KPG

SERVICE MANUAL

KUSTER COMPANY Subsurface Instruments

2900 EAST 29TH STREET - LONG BEACH, CA 90806 PHONE (562) 595-0661 – FAX (562)4267897

E-MAIL: KUSTER@KUSTERCO.COM WEBSITE: WWW.KUSTERCO.COM

2

Contents: Specifications................……………………………….......................................2 Purpose of Equipment…………….……………………………………………….3 Description and Principles of Operation………………………………………….3 Operating Instructions………………………………………..…………………….4 Operating Suggestions……………………………………….……………………6 Tools and Accessories…………………………………………………………...13 Clock and Maintenance Equipment……………………………………..……...14 Measuring Line Reels (Hoists)…………………………………………………..14Bellows Repair Kit with Vacuum Pump……………………………...………....15 Lubricators…………………………………………………………………………15 HP Clocks Operation and Maintenance………………..………………………16 Detailed Disassembly-Assembly procedure………………………………..….19 Drawings…………………………………………………………………………...22 Specifications: Accuracy: Pressure Gauge: +/-0.2% of full scale Temperature Gauge: +/-1°C absolute Sensitivity: 1 part in 2000 Range: Pressure Element: 0-800 psi to 0-30,000 psi 0-56 to 0-2100 kg /sq cm Temperature Element: 25° F to 700° F -4°C to 370°C Dimensions: Pressure Gauge: 1-1/4" O.D. x 73-3/8 ” (38mm> 22,000 psi) 3.2 cm x186 cm Temperature Gauge: 1-1/4" O.D. x 66-1/2" 3.2 cm x166 cm Weight: Pressure Gauge: 15 pounds (6.8 kgs) Temperature Gauge: 13 pounds (5.9 kgs) Clocks, hours, jeweled: 2, 3, 12, 24, 48, 72, 120, 144, 180, 360 Stylus Travel: 5 inches (12.7 cm) (15 turns of lead screw) Charts: Black or Grey matte, White Standard or Flanged type Bourdon Tube: Ni-Span C; temperature compensated to approximately 100°C Equivalent: Completely interchangeable with the Amerada RPG-3 Materials: K-Monel and Hardened Stainless Steel in contact with well fluids Calibration Units: Psi, kg/cm², kPa

3

KPG GAUGE (Interchangeable with RPG-3 Amerada)

PURPOSE OF EQUIPMENT The KPG Pressure Recorder and KT Temperature Element were designed to provide reliable and accurate bottom hole pressure and temperature measurements under static or dynamic reservoir conditions in tubing, in the annulus, or in open hole. The KPG Gauges are designed to meet the demand for a small diameter pressure and temperature recorder using the principle of the multiple coil helical bourdon tube, which has been in use since 1930. DESCRIPTION AND PRINCIPLES OF OPERATION The KPG Pressure Element is of the multiple coil bourdon tube type. Fluid pressure acting on the inside of the bourdon tube causes it to rotate. This rotation is directly transmitted to the stylus without any gears or springs. The bourdon tube is a self-contained unit easily replaced in the field. The bourdon tube material is a nickel alloy, Ni-Span C, which is temperature compensated to about 200°F. For use above 200°F it is recommended that the pressure element be calibrated at the maximum temperature encountered. The rotation of the bourdon tube is transmitted to the stylus shaft, which is connected to the stylus assembly in the recorder assembly. The stylus assembly rotates within a chart carrier. The clock and lead screw assembly move the chart carrier a distance of 5 inches. The stylus assembly burnishes a mark on a coated chart within the chart carrier by means of a stylus point. The mark is about .001" in width; it can be read by means of a 5X power magnifier or by use of the Kuster 2-Way Chart Reader. The Kuster KT Temperature Element is a liquid-vapor phase system connected to a bourdon tube. The bourdon tube rotates from pressure changes caused by heating of the liquid fill of the closed system. The bourdon tube rotation is transmitted to a stylus shaft and stylus assembly in a manner identical to that of the pressure element. A helical bimetal element is used for temperatures above 175°C. The Kuster Clocks are used to regulate the travel of the chart carrier through the lead screw, lead nut and push rods. The clocks are of extremely rugged design to resist vibration, shock and temperature extremes encountered in oilfield geothermal operations. The most reliable materials obtainable are used to complement the rugged design. They need little if any lubrication and maintenance.

4

OPERATING INSTRUCTIONS The Kuster KPG Gauge is shipped in three parts; the pressure element with thermometer well and oil trap; and the recording assembly made up with a carrying plug; and the clock in its case. To make up the gauge for a pressure or temperature survey, proceed in the following manner. 1. Unscrew the carrying plug from the outer housing of the recorder unit; loosen the stylus clamp from the carrying plug with the hexagon wrench. Remove the carrying plug. With the inner housing held horizontally, pull out the cover catch, and lift the cover from the inner housing. Remove the wood-shipping block. Move the chart carrier to the top of its travel then remove the stylus assembly. Remove the chart carrier by inverting the inner housing and let the chart carrier fall into the hand. See Figure 1.

2. Assemble the inner housing to the pressure or temperature element as shown in Figure 2. When making up the inner housing to the element, hold the inner housing nearest the threads and use the inner housing wrench supplied with your Kuster gauge. The use of spanner wrenches is not recommended, because of possible damage to the inner housing. 3. Install the stylus assembly by means of the clamp, attaching it to the

5

extension of the stylus shaft from the element housing. The stylus lift wire should be aligned with the engraved mark on the inner housing. This positions the stylus assembly in the correct position with respect to the chart carrier. Make certain the stylus lift is in the off position. 4. Load the chart carrier. Wrap the chart around the chart mandrel with sides parallel to groove, see Figures 3, 4, and 5. Insert the chart and mandrel into the chart carrier, by first engaging the leading edges into the t-shaped guide. Push the chart and mandrel into the carrier. While inserting, a small amount of side motion and also back and forth motion is helpful. Push the chart all the way in, unlit it projects from the carrier about 1/4 inch. Remove the chart mandrel. Flange type charts are loaded in a similar manner with the chart mandrel and saddle.

5. Assemble the clock in the inner housing by first winding the clock by means of the knurled coupler in a counter-clockwise direction. Disengage the clock by pushing the coupler toward the clock and then counter-clockwise to lock it in the j-slot. Make up the clock in the inner housing. Carefully grasp the inner housing nearest the clock so as not to twist the inner housing guide rails. 6. The chart carrier is replaced in the inner housing with the fingers; do not handle the chart carrier spring. The chart carrier extension should be placed in the chart carrier lift. Move the chart carrier toward the stylus assembly. While moving the chart carrier toward the stylus assembly, insert the chart carrier guide bar into the stylus carrier bearing. Move the chart carrier to its lowest position. Replace the inner housing cover by first engaging the lower end, then the top end, and lock in place with the cover catch. 7. To draw the base line. Place the stylus lift in the off position. Remove the oil trap plug. Disengage the clock. Move the chart carrier to its uppermost position. Place the stylus lift in the on position. Place the gauge in a position nearly vertical (75°). Tap the inner housing lightly to remove any static friction. Hold the lower clutch with the fingers. Release the chart carrier and allow to move slowly to the full extent of its travel. Place the stylus in the off position. Return the chart carrier to the upper position.

6

8. Place the clock in the engaged position. 9. Place the stylus in the ‘on’ position and fix it in that position by turning the lock-ring. 10. Replace the outer housing. 11. The oil trap can be filled with motor oil or equivalent. 12. Make up the oil trap to the gauge. 13. Install the thermometer well with a maximum recording thermometer if required. 14. Attach the wire line to the wire line socket by running through the hole and then winding on itself a few turns, then pulling through. 15. Remove the oil trap plug before placing the gauge in the lubricator.

After a run is made the chart carrier is removed from the gauge and the chart removed. To remove the chart, insert the chart mandrel into the chart carrier about 1/3; grasp the chart and the chart mandrel and pull both together.

16. Wash the bellows in clean solvent to remove any corrosive well fluids. The new Kuster Teflon coated bellows provides additional protection to the bellows from corrosive fluids. It is furnished as standard equipment.

17. The Kuster KT Temperature Element is installed in the same manner as the pressure element. When making-up the temperature element, place the wrench on the flats nearest to the inner and outer housing connection. When clamping the stylus assembly to the stylus shaft extension, the adjusting knob pin must be against the stop pin. When the base line is drawn, the adjusting knob must be against the stop. This is the zero position of the temperature element and the position from which the calibration is made.

OPERATING SUGGESTIONS Drawing The Base Line The base line drawn from a pressure element, which has not been in use for some time will differ from the calibrated zero pressure. To correct the “zero shift," the pressure element should be flexed several times before a run. This can be accomplished with a dead weight tester or in the lubricator. The gauge should be subjected to the maximum pressure (about 80% .of its rating) for two minutes, then relaxed. The base line drawn after 7-10 minutes delay will agree with the manufacturer's calibration. Base lines should agree within the gauge sensitivity; i.e., within 0.002". If the base line is beyond this amount it should be checked before use. Trapped Internal Pressure The position of the base line is influenced by the rise in temperature of the entrapped air in the gauge housing. The entrapped air when heated causes internal pressure. The gauge should be made up at room temperatures and any cleaning solvents, water or oil should be thoroughly removed.

7

KT Temperature Elements Caution: do not loosen and move the adjusting knob of the KT Temperature element. Do not break the joint between the midsection and midsection adapter. To do so, will invalidate the calibration of the element. The KT element may be dismantled for cleaning and inspection by removing the bull nose and housing. Tubing wrenches for this purpose are available from the Kuster Company. Changing Lead Screws The clock running time may be reduced one-half by substituting a fast or double pitch lead screw for the standard or single pitch lead screw supplied with the instrument. To change the lead screw, remove the clock and chart carrier from the gauge. Bring the lead nut to the top of its travel. Remove the screws attaching the lead nut to the cup. Remove the screws holding the upper lead screw bearing to the housing. Pull the lead screw assembly out through the top of the inner housing. To install follow the above in reverse order. Stylus Carrier Assembly The stylus carrier assembly has two springs and a universal coupling which are important to instrument accuracy. The stylus spring and point assembly should be checked at regular intervals for the correct tension. This is easily done with the Kuster Stylus Tension Tester, part number 10142-101, which compares the spring tension with a calibrated mass. The tension can be adjusted by bending the spring.

8

OPERATING SUGGESTIONS (continued) Bellows Kuster Gauges are now assembled with an Inconel alloy bellows that will resist most well acids and alkalis for long periods of time. Although well protected, it is still good practice to wash the bellows with clean solvent after use. Any leakage of the bellows will affect its length. For 1-1/4” gauge at room temperature the bellows should measure 4-3/8" from the shoulder to the end, 6” for old style (See Figure 6). For 1.5” gauge the bellows length is 5”. A change in length means a leak has developed and the bellows must be replaced. The bellows should be replaced by first drawing a good vacuum on the bourdon tube, filling with fluid, attaching the bellows, again drawing a good vacuum, filling with fluid, and sealing tight with the screw provided. A specially designed coil-filling device, part number 10231-101, can be obtained from Kuster Company. Chart Carrier The accuracy of pressure and temperature surveys depends on the chart conforming to the chart carrier. The calibration of the gauge will be changed if the chart carrier is dropped and is out of round or the guide rod is moved off center. The inside of the chart carrier should be washed out at frequent intervals with clean solvent. Dry the solvent before replacing in the inner housing. Check the screws frequently and tighten as required. The chart carrier spring should be replaced when it shows signs of wear or has been overextended. The correct tension of this spring is important. Clean the guide in the inner housing cover on which the chart carrier spring moves. Lubrication The threads of the instrument should be lubricated often to prevent galling. A small amount of Thread Lube is recommended. A small amount of Kuster Clock Oil should be used on stylus shaft bearing on the pressure or temperature elements. A small amount of oil should also be placed on the lead screw bearing. After prolonged high temperature operation, it will be necessary to remove the accumulated tars formed from ordinary lubricants. For continued use at temperatures above 350°F, it is recommended the Kuster instrument oil 550 be used. Corrosive Conditions The KPG gauge is resistant to average oil well corrosive conditions. The housing and bellows with their teflon coating are not affected. Under severe corrosion conditions, the bellows should be protected with a labyrinth oil trap, part no. 10024-101. If this trap is filled with corrosion inhibitor the bellows is protected for long periods of time.

9

Reading Charts Charts can be read to within 0.003" using a steel rule graduated in 1/100ths inch and a 4-6 power magnifier. Optimum accuracy and speed is obtained using a Kuster Chart Reader. In this reader the cross hairs are Projected onto the chart eliminating all parallax. Viewing of the chart and cross hair is through a 5X eyepiece or a 56X microscope. Accuracies are about 0.0001 per inch in both time and pressure directions. Converting pressure or temperature deflections to absolute values is easily accomplished with the calibration tables supplied with your gauge. GEOTHERMAL USAGE KPG pressure and temperature recorders for geothermal use require more frequent maintenance because of the elevated temperatures and, in some cases, the corrosive conditions. Pressure Elements Replace o-rings after each run or when the elastomers got hard. Use special high temperature o-rings, part no. 706-077. If corrosion is low, wash the filter after each run. If corrosion is high, use the labyrinth oil trap, part no.10024-101 filled with corrosion inhibitor. Temperature Element Replace o-rings often - similar to pressure element. Remove corrosive deposits as required. Recorder Wipe inside frequently to remove the condensed oxidation products. Use anti-seize thread lubricant. Use a small amount of instrument oil 550 on the lead screw. Clock Temperatures above 175°C require more frequent lubrication and cleaning of the KPG clock. For lubrication use only recommended high temperature oil such as Kuster oil K-Tox. Re-lubricate after the run and while the clock is heated. Rewind and let the clock run down. Clean very often using a sonic cleaner and brush vigorously to remove all traces of oxidation products.

10

OPERATING SUGGESTIGNS (continued) Mainsprings are dry lubricated and should not be oiled unless the coating is lost. Mainsprings may need replacement when used for long periods of time at elevated temperatures. The package escapement assembly is replaced as a unit and can be done in the field with a minimum of tools. Polish all pivots bearing surfaces to remove oxidation products. CALIBRATION The calibrations of KPG Pressure Recorders by the manufacturer are with increasing pressures. Decreasing pressures will only repeat from the same maximum pressure and corresponding time intervals. If declining pressures are run in the well, it is necessary to calibrate the pressure element downward if the same accuracies are essential. The Kuster Company can perform this service and provide necessary corrections. When a pressure recorder is to be used at temperatures above 200'F, for accuracies consistent with the instrument, it is necessary to calibrate at the maximum temperature to be found in the well. Room Temperature Calibration Assemble the pressure element and recorder as described on pages 4-6. Make up to the calibration sub and connect to the tester. Pressurize the gauge to the maximum pressure of the element. Maintain the pressure for two minutes. Allow to relax for two minutes. Pressurize again to the maximum pressure. Allow to relax for two minutes. Pressurize the third time: allow to relax for 7 minutes. Draw the base line as described on page 6. The recorder should be in a vertical position and the bellows on the same level as the dead-weight tester. Apply pressure in about 5 or 6 steps in equal increments; i.e., 200, 500, 1000 or 2000 psi. Each calibration pressure level should be reached by increasing the pressure applied to the element. If the pressure level is passed in error, the pressure should be decreased 500. psi and the pressure level correctly re-established. The chart carrier is moved manually about 1/4 inch for each pressure level; the gauge rapped with a sharp blow; and the chart carrier again moved 1/4" at the same pressure level. This procedure will show static friction in the instrument, which must be corrected before proceeding. Elevated Temperature Calibration Follow preliminary steps of room temperature calibration. Install a 3-hour clock and a double pitch lead screw or use an outer housing with an external chart carrier advance (available from Kuster Company). Allow 30 minutes for

11

the gauge to reach equilibrium with the bath temperature. Attach the tubing connection to the dead weight tester. Apply pressures in the same manner as for room temperature calibrations. Allow 3-4 minutes at each pressure level if the clock is used to advance the chart carrier; this is eliminated with the manual advance. The scribed line may not return to the base line. This is caused by an increase of internal pressure of the fluid in the pressure element (which is a closed system with the bellows) when subject to elevated temperatures. This base line shift is not significant to the pressure information, because the calibration tables are made from a base line drawn at room temperature. The calibration of the KT Temperature Gauge must be done in a controlled temperature bath. The gauge is assembled as described on pages 4-6 of the operating instructions and pages 8-9 of this section. The temperature recorder must be calibrated with increasing temperature levels. At each temperature level, the instrument should be allowed to "soak" for 30 minutes to reach equilibrium with the bath. The chart carrier is moved after temperature equilibrium is reached by using the manual advance or by means of a 3-hour clock. Temperatures at each level should be verified for accuracy by means of a portable potentiometer or calibrated glass thermometers. FREQUENCY OF CALIBRATION The frequency of calibration of pressure recorders is dependent upon use. Some users calibrate before and after each run; using the same chart for both the calibration and the run. Other users calibrate at regular intervals of once each six months or thirty runs; whichever occurs first. If during the check calibration at any pressure level the deflection is beyond 0.2% (0.004") of a previous calibration, the instrument should be repaired, and a new calibration table made. The Kuster pressure and temperature gauges are supplied with a direct reading calibration table. The table is prepared by using a "constant modulus" between each calibration level. The table is supplied in any of the following units: psig, Atm, kg/sq, cm, kPa.

12

SOURCES OF ERROR Several exaggerated examples of charts from malfunctioned gauges: 1. Trace fails to return to baseline.

a) Pre-pressure before each use. b) Gas leaking into the bellows.

Check bellows length immediately after run.

c) Temperature expands fill fluid causing deflection.

2. Trace returns below baseline.

a) Bourdon tube leak resulting in shortened bellows.

b) Leaking O-ring allowing gas to leak into gauge during survey. A slight blow when the gauge is opened can be detected.

3. Jagged trace on chart while gauge is not moving. -Friction due to dirt, improper adjustment, etc. Check lead nut bearing. Check stylus spring. Check stylus shaft bearing. 4. Trace does not start or stop on baseline. -Gauge was tightened after baseline was drawn. 5. Crooked base line. -Dirty lead screw and lead screw nut. Misalignment. Sloppy fit of chart carrier. 6. Different deflections for identical depth points because the gauge is stopped on the way out of the well. -Due to hysteresis effect of the bourdon tube. Suggest special calibration with declining pressures by factory.

1

2

3

4

5

6

13

TOOLS AND ACCESSORIES KPG Tools and Accessories with each pressure recorder 1. 10003-001 Wire Line Socket 2. 706-077 O-Rings (10) 3. 10011-001 Oil Trap 4. 10011-004 Oil Trap Plug 5. 10013-001 Thermometer Well 6. 10016-101 Carrying Plug 7. 10128-001 Chart Mandrel 8. 10130-101 Charts, black (25) 9. 959-075 Outer Housing Wrench (2) 10. 10162-101 Inner Housing Wrench 11. 951-006 Stylus Arm Hex Wrench 12. 915-001 Thread Lube 13. 150-001 Calibration Tables 14. 120-001 Instruction Manual KPG Tools and Accessories with each temperature recorder 1. 10003-001 Wire Line Socket 2. 706-077 O-Rings (10) 3. 10016-101 Carrying Plug 4. 10128-001 Chart Mandrel 5. 10130-101 Charts, black, (25) 6. 10162-101 Inner Housing Wrench 7. 959-075 Outer Housing Wrench (2) 8. 751-006 Stylus Arm Hex Wrench 9. 915-001 Thread Lube 10. 150-001 Calibration Table 11. 120-001 Instruction Manual KPG Tools and Accessories with each pressure element 1. 10008-001 Stylus Shaft Guard 2. 10010-001 Bellows Guard 3. 150-001 Calibration Table KPG Tools and Accessories with each temperature element 1. 10008-001 Stylus Shaft Guard 2. 150-001 Calibration Table KPG Recorder Accessories (optional) 1. 10024-101 Labyrinth Oil Trap 2. 10041-004 Tandem Sub 3. 10142-101 Stylus Tension Tester 4. 11213-003 Universal Joint Sub 5. 10230-001 Calibration Adapter 6. 770-001 Steel Rule (6 inch) 7. 8011-103 Time Scale (plastic) 8. 10254-001 Carrying Case 9. 10320-101 Instrument Slide 10. 11150-102 No-Blow Tool 11. 10325-00’7 Recorder Housing (calibration) 12. 10315-101 Standing Valve Shock Absorber

14

Clock Maintenance Equipment Q-ty Part # Description____ 3 966-001 Screwdriver Set 1 968-002 Screwdriver 2 983-001 Tweezers 1 10245-001 Vise 2 973-001 Hammer, Brass 1 971-002 Hammer, 4 oz. 2 961-001 Pin Vise 1 978-001 Pliers 12 775-001 Polishing Paper 2 938-001 Oilers 1 1996-002 Optivisor 1 1996-001 Optiloupe 4 984-001 Brushes 3 875-001 Files 1 1099-104 Mainspring Winder 1 gal. 917-101 Clock Cleaner Solution 1 gal. 919-101 Clock Rinse Solution ½ oz. 910 –101 Instrument Oil 550

Ultrasonic Cleaner Part # Description____________________ 1992-101 5-3/8” x 5 3/8” x 3 Small 110V 1992-102 6” x 5-3/8” x 4 Medium 110V 1992-103 9-3/8” x 5-3/8”x 4 Large 110V 1992-202 6” x 5-3/8” x 4” Medium 220V 1992-203 9-3/8” x 5-3/8”x4 Large 220V

Measuring Line Reels Wire Line Hoists Rugged and dependable wire line hoists designed to match the petroleum industry requirements. Options available are: a) offshore or land type: skid or trailer mounted b) gasoline or diesel: 7.5, 10, 15 or 20hp (nom) c) wire size: .060, 072. .082, .092 dia. d) type of wire; standard, galvanized, stainless e) reel capacity 10,000 to 24,000 feet (.060 dia.) f) hydraulic or mechanical linkage; direct or three speed gear box transmission g) measuring device, feet or meters h) weight indicator, kilograms or pounds

15

Bellows Repair Kit with Vacuum Pump The complete equipment for the re- placement of bellows in KPG, RPG-3, RPG-4 and K-3 gauges. Includes vacuum pump with waste trap, hose, bellows repair kit. 110 or 220 VAC, 50/60kz belt guard, line switch. Bellows Repair Kit and Vacuum Pump: 115V, 60hz Part #……….10233-101 220V, 50/60hz Part #..….10233-102

Bellows Repair Kit Damaged bellows must be replaced to prevent corrosion of the instrument and to maintain accuracy. The bellows repair kit is easily used to clean and refill the bourdon tube and bellows. For KPG, RPG-3, RPG-4 and K-3 gauges. Use with good vacuum pump. Bellows Repair Kit, complete: Part No. 10231-101 with 2 spare bottles. 2 sets o-rings, connector hose. Bellows and Bourdon Tube Fluid Part No. 903-101

Lubricators Alloy steel for pressures up to 15,000 psi. Complete lubricator includes:

a) Stuffing box b) Grease control head c) Grease injection unit d) Risers and unions e) Bleed off valve f) Blowout preventer g) Tooltraps

HP Clock Operation and Maintenance. NOTE: For geothermal applications we recommend to disassemble and clean clocks after each run. LOADING CLOCK TO THE GAUGE:

1. Wind up clock ccw fully

2. Push winding knob down and turn it ccw to lock down.

3. Screw clock onto gauge

4. Release the clutch, pushing down at turning cw Each Kuster HP Clock is tested before shipment. The clock is fully wound and runs full duration in the oven at 400F. The HP KPG mainspring arbor rotates 15 times during its total elapsed clock hours. When the clocks are fully wound, you will note that there will be extra turns (overwind). Clocks should always be fully wound to ensure that the train receives sufficient torque (power) to compete its time cycle accurately. IMPORTANT:

1. For operation over 250F (121C), do not use any lubricant other than Kuster K-TOX (p/n 911-202). Other lubricants will break down at high temperatures leaving hard deposits and gum that will stop the clock and sometime be impossible to remove.

2. After disassembly all components should be cleaned in an ultrasonic cleaner with L&R NOFOME cleaning solution (p/n 917-101) and then rinsed in clean denaturated alcohol. Never use rinse that contains a lubricant. These lubricants are not intended for use at elevated temperatures.

DISASSEMBLY-ASSEMBLY PROCEDUR FOR CLOCK CLEANING:

1. Unscrew two set-screws from the clock cover.

2. Unscrew two escapement-holding screws.

3. Unscrew two cross screws from the top plate

4. Tap them out on table

5. Holding top plate to clock frame, unscrew last two screw from the top plate

17

6. Continue to hold upper plate at the frame with your left hand and holding the clutch with your right hand little finger from unwinding, turn the assembly 180° and tap the upper plate off the frame. After that, you can let clock slowly unwind, if there are any winds left.

7. Check all the gears with the loupe for nicks, dings and dents

8. Check all the bearings. They should turn freely and smoothly. If they

do not, clean and lubricate them before they replaced back.

9. Check escapement assembly with a loupe for problems and replace all damaged parts

10. Clean all the parts in the ultrasonic clock cleaner for about 2 min

11. Rinse them for about 2 min

12. Dry the parts out with low-pressure air. Very careful with hairspring.

(Better dry escapement assembly with the heat).

13. Oil the escapement assembly top and bottom pivot points (3 points on each side)

14. Grease the one fork entrance pallet.

15. Assemble clocks starting with all the gears, then slide on the top plate.

16. Cover the top plate with the frame (bottom), put the screws in. First

put four screws for the top plate, then put two screws for escapement.

17. Check the clearance on balance wheel pivots and adjust if necessary.

18. Check the condition of hairspring. Coils should be evenly spaced without touching each other.

19. Check all the gears for the end-play

20. Put 6 winds on upper clutch and let it run down.

21. When clock stops, wind it up back fully, counting the winds. Observe

the motion of the clock and listen to it normal work. First 5-10 minutes of galloping is normal. In ideal case the amount of additional winds you are going to get is 30 for 3-hour clock. That would mean that 6 winds had completely winded down and the total amount of winds you put on clock would equal 30 (see Kuster clock total winds table below).

18

Note: Any KPG gauge needs only 15 winds for full lead screw travel.

22. If everything is normal, let the clock completely run down and put them aside for a new survey.

23. If you don’t get nominal winds but for example 26, that would mean

that after you put 6 winds on the clock, they run only 2 winds and then stopped, having 4 unwinds on it.

24. In this case you need to troubleshoot escapement more than anything

else. Most probable problems are:

a) Escapement wheel teeth worn out b) One of the jewels on the escapement is broken

In both cases escapement replacement is required. If clock is ever flooded remove mainsprings from tandem shells, wipe off thoroughly and run in ultrasonic cleaner. They have a special low friction coating on them, and no further lubrication is necessary. Just prior to reassembly they should be wiped with a clean rag and alcohol. Grease ratchet (2-3 dabs on ratchet teeth), arbor flats (one very dub on each flat) and thrust washer in barrel cap (2-3 dabs).

Clock hours 3 12 24 72 120 360 Total Winds, average 30 30 25 22 20 18

19

Detailed Assembly-Disassembly procedure: Gauge Assembly:

1. In vertical position fill oil trap with oil and connect it along with thermometer well to the pressure element section.

2. Plug oil trap (don’t forget to take it off at the well site) and put aside. 3. Put inner housing in horizontal position and take the inner housing

cover off 4. Remove the transportation wood block from the inner housing,

unscrew carrier-stylus assembly from the transportation plug.

5. Pull the carrier-stylus assembly from the inner housing

6. Pull the stylus assembly from the carrier-stylus assembly.

7. Load the chart.

8. Remove the plastic or paper cover from the chart

9. Connect inner housing to the pressure element housing and tighten it up

10. Put carrier-stylus assembly into the inner housing

11. Install stylus assembly onto the end of stylus shaft and tighten it up.

12. Slide carrier assembly back to the clock side and be sure that the

stylus is just (within 1/16”) on the right side of the center. (if you look from the element section) Adjust it if needed.

13. Put recording section cover back

14. Slide carrier assembly to the clock side until it stops

15. Release stylus (put in “on” position)

16. Draw the base line, sliding carrier assembly towards element section

until it stops.

17. Put stylus in “off” position

20

18. Move carrier assembly back to clock. 19. Wind up the clock and lock the clock clutch

20. Connect clock to the inner tube

21. Unlock the clock clutch (engage with carrier assembly)

22. Put stylus in “on” position and fix it in that position by turning the lock-

ring.

23. Install outer housing onto recording section and tighten it up. Gauge Disassembly:

1. Put gauge in the vise (preferably vertical vise with gauge protective inserts)

2. Remove recording section outer housing from the gauge

3. Put stylus in ‘off’ position

4. Disconnect clock clutch, lock it and unscrew clock from the inner

housing.

5. Remove cover from the inner housing

6. Unscrew stylus assembly from the shaft

7. Remove carrier-stylus assembly from the inner housing

8. Remove inner housing from the gauge

9. Inspect, clean it and put aside

10. Remove oil trap and thermometer well from the gauge

11. Check the length of the bellows. It is supposed to be 4-3/8” for 1-1/4” gauge and 5” for 1-1/2” gauge. Check the bellows for leak and damage.

12. If it is dirty clean it and dry it

13. Put protective caps on pressure terminal section and put aside

14. Remove chart from the chart carrier.

21

15. Inspect carrier and stylus assembly, and clean it 16. Put carrier-stylus assembly into inner housing

17. Install transportation plug on inner housing

18. Tight stylus assembly on transportation plug

19. Slide carrier assembly towards pressure element and install

transportation wood block into the inner housing

20. Install inner housing cover back.

22

23

24

25

26

27

28