Digital Chart Recorder Operation System Version 2 Test Technician Level Objective 1: Configuring Tests and Operating the Test Console and System Prepared by: www.totallyautomated.com

Startup Screen This screen is the default screen for the system. It is always open. A test is configured and operated using the controls on this screen. The navigation links are also contained on this screen. Navigation links: Click on the selections to open a different screen in front of this one. Test Console: This screen is always open in the background.

Testing Console Sensor Selection: For systems with more than one sensor. Click on the sensor to be used for the current test Test Settings: Used to setup a test Test Status: Indicates what step the testing system is currently processing. The active step’s text is colored blue and frame is colored red. Pressure Control Status: Displays the current step the testing system is operating. The typical operation is for the system to pump up to the test pressure, stabilize and then begin the hold. Pump up and stabilization may cycle several times before entering a hold. Abort button – Clicking this button will stop the test. System Status Message: This message changes to provide feedback to the operator regarding the status of the test and any interaction that is required by the operator.

Testing Setup After the settings are validated the Test Status will indicate that the test is waiting to start. Click this button to start the test. Test Settings – Use this section to setup the test. Enter technician name Enter the part # and revision Enter the test procedure and section Enter the test name Enter the Work Order # Enter the part serial # Enter the Project # Enter the gage serial # Enter the test pressure (psi) Enter the hold period (minutes) Enter the maximum allowed pressure drop in %/hour Enter a note (optional) Enter the logging rate (minutes). This is the rate that the system will log the data to the file. It is not the graphing rate. Select the sensor that will primary reading for the test and the stabilization. Settings Instructions: This message changes to supply instructions to the operator for setting up the test. After all of the settings are entered the Settings Instructions will indicate “Waiting for Validation” and this button will flash red. Click this button to validate settings. System Status Message: This message changes to provide feedback to the operator regarding the status of the test and any interaction that is required by the operator Test Requirements: Get these from the TST or engineer. This is the allowed pressure drop per hour allowed for the test during the hold. Default values are displayed here.

Testing Modes (Pump Up – Initial) Once the settings are validated, click the Start button to begin testing. The system will calibrate the sensor. After this is completed the system will be ready for Pump Up. The operator will need to pump up the pressure manually since this system is not automated. The pump up status changes colors based on the current pressure and setpoint. The pump up status is blue below the setpoint, changes to yellow between the setpoint and the allowed % pressure drop/hour value, changes to green above the allowed % pressure drop/hour and changes to red if the pressure is 5% (adjustable) above the setpoint which causes a shutdown. Blue indicates that pressure is below setpoint. Maximum Pressure: Displays the calculated maximum pressure before the test is aborted. This is based on the maximum percentage (default 5%) that is adjustable on the system settings screen. Current Pressure and Pressure Setpoint: Displays the current pressure and the test pressure setpoint. Test pressure setpoint is test pressure + offset Pump Up Status: This text displays the status of the pump up mode. This can be used to instruct the operator of the current state of the pump up sequence.

Testing Modes (Pump Up – Between setpoint and maximum pressure loss initial setpoint (default of 3%)) When the pressure exceeds the setpoint but is less than the allowed pressure drop setting (%/hr) the Pump Up Status changes color to yellow. Yellow indicates that pressure is above setpoint but less than the allowed test pressure loss.

Testing Modes (Pump Up – Between Setpoint and maximum pressure setpoint (default 5%)) When the pressure is greater than the maximum pressure loss value but less than the maximum test pressure then the pump up status color is green and the Pressure Shut-In button appears. Click this button once the pressure has been shut-in. Once the pressure has been shut-in the stabilization mode will begin. Green indicates that pressure is above the setpoint and maximum pressure loss but less than the maximum test pressure. The Pressure Shut-In button blinks. Click this once the pressure has been shut-in. The pressure must be shut-in manually by the operator. Once the pressure is shut-in the stabilization will begin

Testing Modes (Stabilization) When the pressure is shut-in the stabilization mode begins. The pressure loss must be less than the Allowed Pressure Drop setting or the Stabilization Status will be yellow. When the pressure loss is less than the setting then the Stabilization Status changes to green and the Pump Up and Hold appears. If the pressure drops below the setpoint then the system automatically reverts to the Pump Up mode and starts the cycle again. The system will only allow four failures to stabilize before it aborts. Green indicates that pressure loss (%/hr) is less than the Allowed Pressure Drop setting. Yellow indicates that pressure drop exceeds the setting. Click this button to begin the hold. It is not recommended to enter the hold until the stabilization indicator is green. Click this button to return to the Pump Up mode. Minimum Pressure Setpoint: Not shown here. During pump up the pressure must be above this value to enter stabilization mode. This value is calculated by the system based on the allowed pressure drop rate. Percent Change Indication: The % Loss indicates the % pressure change after the pressure is shut in. This value must be less than the Allowed Pressure Drop rate setting to set the Stabilization status to green. If it exceeds the setting then the color will be yellow.

Testing Modes (Hold) When the system enters the hold mode the hold timer will begin the count down. If the pressure drops below the minimum pressure then the test will abort. If the hold timer expires without an abort then the results of the test will automatically be displayed for printing. During hold mode the Pump Up and Stabilization Systems are idle. The pressure must be above this value to begin the hold. If the pressure drops below this value then the operator will need to go back to pump up and pump the pressure up above this value. This is a calculated value based on the TST requirements for the hold Hold timer status.

Testing Modes (Completed) If the test is successful then the reset button will appear. Click this to begin another test after printing the report. Pressure must be removed from the system manually. Do not begin another test until the report is printed. Test Reset Button: Appears when a test is successful to allow the operator to print the report before progressing to the next test.

Test Report This screen automatically displayed when the test is completed. The purpose is to provide a screen to print as a report. The graph does not stop after the test so the screen should be printed immediately after the test is completed. The brown lines indicate the start and stop of the hold. The blue line is the system pressure.

Shutdowns Any shutdown causes the system to stop the test. Explanations of shutdowns that are not obvious are shown below. When a shutdown occurs, the Shutdowns text in the menu will turn red and blink. When the shutdown condition has been cleared, click the RESET button to reset the shutdown so that testing can be restarted. The items will turn red when the shutdown occurs indicate the condition that caused the shutdown. Pressure sensor malfunction. Replace the sensor, check the wiring/power or replace the fuse. Rate of change calculation exceeded the maximum or minimum value (-35K to 35K.) Not used. Pump up attempts exceeded the allowed value. A setting value of 0 disables this condition. A typical limit is 3. Maximum system pressure was exceeded. Pressure exceeded the entered overpressure percentage from the settings screen This occurs if the system datalogger is at 80% capacity. Once the datalogger reaches 80% capacity this shutdown will stop testing to eliminate data loss. This item is currently inactive. Pressure dropped below minimum pressure during the hold and the operator decided to abort the test Initial pressure during calibration exceeded 100 psi This is no longer active Calculated sensor accuracy exceeded the threshold setting. See the transducer screen. Reset Button: This button must be pressed to reset a shutdown/abort. It appears when a shutdown occurs and will not clear until the shutdown condition is cleared.

Alarms Alarms do not cause the testing to stop. Alarms are only a warning. These will turn yellow to indicate a alarm condition and the text will change to describe the alarm condition. Items that turn orange indicate that a sensor has failed. When a new alarm occurs, the Alarms menu item will turn red and blink until the Acknowledge button is clicked. Pressure transducer warning. This turns orange in the event of a sensor failure. Test Cell Interface is not connected to the PC. Connection between the data-logger and local data file has failed. Failure to copy to the local data file to the alternate location When a new alarm occurs this button must be clicked to stop the blinking of the Alarms text on the Menu screen.

Objective 1: Training Activity 1 Discussion Questions: Where do you get the TST requirements to enter for the test? What is the typical overpressure percentage limit? Why do you have to select a pressure sensor? Does the system automatically pressure up the system or operate any valves? What is the easiest way to determine what you need to do during a test based on the recorder information? What is the purpose of the STOP button? If a shutdown occurs then how do you determine what caused it? Once you click the shut in button and shut the pressure in on the test fixture should you ever add pressure to the system if you are in stabilization?