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Part Number Edition Date

TM-512 Second November 2002

Copyright © 2001 - 2002 Acadiana Oilfield Instruments, Inc.


All rights reserved.

AOI Instrumentation and the AOI logo are trademarks of


Acadiana Oilfield Instruments, Inc. All other brand names
and product names are trademarks or registered trademarks
of their respective companies.

AOI Instrumentation
105 Bonin Road
Lafayette, Louisiana 70508 USA
www.aoiinstrumentation.com

Printed in the U.S.A.

4 101396 Tension Sensator Load Cell Installation and Maintenance Manual


Contents

1 Introduction 7

2 Installing the Sensator in the Anchor 9

3 Maintaining the Sensator 13


Checking and correcting the sensator gap . . . . . . . . . . . . . . . . . . . . 13

Checking and correcting excessive air in the sensator . . . . . . . . . . . 16

Removing the sensator from the anchor . . . . . . . . . . . . . . . . . . . . . . 17

Cleaning the sensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18


Cleaning the sensator’s exterior . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cleaning the sensator’s interior . . . . . . . . . . . . . . . . . . . . . . . . . 19

Disassembling the sensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Reassembling the sensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

101396 Tension Sensator Load Cell Installation and Maintenance Manual 5


6 101396 Tension Sensator Load Cell Installation and Maintenance Manual
1 Introduction
This manual explains how to install and maintain AOI Instrumentation™
101396 Tension Sensator Load Cells. This manual also includes instructions
for removing, disassembling, and reinstalling 101396 Tension Sensator Load
Cells.

Note
The 101396 Tension Sensator Load Cell may sometimes be referred
to in any of the following ways:
- Sensator
- Tension Load Cell
- Tension Cell
- 36.7 Tension Load Cell
- 36.7 Square-inch Load Cell
For consistency, throughout this manual the 101396 Tension Sensator
Load Cell is referred to as the sensator.

Sensators are used in deadline anchor systems to transmit load information to


weight indicators, enabling operators to make sure optimum load capacities
are not exceeded.

not to scale

load signals

deadline 101396 weight


anchor Sensator indicator

101396 Tension Sensator Load Cell Installation and Maintenance Manual 7


Chapter 1. Introduction

The following table lists the types of deadline anchor systems and weight
indicators that use the 101396 sensator.

Table 1. Deadline anchor systems and weight indicators that use


101396 sensators

Anchor model

Weight indicator Rating


model (pounds per line) Hercules National

50 50,000 HA129T D

75 75,000 HA131T EB

100 100,000 HA131T EB

8 101396 Tension Sensator Load Cell Installation and Maintenance Manual


2 Installing the Sensator in the Anchor
Follow the instructions in this chapter to install the sensator in the anchor.

1. Apply grease to the cotter pins, anchor ears, and to the sensator eyes.

Sensator

upper
sensator eye
anchor ears
disconnect check
valve

sensator pins

lower
sensator eye

cotter pins

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Chapter 2. Installing the Sensator in the Anchor

2. Mount the sensator, sensator pins, and cotter pins in the anchor with the
sensator check valve and disconnect located at the top and the side toward
the anchor drum.

3. Fill the system with fluid as follows:


a. Remove the cap from the check valve (see the illustration on page 9).

b. Screw the hand pump (part number 101349-102) onto the check valve
body. (Do not tighten the swivel nut.)

reservoir

hand pump

swivel nut
(connects to
check valve)

plunger

c. Fill the hand pump reservoir with A-11 hydraulic fluid.

Note
Keep the hand pump reservoir at least half full at all times to avoid
introducing air into the system.

d. Push the hand pump plunger slowly to expel air from the pump at the
check valve. When air bubbles cease, tighten the hand pump swivel
nut.
e. Push open the poppet in the sensator disconnect to allow excess air to
escape.
f. Repeat the pumping and bleeding procedure until all the air is bled
from the sensator.

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Chapter 2. Installing the Sensator in the Anchor

g. Release the poppet and continue to pump fluid into the sensator until
the sensator gap is approximately 0.62 inches.

.62 inches
(16 mm)

h. Remove the hand pump and replace the check valve cap.

i. Recouple the disconnect. (Use only your hands to recouple the


disconnect—do not use tools to tighten.)

Warning When you recouple the disconnect, make sure that the disconnect
halves are properly aligned. Improper alignment can damage the
o-ring and cause fluid leakage.

101396 Tension Sensator Load Cell Installation and Maintenance Manual 11


12 101396 Tension Sensator Load Cell Installation and Maintenance Manual
3 Maintaining the Sensator
This chapter explains how to perform periodic maintenance required to keep
the sensator functioning correctly.

Checking and correcting the sensator gap

Check the sensator every day and before every heavy pull.

Follow these steps to make sure the sensator gap is approximately 0.62 inches
(16 mm) and correct the gap if necessary:

1. Make sure the block (in the derrick) is empty.

2. Measure the gap.

.62 inches
(16 mm)

If the gap is approximately 0.62 inches (16 mm):

The gap is correct.


If the gap is less than 0.50 inches (13 mm):

Proceed to step 3.

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Chapter 3. Maintaining the Sensator

Checking and correcting the sensator gap

3. Inspect the sensator, the disconnect, the weight indicator hose, and the
weight indicator for fluid leaks. Repair or replace components as
necessary to eliminate leaks.

disconnect

check valve
cap

4. Readjust the cell gap as follows:

a. Remove the cap from the check valve.

b. Screw the hand pump (part number 101349-102) onto the check valve
body. (Do not tighten the swivel nut.)

reservoir

hand pump

swivel nut
(connects to
check valve)

plunger

c. Fill the hand pump reservoir with A-11 hydraulic fluid.

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Chapter 3. Maintaining the Sensator

Checking and correcting the sensator gap

Note
Keep the hand pump reservoir at least half full at all times to avoid
introducing air into the system.

d. Push the hand pump plunger slowly to expel air from the pump at the
check valve. When air bubbles cease, tighten the hand pump swivel
nut.
e. Push open the poppet in the sensator disconnect to allow excess air to
escape.
f. Repeat the pumping and bleeding procedure until all the air is bled
from the sensator.
g. Release the poppet and continue to pump fluid into the sensator until
the sensator gap is approximately 0.62 inches.

.62 inches
(16 mm)

h. Remove the hand pump and replace the check valve cap.

i. Recouple the disconnect. (Use only your hands to recouple the


disconnect—do not use tools to tighten.)

Warning When you recouple the disconnect, make sure the disconnect
halves are properly aligned. Improper alignment can damage the
o-ring and cause fluid leakage.

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Chapter 3. Maintaining the Sensator

Checking and correcting excessive air in the sensator

Checking and correcting excessive air in the sensator

Excessive air in the system can cause incorrect stroking. This section
describes how to check for excessive air and how to eliminate it to assure the
sensator stroke is correct.

1. Check the sensator stroke indication for a light load and a heavy load (for
example, when the stroke is going into and out of the hole).

A difference greater than 0.08 inches (2 mm) between an empty load and
a load of approximately half the weight indicator capacity means that
excessive air is in the sensator.

2. If excessive air is in the system, eliminate it as follows:


If the weight indicator is not panel-mounted:

Loosen the plug (behind the damper block) on the weight indicator to
bleed the air.
If the weight indicator is panel-mounted:

Bleed the air from one of the damper block connections.

3. Follow the procedure in “Checking and correcting the sensator gap” on


page 13 to make sure the gap is still correct. Correct the gap if necessary.

16 101396 Tension Sensator Load Cell Installation and Maintenance Manual


Chapter 3. Maintaining the Sensator

Removing the sensator from the anchor

Removing the sensator from the anchor

This section explains how to remove the sensator from the anchor for cleaning
or maintenance.

1. Make sure the block (in the derrick) is empty and that the sensator is fully
loaded with hydraulic fluid.

2. Uncouple the disconnect.

disconnect

check valve
cap

3. Securely block the anchor on the bottom stop.

4. Remove the load from the sensator as follows:

a. Open the poppet in the sensator disconnect.

b. Drain fluid from the sensator until the load is relieved from the
sensator and transferred to the anchor stop.

5. Remove the cotter pins, sensator pins, and sensator from the anchor,
taking care not to damage the anchor or the sensator. (See the illustration
on page 9.)

Note
If it is difficult to remove the pins from the anchor, use penetrants or
other liquids to free them.

101396 Tension Sensator Load Cell Installation and Maintenance Manual 17


Chapter 3. Maintaining the Sensator

Cleaning the sensator Cleaning the sensator’s exterior

Cleaning the sensator

This section explains how to clean the exterior and interior of the sensator.

Cleaning the sensator’s exterior


After you remove the sensator from the anchor (as described above), clean off
any dirt, ice, or other material that have accumulated on the sensator. (If
necessary, you can use a high-pressure water hose to clean the sensator.)

Clean off any rust or corrosion that has formed on the sensator pins or the
anchor ears.

anchor ears

sensator pins

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Chapter 3. Maintaining the Sensator

Cleaning the sensator’s interior Cleaning the sensator

Cleaning the sensator’s interior


After you disassemble the sensator (as described in “Disassembling the
sensator” on page 20), use steel wool or a wire brush to clean all metal parts.

Check the hose (11 in the illustration below) for breaks or cuts and make sure
the inside of the hose is clear.

11

9
8

Wash the diaphragm (9), retainer ring (7), and diaphragm sub-assembly
casing (8) in detergent, rinse with clean water, and dry with air or a cloth.

Warning Do not use solvents or distillates to clean the diaphragm, retainer


ring, and diaphragm sub-assembly casing. Do not sandblast the
retainer ring or sub-assembly casing. Using solvents or
sandblasting can cause the diaphragm to become unseated when
the diaphragm is under pressure.

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Chapter 3. Maintaining the Sensator

Disassembling the sensator Cleaning the sensator’s interior

Disassembling the sensator

Use the following illustration, parts list, and instructions in this section to
disassemble the sensator.
12 13
1
15 14

11

10
16
9

8 2
7

6
5

4
3

Table 2. 101396 Sensator parts list

Item Part Quantity


number number Description required

1 101336 Housing, upper 1

2 888257-312 Screw, 5/16–18 x 3/4, skt head 16

3 101337 Housing, lower 1

4 101306 Bolt, tie 16

5 109106 Plate, load 1

6 109111 Spacer 16

7 109119 Ring, retainer 1

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Chapter 3. Maintaining the Sensator

Cleaning the sensator’s interior Disassembling the sensator

Table 2. 101396 Sensator parts list (continued)

Item Part Quantity


number number Description required

8 109107 Casing 1

9 21-367 Diaphragm 1

10 301811 Elbow, 1/4M x 1/8F 1

11 101367 Hose, 12-inch with coupling, 3/16-inch 1


ID

12 109026 Junction block 1

13 888257-889 Screw, 5/16–18 x 3/4, fil head 2

14 98-21P Check valve, with cap 1

15 98-900A-20 Disconnect, male half with dust cap 1

16 98-996 Nipple, 1/4 x 1-1/2 inch 1

17 98-900A-02 *Disconnect, female, hose half 1

* Not shown.

Follow these steps to disassemble the sensator:

1. Clamp the bottom half of the sensator pad eye in a vise.

pad eye

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Chapter 3. Maintaining the Sensator

Disassembling the sensator Cleaning the sensator’s interior

2. Remove the two junction block screws (13).

3. Pull up the junction block (12) and unscrew it from the hose by holding
the hose coupling with a wrench and turning the junction block counter-
clockwise.

4. Remove the bolts (4) from the upper housing (1). Lift the upper housing
off the sensator.

5. Remove the bolts (4) from the lower housing (3).

6. Lift out the diaphragm sub-assembly (2, 7, 8, and 9) and the


load plate (5).

7. Unscrew the hose (11) from the elbow (10).

8. Remove the screws (2) from the diaphragm sub-assembly (2, 7, 8, and 9).
Separate the casing (8), diaphragm (9), and the retainer ring (7).

9. Clamp the junction block (12) in a vise and remove the check valve (14)
and the disconnect (15).

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Chapter 3. Maintaining the Sensator

Cleaning the sensator’s interior Reassembling the sensator

Reassembling the sensator

Refer to the following illustration and the table on page 20 to reassemble the
sensator.
12 13
1
15 14

11

10
16
9

8 2
7

5 6
4
3

female male

1. Clamp the junction block (12) in a vise. Apply thread sealer to the check
valve (14) and to both ends of the ¼-inch nipple (16) pipe threads.

2. Thread the anchor half disconnect (15) to the nipple (16), then thread both
components—along with the check valve (14)—to the junction block and
tighten.

3. Place the diaphragm (9) in the groove in the diaphragm sub-assembly (8).
Slip the retainer ring (7) over the diaphragm and align the holes in the
retainer ring with the holes in the casing.

4. Apply locktight sealant to the cap screw threads and start (but do not
completely tighten) all 16 screws (2).

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Chapter 3. Maintaining the Sensator

Reassembling the sensator Cleaning the sensator’s interior

5. Tighten the cap screws a few turns at a time, alternating between


opposing pairs of screws. Make at least 4 or 5 complete rounds of
tightening before final complete tightening.

Note
When properly assembled, the casing and the retainer ring form a
flush seal around the circumference.

6. Apply thread sealer to the threads on both ends of the hose (11). Tighten
the hose into the elbow (10).

7. Clamp the lower housing (3) in a vise and place the load plate (5) on the
housing. Center the scallops of the load plate on the housing bolt holes.

8. Place the diaphragm sub-assembly (2, 7, 8, and 9) over the load plate (5),
with the threaded holes in the casing aligned with the bolt holes in the
lower housing (3) and the elbow (10) is in the position shown in the
illustration on page 23 and below.

elbow

9. Position the spacers (6) over the bolt holes in the lower housing (3).
Loosely thread the lower housing bolts (4) into place.

10. Position the spacers (6) over the bolt holes in the load plate (5).

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Chapter 3. Maintaining the Sensator

Cleaning the sensator’s interior Reassembling the sensator

11. Loop the hose (11) as shown by the dashed line in the top view and pull
the end through the hole in the upper housing.

hose

12. Loosely thread the junction block (12) on the hose end (11).

13. Position the upper housing (1) so that the bolt holes are centered over the
spacers (6). Thread the upper housing bolts (4) into place. Tighten all the
upper housing and lower housing bolts.

14. Tighten the hose (11) into the junction block (12) by holding the hose
coupling with a wrench and rotating the junction block clockwise. Make
sure that, when tight, the junction block is in the relative position shown
in the illustration on page 20.

15. Apply Locktite sealant to the junction block screws (13). Insert the screws
and tighten them.

Reassembly of the sensator is now complete. Prepare the sensator and anchor
for operation as follows:

1. Replace the sensator, sensator pins, and cotter pins in the anchor.

2. Refill the system with hydraulic fluid and check the sensator gap as
described in “Checking and correcting the sensator gap” on page 13.

101396 Tension Sensator Load Cell Installation and Maintenance Manual 25


26 101396 Tension Sensator Load Cell Installation and Maintenance Manual