Radioactive Densometer Best

Practices for FLECS Systems

Radioactive Densometers on cementing units should be operated in Frequency Mode.
Make sure you have the calibration sheets for both densometers with you and use them to
double check your calibration numbers on the FLECS system when you suspect
something is wrong. You need LO-CAL and HI-CAL values as well for each sensor and
when your densometers are sent in for recalibration be sure to specify that the LO-CAL
and HI-CAL points be included in the calibration and placed on the calibration sheet
returned to you.

Pre-Job Auto Calibration Procedure

Method 1(Preferred Method)
Pre-Job AUTOCAL on LO-CAL (Frequency Mode)
1. Empty both the recirc densometer and downhole densometers of fluid.
2. Power both densometers up and let them warm up for 15 minutes.
3. Put both Recirc and Downhole densometer Cal knobs in the LO-CAL position by
pulling the knob out and rotating it counter-clockwise (to the left if facing the
knob).
4. Select the Recirc Densometer button on the Job Screen.
5. You should now be at the “Set Densometers” screen with the “Set Recirc” button
depressed and showing green.
6. Press the “AUTOCAL on LO-CAL” button
7. Wait 15 seconds while count sample is taken.
8. Select the Downhole Densometer button on the Job Screen.
9. You should now be at the “Set Densometers” screen with the “Set Downhole”
button depressed and showing green.
10. Press the “AUTOCAL on LO-CAL” button
11. Wait 15 seconds while count sample is taken.
12. After the AUTOCAL completes, the numbers being displayed by both
densometers should be within 0.15 lbs of the LO-CAL numbers specified for each
device.
13. Now put both densometer’s cal knobs in the HI-CAL position by pulling the knob
out and rotating it clockwise (to the right if facing the knob), past the operate
position to the HI-CAL postion.
14. Compare the reading shown on HI-CAL with the HI-CAL number in each
densometer’s calibration table. It should be within of 0.15 lbs of the HI-CAL
number. If it is not, the densometer should be recalibrated as soon as possible.
15. Put both densometer’s cal knobs back in the operate position by pulling them out
rotating them counter clockwise to the “middle” position where the cal knobs will
recede into the housing to the operate position.
16. Both densometers should now be reading close to air.
 Note: Auto Cal is not kept between sessions and will be lost when unit is shutdown.

Pre-Job AUTOCAL on LO-CAL (Current Mode_4-20mA)

NOTE: Operating radioactive densometers in 4-20mA mode is not recommended.
However, a procedure is provided should you choose to ignore this recommendation.
1. Empty both the recirc densometer and downhole densometers of fluid.
2. Power both densometers up and let them warm up for 15 minutes.
3. Put both Recirc and Downhole densometer Cal knobs in the LO-CAL position by
pulling the knob out and rotating it counter-clockwise (to the left if facing the
knob).
4. Select the Recirc Densometer button on the Job Screen.
5. You should now be at the “Set Densometers” screen with the “Set Recirc” button
depressed and showing green.
6. Enter the LO-CAL number for your densometer in the text field. You may need to
refer to a calibration sheet or contact a technician to get this number.
7. Press the “Set Density to Value” button.
8. Select the Downhole Densometer button on the Job Screen.
9. You should now be at the “Set Densometers” screen with the “Set Downhole”
button depressed and showing green.
10. Enter the LO-CAL number for your densometer in the text field. You may need to
refer to a calibration sheet or contact a technician to get this number.
11. Press the “Set Density to Value” button.
12. The numbers being displayed by both densometers should be very close to their
respective LO-CAL settings.
13. Now put both densometers cal knobs in the HI-CAL position by pulling the knob
out and rotating it clockwise(to the right if facing the knob).
14. Compare the reading shown on HI-CAL with the HI-CAL number in each
densometer’s calibration table. It should be within of 0.15 lbs of the HI-CAL
number. If it is not it, then the densometer should be recalibrated as soon as
possible.
15. Put both densometer’s cal knobs back in the operate position.
16. Both densometers should now be reading close to air.
Note: Auto Cal is not kept between sessions and will be lost when unit is shutdown.

Method 2 (2nd Preferred Method)

NOTE! Use AUTOCAL on water ONLY if you don’t have HI-CAL and LO-CAL Points
for your densometers.
Pre-Job AUTOCAL on WATER (Frequency Mode)
1. Power both densometers up and let them warm up for 15 minutes.
2. Fill both the recirc densometer and downhole densometers with fresh water. Static
or motionless water is best because it eliminates air bubbles commonly present
when water is being pumped or recirculated. This may not be possible on some
systems and you will have to go ahead and recirculate. However, keep in mind
that recirculating the water entrains the water with air bubbles and may cause the
 sensor to read as much a 3/10th of a lb light depending on the amount of air
entrainment.
3. Select the Recirc Densometer button on the Job Screen.
4. You should now be at the “Set Densometers” screen with the “Set Recirc” button
depressed and showing green.
5. Press the “AUTOCAL on Water” button.
6. Wait 15 seconds while count sample is taken.
7. Select the Downhole Densometer button on the Job Screen.
8. You should now be at the “Set Densometers” screen with the “Set Downhole”
button depressed and showing green.
9. Press the “AUTOCAL on Water” button
10. Wait 15 seconds while count sample is taken.
11. The numbers being displayed by both densometers should be very close to 8.32
lbs per gallon or 1000 Kg/M3.
Note: Auto Cal is not kept between sessions and will be lost when unit is shutdown.

Pre-Job AUTOCAL on Water (Current Mode_4-20mA)

NOTE: Operating radioactive densometers in 4-20mA mode is not recommended.
However, a procedure is provided should you choose to ignore this recommendation.
1. Power both densometers up and let them warm up for 15 minutes.
2. Fill both the recirc densometer and downhole densometers with fresh water. Static
or motionless water is best because it eliminates air bubbles commonly present
when water is being pumped or recirculated. This may not be possible on some
systems and you will have to go ahead and recirculate. However, keep in mind
that recirculating the water entrains the water with air bubbles and may cause the
sensor to read as much a 3/10th of a lb light depending on the amount of air
entrainment.
3. Select the Recirc Densometer button on the Job Screen.
4. You should now be at the “Set Densometers” screen with the “Set Recirc” button
depressed and showing green.
5. Enter 8.33 in the text field.
6. Press the “Set Density to Value” button.
7. Select the Downhole Densometer button on the Job Screen.
8. You should now be at the “Set Densometers” screen with the “Set Downhole”
button depressed and showing green.
9. Enter 8.33 in the text field.
10. Press the “Set Density to Value” button.
11. The numbers being displayed by both densometers should be very close to 8.33
lbs per gallon or 1000 Kg/M3.
Note: Auto Cal is not kept between sessions and will be lost when unit is shutdown.

When do my densometers need recalibration?

New and freshly recalibrated densometers will naturally be off a tenth or two when
connected to your FLECS system. This difference has to do with cable lengths and
differences in the electronics between the calibration device and FLECS electronics.
When this error increases by an extra ½ lb over the service life of the densometer it is
about time to have the unit recalibrated. If the densometer is consistently reading ½
pound or more off AFTER AUTOCALibration to Lo-Cal or Water then you need to have
the densometer checked and recalibrated.

Recalibrate when…
1. Prior to AUTOCAL, the start up error has increased ½ lb since the last recalibration.
a. Example: Prior to an AUTOCAL your new or freshly recalibrated
densometer read water as 8.43 lbs. One year later it reads water as 8.93 lbs. It
is time to recalibrate.
2. After an AUTOCAL on LO-CAL the densometer reads over 0.15 lbs off when the
densometer knob is put in HI-CAL.
3. The densometer is consistently reading fluids too high or too low after an
AUTOCAL. Use a pressurized mud cup to check your suspicions and consult a
technician.

Why don’t my Recirc Densometer and Downhole Densometer

agree with each other?
Cement slurries naturally have some air entrainment introduced into them from the
mixing system. The level of air entrainment can vary depending on cement, additives,
mix speed and equipment condition. This air entrainment will cause the recirc
densometer to read the slurry a little lighter than what it is. The target density may be
14.5 lbs but the system is actually mixing an aerated 14.8 lb slurry. However, the recirc
reads it as 14.5 because of the air entrainment and continues to mix it at that weight.
When the slurry reaches the downhole densometer the spaces caused by the bubbles are
compressed out by the well head pressure. The downhole densometer will now read the
true slurry weight of 14.8 lbs.

Which densometer is closer to right? Well, this is where it is handy to keep a well
maintained pressurized mud cup. Once the density has leveled out on a slurry, take a
cement sample from the downhole tub compartment and write down the density being
displayed by both the recirc and downhole densometers at the time the sample was taken.
Weigh the cup on the scales. You should now have some indication and you can adjust
your target mix density accordingly.

At times, you will discover that you need to lighten your target mix density a few tenths
in order for the downhole densometer to deliver product at the weight specified by the
customer.

Why AUTOCAL on LO-CAL instead of with Water like we’ve

always done?
1. The LO-CAL number is much closer to the operating range of densities that
slurries are mixed in. Most LO-CAL numbers are in the 10 to 14 lb range.
AUTOCALing in this region centers the correction around the most likely region
of operation.
 2. Double checking the AUTOCAL on LO-CAL by putting the Densometer in HI-
CAL checks the densometers linearity across the sensor’s operating range and is a
second confirmation that the device is in good operating condition.
3. Emptying the densometer of fluid and using LO-CAL eliminates variations
inherent using water due to sediment levels, air entrainment or accidental drainage
or loss of fluid flow during the autocal period.

Can I still AUTOCAL on WATER?

Yes. But it is NOT the preferred method, it is NOT as consistent and will NOT be as
accurate as an AUTOCAL on LOCAL. Discrepancies between the downhole densometer
and the recirc densometer are more likely to occur because of air entrainment, differing
sediment levels and the potential loss of fluid during the autocal period. That being said it
is however, the 2nd preferred method.

Can I AUTOCAL on AIR or on HICAL?

AUTOCALing on AIR or on HI-CAL is not recommended. These two values are at the
far ends of the densometers operating range and AUTOCAL operations at these points is
not likely to produce satisfactory results. We don’t mix air and most slurries are not near
the HICAL density value.

Troy Bachman, P.E.

Halliburton Technology Center
Duncan, Oklahoma