easily be damaged if the O-Rings or threads are dirty.
Gauge Thread Repair
Thread Repair Male Threads Clean the grease off the threads with a solvent. Inspect the threads for nicks, using your bare fingers to feel for any burrs. Use a small, fine file to remove any burrs found. Female Threads If a female thread has been damaged, use a BOTTOM Tap to rechase the threads. Specify a Bottom TAP for 17-4 PH SS.
Thread Repair Taps for reworking gauge g threads. TAPCO USA, Inc. 5605 Pike Road Loves Park Rockford, ILLINOIS 61111 (815) 877-4039 Specify TAP for 17-4 PH SS. - 1.1875-6 STUB ACME-2G, Bottom TAP (For All Gauges) PITCH DIA. MAX 1.1288 -MIN 1.1100-1.3750-10 STUB ACME-2G, Bottom TAP (For 1-11/16 Gauge) PITCH DIA. MAX 1.3356 -MIN 1.3191
Shipping the Gauge Back to IES for Repair
Shipping the Gauge for Repairs You can use a 3 inch dia, schedule 80, PVC pipe to ship the OWR SECTION back to IES for repair Ship ONLY the OWR SECTION (with black thread protectors installed on BOTH ends)
WARNINGS!
ALWAYS Store the Gauge Completely Assembled NEVER store a Battery Pack inside the gauge if it is not being used for a job. Store the gauge completely assembled, to keep dirt and moisture out, and to protect the gauge threads and O-Rings.
NEVER DISASSEMBLE THE OWR SECTION! NEVER disassemble the internal parts of the OWR SECTION. There are NO User Serviceable Parts inside the OWR SECTION (the section with the Gauge S/N scribed on it). If you disassemble the OWR SECTION The material used for packing the electronics will spill out, and you will NOT be able to repack it properly. If this material gets on the gauge threads, it could seriously damage them!
NEVER DISASSEMBLE THE OWR SECTION! NEVER unscrew this part on the OWR SECTION
NEVER DISASSEMBLE THE OWR SECTION! NEVER remove e these screws s on the OWR SECTION
Gauge Maintenance Procedures after EVERY Job
Gauge Maintenance Procedures After EVERY Job after EVERY Job! 1. Be sure you have downloaded and saved the gauge data in TWO locations, and verified the gauge data is OK BEFORE you DISCONNECT the Battery Fixture or install the RED KILL SWITCH! If you do, you will LOSE ALL YOUR DATA! 2. ALWAYS remove the OLD batteries. Never stored the gauge with old batteries inside because they might leak and damage the gauge. g 3. Pump NEW grease (Blue FM Glacier grease) through the pressure ports with the grease gun, until it is clear blue. This will clean out the small micro screen holes. Then, inspect the screens for damage, by unscrewing the hollow lock nuts, and pumping the screens out with the grease gun. 4. Remove and replace ALL the O-Rings (Viton or Aflas) in the Battery Section and OWR Section. Inspect the PEEK backup rings and replace as needed.
Gauge Maintenance Procedures After EVERY Job after EVERY Job! 5. Remove and Replace the Large (#2-125) and Small (#2-018) INTERNAL O-Rings located in the OWR Section (between the OWR Section and SENSOR Section). FIRST, Pump NEW grease (Blue Glacier FM grease) into the pressure ports until it is clean (BEFORE you disassemble the OWR Section and Sensor Section). This prevents contaminated grease from being pulled inside the Sensor Section when you unscrew the two sections. Unscrew the OWR and SENSOR sections, replace the internal O- Rings, and inspect and replace the small PEEK backup rings as needed. Pump NEW grease into the Sensor Section and re-assemble the Sensor and OWR Sections. NOTE: There are TWO PEEK backup rings for each small internal O-Ring. They go on BOTH sides of the small Viton O-Rings. BE SURE to clean out the old grease inside the pressure sensor hole, and put fresh grease inside it.
Gauge Maintenance Procedures After EVERY Job after EVERY Job! 6. IMMEDIATELY, after the job, disassemble, Inspect, and Re- Grease the Shock Mitigater. Replace the Viton tubing AND the Bolts, if the rubber is deformed, hard, or brittle. (9/16 OD x 5/16 ID Viton Tubing, 75A) If any bolts break or bend, replace ALL the bolts. Clean and Re-grease the Shock Mitigater shaft and cylinder with Blue Glacier FM grease. Do this immediately after the job to prevent the shoulder bolts or Shock Mitigater from rusting.
Breaking the Gauge Sections AFTER a Job
Breaking the Gauge Sections AFTER a Job ONLY use the supplied ½ HEX Wrenches to break the gauge sections. DO NOT use a PIPE WRENCH! Scarring the s rface co ld damage the High Scarring the surface could damage the High Pressure Rating of the gauge.
Remove the USED Battery Pack after EVERY Job
Before Removing the Battery after a JOB 1. Be sure the Gauge data is saved in TWO locations. 2. Have someone verify the data is ok. 3. THEN, you can disconnect the Battery Pack and properly discard the battery, to prevent leakage from damaging the Gauge. NOTE: NEVER store a Gauge in LONG TERM Storage with a Battery Pack in it!
Battery Warnings! The Gauge uses Volatile Data Memory, so if you remove the battery power from the Gauge the Gauge Data will be ERASED and permanently LOST! If you discount the Battery Fixture from the Gauge (OWR Section) the Gauge Data will be ERASED and permanently LOST! If you install the RED KILL SWITCH in the Battery Fixture the Gauge Data will be ERASED and permanently LOST!
Battery Fixture Warning! Sensor Section OWR Section Bull Nose Data Readout Section NEVER break the gauge between the OWR and BATTERY Sections. You will lose ALL your data!!! Battery Section ALWAYS break the Gauge at the Data ALWAYS break the Gauge at the Data Readout Section, to download the data!
Pressure Port Maintenance after EVERY Job
Cleaning the Pressure Ports and Micro Screens after EVERY Job FIRST, always Pump NEW Grease through the Pressure Ports after EVERY Job. Leave the Micro Screens installed. Using a Grease Gun connected to the 1/8 port, pump Blue Glacier FM grease into the Sensor Section until clean, blue grease comes out of both pressure ports. This cleans out the 4000 micro holes in the Micro Screens.
Cleaning the Pressure Ports and Micro Screens 1 2 4 Use 1/8 Nipple 3 Using the Grease Gun pump Blue Glacier FM grease Using the Grease Gun, pump Blue Glacier FM grease into the Gauge Sensor Section until clear, blue grease comes out of both pressure ports.
Removing and Inspect the Pressure Port Micro Screens Remove and Inspect both Micro Screens Unscrew BOTH Hollow lock nuts holding the micro screens Use the grease gun to pump out both screens Inspect the micro screens for any cracks or visible holes Put the micro screen back first, followed by the two washers, then the hollow lock nut Hand tighten the hollow lock nut Re-insert the 1/8 plug, hand tight
Removing the Pressure Port Micro Screens After cleaning the screens, unscrew the hollow lock nuts holding the screens in place. Use the grease gun to pump out the screens for inspection. DO NOT insert anything inside the holes to try to pry DO NOT insert anything inside the holes to try to pry the screens out!! They will be damaged!!
Inspecting the Pressure Port Micro Screens Two Pressure Ports/Screens Micro Screen NOTE: Be sure the micro screen, and 2 washers are re-installed in the order shown. Debris Screens protect the internal pressure sensor, and must ALWAYS be used. Inspect and clean them after EVERY job.
Replace ALL the Gauge O-Rings after EVERY Job
Replace ALL the Gauge O-Rings after EVERY Job Replace ALL the Internal and External Gauge O-Rings after EVERY job External O-Rings (#2-125): Battery Section and OWR Section Internal O-Rings (#2-125 and #2-018): Between Sensor Section and OWR Section Large Stub Acme Thread O-Rings (#5-964): Bull Nose, Sensor Section, and Shock Mitigater Inspect the PEEK Backup Rings and replace as needed
Replacing the O-Rings on the Large Stub Acme Threads
Large Stub Acme Thread O-Rings Replace the Large Stub Acme Thread O-Rings (#5-964): Bull Nose, Sensor Section, and Shock Mitigater, AS NEEDED, if they become nicked or torn. Use four O-rings, two per groove.
Replacing the External Section O-Rings after EVERY Job (Battery Section and OWR Section)
External Section O-Rings OWR Section (Connector Side) Replace the Large O-Rings (#2-125) on the Battery Section and the OWR Section, after EVERY Job. Battery Section
Replacing the Internal Section O-Rings after EVERY Job (Between the OWR and SENSOR Sections)
Replacing the Internal O-Rings 1. FIRST, Clean out the dirty grease inside the pressure sensor ports by connecting a grease gun/nipple to the 1/8 port, and pump new Blue FM Glacier Grease into it until clear, blue grease comes out of both ports. 2. Unscrew the Sensor Section and the OWR Section. 3. Remove and replace ALL the Large and Small internal O-Rings (Viton or Aflas), between the OWR and SENSOR Sections. NOTE: The O- Rings MUST be replaced after EVERY Job! Inspect the internal PEEK backup rings and replaced as needed. Re-grease the O-Rings.
Replacing the Internal O-Rings 4. Clean the internal pressure sensor cavity if the grease is dirty, using a Cotton Tip. DO NOT insert anything sharp or hard into the pressure sensor cavity. Put new Blue FM Glacier Grease inside it, with your finger, filling it up to the top. 5. Fill the inner cavity of the SENSOR SECTION with Blue FM Glacier Grease by pumping grease into it with the grease gun. Fill the FIRST SMALL CAVITY ONLY (see picture)! If you put too much grease inside the SENSOR SECTION, you will not be able to screw the Sensor Section and OWR Sections back together completely, because it will cause a grease lock. If this happens, you will need to remove the extra grease inside the cavity.
Replacing the Internal O-Rings 6. Screw the sections together BY HAND, ONLY! NOTE: NEVER USE A WRENCH TO TIGHTEN THESE GAUGE SECTIONS together! The Sensor and OWR Sections must meet together with NO GAP. If there is a GAP, then you will need to remove the excess grease inside the cavity, and STEP #5 will need to be repeated. Grease will come out the pressure ports as you screw the two sections together.
Clean the Pressure Ports and Micro Screens FIRST 1 2 4 Use 1/8 Nipple 3 Pump Blue Glacier FM grease into the Gauge Sensor Pump Blue Glacier FM grease into the Gauge Sensor Section until clear, blue grease comes out of both pressure ports.
Replacing the Internal O-Rings Sensor Section Replace ALL the internal Replace ALL the internal O-Rings after EVERY job OWR Section
Install New Small Internal O-Rings O-Ring #2-018, 75A (Viton or Aflas) Install new O-Rings and place a PEEK backup ring on EACH side of the O-Ring
Check Peek Backup Ring Placement BE SURE the PEEK backup ring groove is in the correct position
Put New Grease in Sensor Port Clean out the old grease inside the pressure sensor port with a Cotton Tip Swab. Put new grease inside the pressure sensor hole, and on the O-Rings
Install New Large Internal O-Rings and Peek Backup Rings For the Large O-Rings in the OWR Section, use only ONE PEEK backup ring with every O-Ring. O-Ring #2-125, 75A (Viton or Aflas)
Be sure the Peek Backup Ring is in the Right Position The PEEK Backup Ring goes on the Threaded side The O-Ring goes on the High Pressure side IMPORTANT NOTE: The PEEK backup ring MUST be positioned on the Threaded side, and the O-Ring MUST be positioned on the High Pressure side. One Backup per O-Ring.
Grease the O-Rings ALWAYS grease the O-Rings, inside surface, and threads BEFORE assembling the gauge sections.
Fill Sensor Cavity with Grease Be sure the micro screens, hollow lock nuts, and the 1/8 grease gun fitting are installed. DO NOT OVERFILL!! VERY IMPORTANT!! Pump grease into the grease fitting, until the first deepest internal cavity is filled to the first ridge. Use a flashlight to see.
Grease Sensor Port and O-Rings Be sure the grease is inside the pressure sensor hole, and on the O-Rings
Assemble OWR and Sensor Sections Together NOTE: Screw the Gauge sections together by hand, ONLY. This way you can feel if there are any yproblems with the threads. Start the sections in the Vertical position.
Assemble OWR and Sensor Sections Together Leave the grease gun fitting installed while screwing the sections together As the sections are screwed together, the grease will squeeze out through both pressure ports
BE SURE Both Sections are Completely Assembled NO! YES! There should be NO GAP between the two gauge Sections, after they are screwed together!!
Gauge Assembly and Maintenance by Scott A. Ager