XC-132

Printed in U.S.A. March 10, 1999

Manufacturers of Precision Instruments

INSTALLATION, OPERATION, MAINTENANCE&

ILLUSTRATED PARTS BREAKDOWN

MINI DRILLWATCH SYSTEM

Part Number XC-132

Revision A

Manual XC-132contains 142 pages as follows:

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999i through Iv . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Table of Contents . . . . . . . . . . . . . . . . . . March 10, 1999List of Figures . . . . . . . . . . . . . . . . . . . . . March 10, 1999List of Tables. . . . . . . . . . . . . . . . . . . . . . March 10, 1999Chapter 1 . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Chapter 2 . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Chapter 3 . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Chapter 4 . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Chapter 5 . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Chapter 6 . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Chapter 7 . . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Appendix A . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999Appendix B . . . . . . . . . . . . . . . . . . . . . . . March 10, 1999

ii March 10, 1999M/D Totco

IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D Totco equipment. The service procedures recommended by M/D Totco and described in the technical manuals are recommended methods of performing service operations. When these service operations require the use of tools specially designed for the purpose, those special tools should be used as recom-mended. Warnings against the use of specific service methods that can damage equipment or render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D Totco could not possibly know, evaluate and advise service people of all conceivable ways in which service might be done or of all possible associated hazardous consequences. Accordingly, anyone who uses service procedures or tools which are not recommended by M/D Totco must first satisfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized by the method selected.

March 10, 1999 iiiM/D TOTCO

LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITA-TION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PUR-POSE.

M/D Totco warrants to Buyer (“Purchaser”) of new products manufactured or supplied by M/D Totco that such products are, at the time of delivery to the Purchaser, free of material and workmanship defects, subject to the following exceptions: (a) Any product that has been repaired or altered in such a way, in M/D Totco’s judgment, as to affect the product adversely, including any repairs, rebuilding, welding or heat treating outside of an M/D Totco -authorized facility, (b) Any product that has, in M/D Totco’s judgment, been subject to negligence, accident or improper stor-age, (c) Any product that has not been installed, operated and maintained in accordance with nor-mal practices and within the recommendations of M/D Totco , (d) For all items of special order by Purchaser that are not manufactured by M/D Totco , Purchaser should submit warranty claims directly to the manufacturer thereof.

M/D Totco’s obligation under this warranty is limited to repairing or, at its option, replacing any products which, in its judgement, proved not to be as warranted within the applicable warranty period. All costs of transportation of products claimed not to be as warranted and of repaired or replacement products to or from authorized M/D Totco service facility shall be borne by Purchaser. M/D Totco may, at its sole option, elect to refund the purchase price of the products, and M/D Totco shall have no further obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Purchaser. Replacement parts provided under the terms of this warranty are warranted for the remainder of the warranty period of the product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are: a) Hydraulics and Mechanical Equipment: one (1) year from date of installation or fifteen (15) months from date of shipment from M/D Totco , which-ever occurs first, b) All Elastomer Diaphragms: six (6) months from date of shipment fromM/D Totco , c) Electronic Equipment: six (6) months from date of shipment from M/D Totco .

iv March 10, 1999M/D Totco

Table of Contents

CHAPTER 1INTRODUCTION

1-1 INTRODUCTION .............................................................................................................................1-11-2 SCOPE OF MANUAL......................................................................................................................1-11-3 INTENDED AUDIENCE...................................................................................................................1-11-4 PERSONNEL QUALIFICATIONS...................................................................................................1-11-5 NOTES, CAUTIONS AND WARNINGS..........................................................................................1-21-6 RELATED DOCUMENTS................................................................................................................1-2

CHAPTER 2DESCRIPTION

2-1 INTRODUCTION .............................................................................................................................2-12-2 FUNCTION ......................................................................................................................................2-12-3 MAIN COMPONENTS.....................................................................................................................2-1

2-3-1 DAQ .......................................................................................................................................2-32-3-2 Mini DRILLWATCH Display Panel .........................................................................................2-42-3-3 Display Barrier Box ................................................................................................................2-52-3-4 I.S. Alarm Horn.......................................................................................................................2-52-3-5 Connecting Cables.................................................................................................................2-62-3-6 Laptop PC ..............................................................................................................................2-62-3-7 VIP Workstation .....................................................................................................................2-6

2-4 SENSORS .......................................................................................................................................2-62-4-1 Pressure Transducer Assembly (P/N 220631).......................................................................2-72-4-2 EDMS Drawworks Encoders (P/N 219062) ...........................................................................2-72-4-3 Rotary RPM Sensor (P/N 232389).........................................................................................2-82-4-4 Rotary Torque Sensor (P/N 218041) .....................................................................................2-82-4-5 Top Drive RPM and Torque Sensors .....................................................................................2-92-4-6 Mud Flow Sensor (P/N 270700-116)......................................................................................2-92-4-7 Pump Stroke Sensor (P/N 232389)......................................................................................2-10

2-5 Mini DRILLWATCH Specifications .............................................................................................2-11

CHAPTER 3INSTALLATION

3-1 INTRODUCTION .............................................................................................................................3-13-2 INSTALLATION LOCATION REQUIREMENTS.............................................................................3-13-3 DAQ INSTALLATION .....................................................................................................................3-3

3-3-1 Mount the DAQ ......................................................................................................................3-33-3-2 Ground the DAQ ....................................................................................................................3-43-3-3 Connect AC Power Cable to DAQ .........................................................................................3-4

3-4 DISPLAY PANEL INSTALLATION.................................................................................................3-63-5 DISPLAY BARRIER BOX INSTALLATION....................................................................................3-8

3-5-1 Mount the Display Barrier Box ...............................................................................................3-83-5-2 Ground the Display Barrier Box .............................................................................................3-8

3-6 ALARM HORN INSTALLATION.....................................................................................................3-93-6-1 Mount the Alarm Horn ............................................................................................................3-93-6-2 Adjust Alarm Horn Tone and Volume...................................................................................3-10

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Table of Contents MINI DRILLWATCH Manual XC-132

3-7 CONNECT THE DAQ, DISPLAY BARRIER BOX, DISPLAY PANEL & ALARM HORN ............3-123-8 VIP WORKSTATION INSTALLATION..........................................................................................3-153-9 SENSOR INSTALLATION ............................................................................................................3-16

3-9-1 DAQ Sensor Connections ....................................................................................................3-163-9-2 Mud Flow Sensor Installation ...............................................................................................3-18

3-9-2-1 Installation Of Mud Flow Sensor P/n 270700-116......................................................3-183-9-3 Pump Stroke Sensor Installation..........................................................................................3-223-9-4 Pressure Transducer Assembly ...........................................................................................3-27

3-9-4-1 Hook Load Sensor......................................................................................................3-283-9-4-2 Pump Pressure Sensor ..............................................................................................3-283-9-4-3 Rotary RPM Sensor Installation .................................................................................3-303-9-4-4 Rotary Torque Sensor Installation..............................................................................3-32

3-9-5 EDMS Drawworks Encoder Sensor .....................................................................................3-333-10 Mini DRILLWATCH DIGITAL OUTPUTS .....................................................................................3-353-11 SYSTEM POWER-UP ...................................................................................................................3-36

CHAPTER 4CONFIGURATION & CALIBRATION

4-1 INTRODUCTION .............................................................................................................................4-14-2 Mini DRILLWATCH CHANNELS....................................................................................................4-24-3 CALCONFIG SOFTWARE START-UP...........................................................................................4-44-4 LOADING THE Mini DRILLWATCH CONFIGURATION FROM DISK ..........................................4-54-5 CONFIGURATION ..........................................................................................................................4-64-6 CALIBRATION ................................................................................................................................4-9

4-6-1 Analog Sensor Channel Calibration .....................................................................................4-104-6-2 Digital Sensor Channel Calibration ......................................................................................4-16

4-7 SAVE CONFIGURATION/CALIBRATION TO DISK ....................................................................4-184-8 EDMS CALIBRATION...................................................................................................................4-19

4-8-1 Setting Up the System for Full Calibration ...........................................................................4-204-8-2 Recommended Block Height Calibration Points ..................................................................4-224-8-3 E-depth Sensor Calibration Procedure ................................................................................4-234-8-4 CALCONF Procedure ..........................................................................................................4-254-8-5 EDMS Re-Calibration...........................................................................................................4-31

CHAPTER 5OPERATION

5-1 INTRODUCTION .............................................................................................................................5-15-2 Mini DRILLWATCH DATA DISPLAY .............................................................................................5-1

5-2-1 Active Indicators.....................................................................................................................5-35-2-2 Field Names and Units...........................................................................................................5-35-2-3 Function Codes ......................................................................................................................5-3

5-3 KEYPAD OPERATION ...................................................................................................................5-45-3-1 Zero a Field Value..................................................................................................................5-55-3-2 Change Field Value................................................................................................................5-55-3-3 Change/View Alarm Limits .....................................................................................................5-55-3-4 Activate/Deactivate Fields......................................................................................................5-6

5-3-4-1 Activate/deactivate Pump Strokes/Pump SPM ............................................................5-65-3-5 Set Date and Time .................................................................................................................5-65-3-6 Switch Backlighting ON/OFF..................................................................................................5-7

5-4 DISPLAY PANEL FIELDS ..............................................................................................................5-75-4-1 Keyboard Fields .....................................................................................................................5-7

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MINI DRILLWATCH Table of ContentsManual XC-132

5-4-2 Return Flow............................................................................................................................5-85-4-2-1 Function Code 53: SET HIGH ......................................................................................5-85-4-2-2 Function Code 54: SET LOW.......................................................................................5-8

5-4-3 Counter A ...............................................................................................................................5-95-4-3-1 Function Code 1: SET ZERO .......................................................................................5-95-4-3-2 Function Code 10: PRESET.........................................................................................5-95-4-3-3 Function code 15: SET COUNTER ALARM.................................................................5-95-4-3-4 Function Codes 11 & 12: PUMP 1 & 2 .......................................................................5-10

5-4-4 Pump Rates/Total Pump Rate .............................................................................................5-105-4-4-1 Function Code 47: SET LOW FLOW ALARM DISABLE............................................5-10

5-4-5 Depth Of Hole ......................................................................................................................5-115-4-5-1 Function Code 65: SET DEPTH OF HOLE ................................................................5-11

CHAPTER 6MAINTENANCE

6-1 INTRODUCTION .............................................................................................................................6-16-2 PERIODIC INSPECTION OF Mini DRILLWATCH DEVICES.........................................................6-16-3 PERIODIC INSPECTION OF Mini DRILLWATCH SENSORS.......................................................6-16-4 TROUBLESHOOTING TABLE: Mini DRILLWATCH SYSTEM ....................................................6-2

6-4-1 DAQ Power Supply Checkout Procedure ..............................................................................6-66-4-2 Spectrum I/F Board ................................................................................................................6-76-4-3 Display Panel Controller Boards ..........................................................................................6-106-4-4 DAQ Digital Board................................................................................................................6-116-4-5 VIP Workstation Communications Board .............................................................................6-12

6-5 INIT CODES ..................................................................................................................................6-13

CHAPTER 7ILLUSTRATED PARTS BREAKDOWN

7-1 INTRODUCTION .............................................................................................................................7-17-2 ILLUSTRATIONS ............................................................................................................................7-17-3 PARTS LIST....................................................................................................................................7-1

7-3-1 Find Number ..........................................................................................................................7-17-3-2 Part Number...........................................................................................................................7-17-3-3 Description .............................................................................................................................7-17-3-4 Units Per Assembly................................................................................................................7-17-3-5 Use On Code .........................................................................................................................7-1

7-4 ABBREVIATIONS ...........................................................................................................................7-2

Appendix ASHIELDED CABLE GUIDELINES

A-1 INTRODUCTION ............................................................................................................................ A-1A-2 GUIDELINES FOR PREVENTING CABLE DAMAGE................................................................... A-1A-3 ELECTRICAL INTERFACE............................................................................................................ A-1A-4 SHIELDED CABLE SPLICING ...................................................................................................... A-1A-5 CONNECTING DEVICES............................................................................................................... A-2

Appendix B

March 10, 1999 Table of Contents -3M/D Totco

Table of Contents MINI DRILLWATCH Manual XC-132

CONVERSION DATAB-1 INTRODUCTION ............................................................................................................................ B-1B-2 TEMPERATURE CONVERSIONS................................................................................................. B-1B-3 CONVERSION FACTORS ............................................................................................................. B-1

Table of Contents -4 March 10, 1999M/D Totco

List of Figures
CHAPTER 2
DESCRIPTIONFigure 2-1. Typical Mini DRILLWATCH System ................................................................................2-2Figure 2-2. DAQ (Data Acquisition Unit) ............................................................................................2-3Figure 2-3. Mini DRILLWATCH Display Panel...................................................................................2-4Figure 2-4. Display Barrier Box..........................................................................................................2-5Figure 2-5. I.S. Alarm Horn ................................................................................................................2-5Figure 2-6. Pressure Transducer Assembly (P/N 220631) ................................................................2-7Figure 2-7. EDMS Encoder (P/N 219062) .........................................................................................2-7Figure 2-8. Rotary RPM Proximity Type Sensor (P/N 232389)..........................................................2-8Figure 2-9. Rotary Torque Sensor (P/N 218041) ...............................................................................2-8Figure 2-10. Mud Flow Sensor (P/N 270700-116) ...............................................................................2-9Figure 2-11. Pump Stroke Sensor (P.N 232389) ...............................................................................2-10

CHAPTER 3 INSTALLATION

Figure 3-1. Installation Location Requirements: Mini DRILLWATCH System....................................3-2Figure 3-2. DAQ Installation Dimensions...........................................................................................3-3Figure 3-3. DAQ Power Supply Cover ...............................................................................................3-5Figure 3-4. DAQ ac Power Connections............................................................................................3-6Figure 3-5. Display Panel Mounting Dimensions ...............................................................................3-7Figure 3-6. Display Barrier Box Mounting Dimensions ......................................................................3-8Figure 3-7. Display Barrier Box Grounding ........................................................................................3-9Figure 3-8. Alarm Horn Installation ..................................................................................................3-10Figure 3-9. Wiring: DAQ to Display Panel........................................................................................3-13Figure 3-10. View of Internal DAQ Wiring: 12 conductor cable to SIF PCB.......................................3-14Figure 3-11. VIP Workstation Installation...........................................................................................3-15Figure 3-12. DAQ Field Termination Board .......................................................................................3-17Figure 3-13. Flow Sensor Components: P/N 270700-116 .................................................................3-20Figure 3-14. Flow Sensor Installation: P/N 270700-116 ....................................................................3-20Figure 3-15. Flow Sensor Wiring: P/N 270700-116 (DAQ with Internal Barriers) ..............................3-21Figure 3-16. Pump Stroke Sensor Installation Dimensions................................................................3-22Figure 3-17. Pump Stroke Sensor Mounting Methods.......................................................................3-23Figure 3-18. Pump Stroke Sensor Installation ...................................................................................3-24Figure 3-19. Pump Stroke Sensor Wiring to DAQ..............................................................................3-25Figure 3-20. Pump Stroke Sensor Wiring to Barrierless DAQ ...........................................................3-25Figure 3-21. Pump Stroke Sensor Position Check ............................................................................3-26Figure 3-22. Pressure Transducer Assembly (P/N 220631-3660) .....................................................3-27Figure 3-23. Hook Load Sensor Installation.......................................................................................3-28Figure 3-24. Pump Pressure Sensor Installation ...............................................................................3-29Figure 3-25. Pump Pressure Sensor to DAQ Wiring..........................................................................3-29Figure 3-26. RPM Proximity Installation.............................................................................................3-30Figure 3-27. Proximity Target Installation ..........................................................................................3-30Figure 3-28. Proximity Bracket Installation ........................................................................................3-31Figure 3-29. Rotary RPM Sensor to DAQ Wiring...............................................................................3-31

March 10, 1999 List of Figures-1M/D Totco

List of Figures MINI DRILLWATCH Manual XC-132

Figure 3-30. Rotary Torque Sensor to DAQ Wiring ...........................................................................3-33Figure 3-31. EDMS Drawworks Encoder Wiring................................................................................3-33Figure 3-32. EDMS Drawworks Encoder Installation .........................................................................3-34Figure 3-33. Typical Digital Output Wiring .........................................................................................3-35

CHAPTER 4 CONFIGURATION & CALIBRATION

Figure 4-1. Recommended Mini DRILLWATCH Config and Cal Procedure ......................................4-1Figure 4-2. Laptop PC Connection to DAQ........................................................................................4-4Figure 4-3. Configuration & Calibration Main Menu Screen...............................................................4-5Figure 4-4. DISK: [LOAD ALL] Menu Screen....................................................................................4-6Figure 4-5. [CONFIGURATION] Submenu ........................................................................................4-8Figure 4-6. SYSTEM/DAQ CONFIGURATION Screen......................................................................4-8Figure 4-7. Typical Channel Configuration Screen ............................................................................4-9Figure 4-8. SYSTEM CALIBRATION SOFTWARE Screen .............................................................4-11Figure 4-9. CALIBRATION [CHANNELS] Submenu........................................................................4-12Figure 4-10. Typical Analog Calibration Screen ................................................................................4-12Figure 4-11. Typical “Raw Minimum” Calibration Screen...................................................................4-13Figure 4-12. Typical "Value Minimum" Calibration Screen ................................................................4-14Figure 4-13. Typical "Raw Maximum" Calibration Screen .................................................................4-15Figure 4-14. Typical "Value Maximum" Calibration Screen ...............................................................4-16Figure 4-15. Typical Digital Calibration Screen..................................................................................4-18Figure 4-16. DAQ Digital Board .........................................................................................................4-21Figure 4-17. DAQ PCB Switch Positions ...........................................................................................4-21Figure 4-18. Calibration Switch Box Connections..............................................................................4-22Figure 4-19. Calibration Switch Box...................................................................................................4-23Figure 4-20. CALCONF Main Menu...................................................................................................4-25Figure 4-21. System Calibration Screen ............................................................................................4-26Figure 4-22. EDMS Calibration Screen..............................................................................................4-28Figure 4-23. Block Height Position Changes .....................................................................................4-29Figure 4-24. Channel Values Screen.................................................................................................4-30Figure 4-25. Mini DRILLWATCH Instruction Label ............................................................................4-31

CHAPTER 5 OPERATION

Figure 5-1. Mini DRILLWATCH Data Display ....................................................................................5-2Figure 5-2. Example screen...............................................................................................................5-3Figure 5-3. Mini DRILLWATCH Keypad.............................................................................................5-4Figure 5-4. KEYBOARD Fields ..........................................................................................................5-8Figure 5-5. RETURN FLOW Fields....................................................................................................5-9Figure 5-6. COUNTER A Field.........................................................................................................5-10Figure 5-7. PUMP RATE Fields .......................................................................................................5-11Figure 5-8. Depth of Hole Field ........................................................................................................5-11

CHAPTER 6 MAINTENANCE

Figure 6-1. DAQ DC Power Distribution Wiring .................................................................................6-7Figure 6-2. Spectrum I/F (SIF) Board ................................................................................................6-8Figure 6-3. Display Panel Controller Boards....................................................................................6-10Figure 6-4. DAQ Digital Board .........................................................................................................6-11Figure 6-5. DCM Communications Board ........................................................................................6-12

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MINI DRILLWATCH List of FiguresManual XC-132

CHAPTER 7 ILLUSTRATED PARTS BREAKDOWN

Figure 7-1. Mini DRILLWATCH System Components .......................................................................7-3Figure 7-2. Mini DRILLWATCH Display Panel...................................................................................7-5Figure 7-3. Terminal Block Detail: Display Panel..............................................................................7-7Figure 7-4. Display Barrier Box..........................................................................................................7-8Figure 7-5. Pump Stroke Sensor .......................................................................................................7-9Figure 7-6. VIP Workstation.............................................................................................................7-10

Appendix A SHIELDED CABLE GUIDELINES

Figure A-1. Recommended Method of Splicing Shielded Cable ....................................................... A-2

March 10, 1999 List of Figures-3M/D Totco

List of Figures MINI DRILLWATCH Manual XC-132

List of Figures-4 March 10, 1999M/D Totco

List of Tables
CHAPTER 2
DESCRIPTION

Table 2-1. Mini DRILLWATCH Specifications ................................................................................2-11


Table 3-1. Alarm Horn Tone Selections..........................................................................................3-11


Table 4-1. Channel Descriptions: Standard Mini DRILLWATCH Configuration ...............................4-2

Table 4-2. Standard Mini DRILLWATCH Channel Configuration Information ..................................4-3

Table 4-3. Mini DRILLWATCH Default Output Assignments: Standard Configuration .....................4-3

Table 4-4. Calibration Defaults: Mini DRILLWATCH Analog Sensor Channels..............................4-10

Table 4-5. Calibration Defaults: Mini DRILLWATCH Digital Sensor Channels...............................4-17

Table 4-6. Block Heights.................................................................................................................4-22

Table 4-7. Sample Calibration Worksheet ......................................................................................4-28

Table 4-8. Calibration Worksheet ...................................................................................................4-32

CHAPTER 5OPERATION

Table 5-1. Summary of Keypad Keys ...............................................................................................5-4


Table 6-1. Troubleshooting Table: Mini DRILLWATCH System ......................................................6-2

Table 6-2. SIF Board Jumpers..........................................................................................................6-8

Table 6-3. JP3 - SIF Board Jumper Settings ....................................................................................6-9

Table 6-4. JP4 - Communication Baud Rate ....................................................................................6-9

Table 6-5. JP5 - Relay Power ...........................................................................................................6-9

Table 6-6. JP6 - Display Power ........................................................................................................6-9

Table 6-7. Mini DRILLWATCH INIT Codes.....................................................................................6-13


Table 7-1. Parts List Abbreviations...................................................................................................7-2

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List of Tables MINI DRILLWATCH Manual XC-132

Appendix B CONVERSION DATA

Table B-1. Conversion Factors ........................................................................................................ B-2

List of Tables-2 March 10, 1999M/D TOTCO

CHAPTER 1INTRODUCTION

1-1 INTRODUCTION

This manual contains installation, operation, maintenance, configuration, calibration and parts information for the Mini DRILLWATCH system, a drill-monitoring system manufactured by M/D Totco. Information in this manual should enable qualified personnel to install, operate, calibrate and maintain a Mini DRILLWATCH system.

1-2 SCOPE OF MANUAL

This manual is divided into the following chapters:

qChapter 1 - Introduction to manual

qChapter 2 - Description of the Mini DRILLWATCH system, its main compo-nents, optional components and sensors; list of system specifica-tions

qChapter 3 - Installation of main components, optional components and sensors

qChapter 4 - Configuration and calibration of sensor channels

qChapter 5 - Operation of display panel keypad, description of display panel fields and function codes

qChapter 6 - Maintenance and troubleshooting

qChapter 7 - Illustrated parts breakdown and recommended spare parts inventory

qAppendix A - Guidelines for working with shielded cable

qAppendix B - Conversion data

1-3 INTENDED AUDIENCE

This manual is intended for use by field engineering, maintenance, operation and repair personnel.

1-4 PERSONNEL QUALIFICATIONS

The procedures described in this manual should be performed only by persons who have read the safety notice on Page B of this manual and who are fully qualified and trained to perform the pro-cedures herein.

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CHAPTER 1 MINI DRILLWATCHINTRODUCTION Manual XC-132

1-5 NOTES, CAUTIONS AND WARNINGS

Notes, cautions and warnings are presented, when applicable, to aid in understanding and operat-ing the equipment or to protect personnel and equipment. Examples and explanations follow.

1-6 RELATED DOCUMENTS

M/D Totco documents related to the use of this manual are listed below:

• Manual 60-10: Data Acquisition Unit (DAQ) and Sensors• Manual 60-21: SPECTRUM 1000 Display• Manual 60-40: TOTAL System Configuration and Calibration software• Manual 27-45A: Mud Flow Sensor 270700-series• Manual 27-44A: Mud Flow Sensor 270700-series Illustrated Parts Breakdown

NOTE

Provides additional information about the current topic.

CAUTION

Provides information to prevent equipment malfunction or damage thatcould result in interruption of service.

WARNING

Provides information to prevent equipment malfunction or damage thatcould result in serious or fatal injury to personnel or major property loss.

Page 1-2 March 10, 1999M/D Totco

l

dis-

para-.

CHAPTER 2DESCRIPTION

2-1 INTRODUCTION

This chapter describes the Mini DRILLWATCH system, including its main components, optional components and sensors. Figure 2-1 is a typical Mini DRILLWATCH system. System specifica-tions are listed in Table 2-1.

2-2 FUNCTION

Mini DRILLWATCH is a combination drilling and mud-monitoring system that collects, processes, displays and monitors the following data:

• hook load and bit weight• rate of penetration and depth of hole• drill pipe rotary rate and torque• top drive RPM and pipe torque• power tong torque• return mud flow• pump rate, strokes, and pressure

If alarm conditions are reached, Mini DRILLWATCH alerts the operator via audible and visuaalarms.

Mini DRILLWATCH data can be output to a VIP Workstation for real-time and historical dataplay and hardcopy printouts.

2-3 MAIN COMPONENTS

The main components of a Mini DRILLWATCH system are listed below and described in the graphs that follow. These components are required in all Mini DRILLWATCH configurations

• Data Acquisition Unit (DAQ)• Mini DRILLWATCH display panel• Display barrier box• I.S. alarm horn

WARNING

WARNING

Only UL-approved and CENELEC-approved components are recommended for use in hazardous locations.


CHAPTER 2 MINI DRILLWATCH
DESCRIPTION Manual XC-132
Figure 2-1. Typical Mini DRILLWATCH System

EDMS CALIBRATION

SWITCH BOX

EDMS ENCODER

ROTARY TORQUESENSOR

PUMP STROKE SENSOR(S)

MUD FLOW SENSOR

PRESSURE TRANSDUCER ASSY(HOOKLOAD, PUMP PRESS, POWER TONG TORQUE)

ROTARY RPMSENSOR(S)

MINI DRILLWATCHDISPLAY

UL DAQ

DISPLAY BARRIER BOX

VIP WORKSTATION


MINI DRILLWATCH CHAPTER 2Manual XC-132 DESCRIPTION

PRELIMINARY

2-3-1 DAQ

The DAQ (Figure 2-2) is the data acquisition and processing device for Mini DRILL-WATCH. Its functions are summarized below.

• Powers rig sensors• Receives and processes rig sensor data and transmits this data to the Mini

DRILLWATCH display panel.• Receives and processes data entered by the operator using the display

panel keypad.• Transmits data to a VIP Workstation for real-time and historical data dis-

play and hardcopy printouts• Configures the system and calibrates sensor channels, when connected to

a laptop PC running configuration/calibration software

For a thorough description of the DAQ, refer to Manual 60-10.

Figure 2-2. DAQ (Data Acquisition Unit)

FRONTVIEW

BOTTOMVIEW


CHAPTER 2 MINI DRILLWATCHDESCRIPTION Manual XC-132

2-3-2 Mini DRILLWATCH Display Panel

The Mini DRILLWATCH display panel (Figure 2-3) is an intrinsically safe device that receives and displays rig sensor data from the DAQ.

The display panel is powered by the DAQ. It contains a keypad that enables the operator to view and set alarm limits, zero channel values, temporarily silence the alarm horn and set functions on and off. When alarm conditions exist, the panel alerts the operator by activat-ing the attached I.S. alarm horn and flashing the data value of the channel in alarm.

Drilling data can be presented in english or metric units.

Figure 2-3. Mini DRILLWATCH Display Panel



PRELIMINARY

2-3-3 Display Barrier Box

The display barrier box (Figure 2-4) ensures a safe energy level for all electrical connec-tions between the DAQ and display panel. The box contains seven barriers, which are used for communication (2), display panel power (1), display panel backlighting (3) and alarm horn power (1).

Figure 2-4. Display Barrier Box

2-3-4 I.S. Alarm Horn

The dual-tone I.S. alarm horn (Figure 2-5) is connected to the display panel and sounds when alarm conditions are reached. During an alarm, the horn can be silenced by pressing the "alarm acknowledge" (ALARM ACK) key on the display panel keypad.

Figure 2-5. I.S. Alarm Horn



n the

f an

2-3-5 Connecting Cables

All Mini DRILLWATCH systems include the following cable assembly shown in Figure 2-1.

• CAL/CONFIG cable assembly - a 5-foot, 9-pin cable assembly that con-nects the DAQ to a laptop PC for configuration and calibration

2-3-6 Laptop PC

A laptop PC is used to calibrate sensor channels and modify the system configuratiousing configuration and calibration software (Chapter 4). It connects to the DAQ via nine-pin CAL/CONFIG cable assembly supplied with all systems (Figure 2-1).

2-3-7 VIP Workstation

The VIP Workstation is used to run VIP (Visulogger Interface Program). It consists oIBM-compatible personal computer, color monitor and printer/plotter.

With VIP, the Workstation can be used to:

• Display real-time and historical data on the monitor and on paper • Store data from the DAQ in data files on the PC hard drive. These data

files can be accessed at the rig site and off-site locations and can be refor-matted for import to spreadsheet or database applications programs.

• Compare data values for each channel to user-specified alarm limits

2-4 SENSORS

The Mini DRILLWATCH display panel displays data supplied by:

• Pressure Transducer Assembly• Drawworks sensor• Rotaty RPM and torque sensors• Top drive and torque sensors• Mud flow sensors• Pump stroke sensors



PRELIMINARY

2-4-1 Pressure Transducer Assembly (P/N 220631)

The Pressure Ttansducer Assembly (P/N 220631-3660) contains three pressure transduc-ers used to convert hydraulic pressure input to a 4-20mA output. Hook Load utilizes a 0-1000 PSI transducer and Pump Pressure and Power Tong Torque utilize 0-5000 PSI transducers.

Figure 2-6. Pressure Transducer Assembly (P/N 220631)

2-4-2 EDMS Drawworks Encoders (P/N 219062)

This sensor detect movement of the block via the drawworks.

Figure 2-7. EDMS Encoder (P/N 219062)

Hook Load

Pump

Power Tong

Pressure



2-4-3 Rotary RPM Sensor (P/N 232389)

Rotary RPM sensors are used to monitor the number of revolutions per minute the rotary table is turning.

Figure 2-8. Rotary RPM Proximity Type Sensor (P/N 232389)

2-4-4 Rotary Torque Sensor (P/N 218041)

Rotary torque sensors measure the amount of torque acting on the rotary table. Large increases in rotary torque can signify downhole problems.

Figure 2-9. Rotary Torque Sensor (P/N 218041)



PRELIMINARY

2-4-5 Top Drive RPM and Torque Sensors

These sensors serve the same purposes as their rotary-table rig counterparts, except that they are integral parts of the top drive mechanism.

2-4-6 Mud Flow Sensor (P/N 270700-116)

Mud flow sensors are used to measure the amount of mud exiting the well bore so that gas kicks, invasion of formation fluid or loss of circulation can be detected. They are powered by dc voltage from the DAQ and output a voltage signal proportional to the amount of mud exiting. The DAQ uses the mud flow sensor signal to calculate% return flow.

A flow sensor mounts on the return flow pipe between the well head and mud pits, with a paddle extending through a cut-out in the pipe. As mud flows through the pipe, the paddle is deflected. The angle of deflection is proportional to the volume of mud flowing and the rate of flow. The sensor outputs a signal proportional to the paddle deflection.

This sensor (Figure 2-10) is approved for use in systems containing a DAQ with internal safety barriers. The sensor contains an electric transmitter whose output signal is propor-tional to the angle of deflection of the paddle.

For details on this sensor, refer to Manual 27-45A.

Figure 2-10. Mud Flow Sensor (P/N 270700-116)



2-4-7 Pump Stroke Sensor (P/N 232389)

Pump stroke sensors are used to detect individual strokes of the mud pump. The pump stroke sensor (Figure 2-11) is powered by +10 VDC from the DAQ and is designed to be mounted through the mud pump inspection plate. It is metal-sensitive and produces a sig-nal pulse whenever a metal plate (i.e., pump crosshead or collar) passes within 10 mm of the sensor head. Each pulse typically represents one pump stroke. The DAQ uses these signal pulses to calculate strokes per minute and total strokes for each pump, as well as for all pumps collectively.

Figure 2-11. Pump Stroke Sensor (P.N 232389)



PRELIMINARY

2-5 Mini DRILLWATCH Specifications

Specifications for Mini DRILLWATCH system components are listed in Table 2-1. For certifica-tion information not listed, contact M/D Totco Engineering.

TABLE 1

NOTE

All specifications are subject to change without notice.

Table 2-1. Mini DRILLWATCH Specifications

Parameter Requirements/Limits

Electrical:

DAQ

Primary Power 85 to 265 Vac Universal input

Frequency 47 to 63 Hz, single phase, < 5% THD

Current 2.0 amperes, typical at 120 Vac

Primary Power Fuse Time-delay fuse, FLM, 250 Vac, 3 amp

DC Power (Internal) Two fused supplies: +5, +/- 15 VDC 40 Watt and +28 VDC 50 Watt

Output +14VDC (nominal) to power display panel+24VDC (nominal) to operate alarms, display panel backlighting

Display Panel

Primary Power +8 VDC (nominal)

Current 75 mA, typical

Backlighting Power +12 VDC (nominal)

Current 210 mA, typical

Alarm Horn Power +12 VDC (nominal)

Display Barrier Box

Display Panel Power +14 VDC Input, +8 VDC Output (nominal)

Display Panel Backlighting +24 VDC Input, +12 VDC Output (nominal)

Alarm Horn +24 VDC Input, +12 VDC Output (nominal)

Alarm Horn

Primary Power +12 VDC Input (nominal)

Current 36 mA maximum



Environmental:

DAQ

Operating Temperature -20oC to +60oC (-4oF to +140oF)

Storage Temperature -30oC to +85oC (-22oF to +185oF)

Humidity 5% to 90% non-condensing

Display Panel




Display Barrier Box:




Alarm Horn



Humidity 95% maximum at 40oC (104oF)

Pressure Transducer Assy

Operating Temperature (-40°F to +175°F)

Storage Temperature (-40°F to +250°F)

Humidity up to 100% non-condensing

Mechanical:

DAQ

Enclosure Stainless steel, NEMA 4X

Dimensions - inches (mm) 21.5 L x 19.11 W x 13 D (546 mm x 485 mm x 330 mm)

Mounting Hole Separations 19.5 L x 13.8 W (495 mm x 351 mm)

Mounting Hole Diameter 0.40 (10.2 mm) diameter

Door Clearance Area 21.5 L x 28 D (546 mm x 711 mm) @ 90o arc

Weight 57 lb (126 kg)

Display Panel

Enclosure Stainless steel, NEMA 4X

Table 2-1. Mini DRILLWATCH Specifications (Continued)




PRELIMINARY

Dimensions - inches (mm) 18.14 L x 30.72 W x 4.83 D (460.7 mm x 780.3 mm x 122.7 mm)

Mounting Hole Separations 19.75 L x 21.20 W (501.6 mm x 538.5 mm)

Mounting Hole Diameter 0.44 (11.2 mm)

Weight 58 lb (26.3 kg)

Display Barrier Box

Enclosure Sheet steel, zinc-sprayed and painted, NEMA 4

Dimensions - inches (mm) 12.05 L x 12.80 W x 6.30 D (306 mm x 325 mm x 160 mm)

Mounting Hole Separations 7.99 L x 13.03 W (203 mm x 331 mm)

Mounting Hole Diameter 0.39 (10.0 mm)

Weight 16.3 lb (7.4 kg)

Alarm Horn

Enclosure Molded ABS, NEMA 4


Mounting Hole Separations 6.02 (153 mm)

Mounting Hole Diameter 0.31 (8 mm)


Pressure Transducer Assy

Enclosure Stainless Steel, NEMA 4X


Mounting Hole Separations 6.0 (152.4 mm)

Mounting Hole Diameter .31 (8mm)


Suitable for Area:

DAQ NEC Class 1 Div 2, IEC Zone 2

Display Panel CENELEC Zone 0, 1, 2

Display Barrier Box Non-hazardous

Alarm Horn CENELEC Zone 0, 1, 2

Mud Flow Sensor NEC Class 1 Div 1, IEC Zone 0, 1, 2

Pressure Transducer Assy NEC Class 1 Div 1, IEC Zone 0, 1, 2

Pump Stroke Sensor NEC Class 1 Div 1, IEC Zone 0, 1, 2, CENELEC Zone 0, 1, 2

Table 2-1. Mini DRILLWATCH Specifications (Continued)






3-1 INTRODUCTION

This chapter contains procedures for the following:

• Main component installation• Optional component installation• Sensor installation.

3-2 INSTALLATION LOCATION REQUIREMENTS

Figure 3-1 shows location requirements for Mini DRILLWATCH main components, optional components and sensors.

WARNING

Install Mini DRILLWATCH components in accordance with the proceduresin this chapter and use only replacement parts listed in the spare partsinventory (Table 7-2). Incorrect installation could result in explosion or firehazard.


CHAPTER 3 MINI DRILLWATCHINSTALLATION Manual XC-132

FIGURE 1

Figure 3-1. Installation Location Requirements: Mini DRILLWATCH System


MINI DRILLWATCH CHAPTER 3Manual XC-132 INSTALLATION

3-3 DAQ INSTALLATION

To install the DAQ, follow the steps below.

1. Mount the DAQ (Section 3-3-1).

2. Earth ground the DAQ (Section 3-3-2).

3. Connect AC power cable to DAQ (Section 3-3-3).

3-3-1 Mount the DAQ

Mount the DAQ in a non-hazardous area, using four 3/8-16 UNC (or M8) mounting bolts (Figure 3-2). The DAQ can be bolted directly to a rigid structure or bolted to mounting brackets and then clamped securely to a rigid structure. Allow a clearance of approxi-mately 30 inches (762 mm) in front and on the hinged side so that the door and case can swing fully open. Allow adequate clearance below the DAQ for service loops which allow opening of the case to access the rear compartment.

Figure 3-2. DAQ Installation Dimensions



ession

3-3-2 Ground the DAQ

To earth ground the DAQ, you will need the following:

• Grounding cable assembly or equivalent• For onshore installation only:

1. copper-clad grounding rod that is 8 feet long

2. 1/2-inch in diameter, and 2) 1/2-inch copper clad ground clamp

Follow the steps below to earth ground the DAQ.

1. Connect one end of grounding cable assembly, or equivalent, to DAQ ground-ing lug, located on side of DAQ and labeled BARRIER GROUND.

2. For offshore installation, make secure compression connection between cable assembly ground clamp and rig substructure.

For onshore installation, drive grounding rod into ground, leaving just enough of rodexposed for attachment of cable assembly ground clamp. Then make secure comprconnection between grounding rod and 1/2-inch ground clamp.

3-3-3 Connect AC Power Cable to DAQ

To connect the AC power cable to the DAQ, follow the steps below.

1. Open DAQ rear door.

2. Ensure that DAQ ON/OFF switch is set to OFF position; then remove power supply cover as shown in Figure 3-3.

NOTE

Grounding requirements may vary. Consult local electrical codes forspecific requirements.

CAUTION

All earth ground connections must be made in non-hazardous areas.Ensure that all connecting surfaces are bare metal and completely free ofgrease, paint or oxidation. Do not solder earth ground connections.

CAUTION

Ensure ground wire is properly installed before connecting AC power cable

NOTE

No changes are needed in the DAQ when wiring either 120V/60Hz or 220V/50Hz as the main power source.



Figure 3-3. DAQ Power Supply Cover

3. Route end of 3-conductor AC power cable with ring terminals through DAQ cable gland (Figure 3-4).

4. Observe wire color coding and connect terminals to terminal block as follows: line to black, neutral to white, and ground to ground lug.

5. Tighten cable gland nut to secure cable; then replace power supply cover.

6. Connect other end of ac cable to rig AC power source.

7. Roll and tie excess cable away from rig traffic and working space.



lted cture

Figure 3-4. DAQ ac Power Connections

3-4 DISPLAY PANEL INSTALLATION

Consider the following when selecting a rig floor mounting location for the display panel:

• Panel data displays must be clearly visible to the operator.• The operator must be able to use the panel keypad during normal rig operations.• The panel must not hinder normal rig floor activities.• The panel location must permit proper routing of all cables.• There must be adequate clearance below the panel for connecting cables.• There must be adequate clearance in front of the panel to allow removal of the

cover for maintenance.Mount the panel using four 3/8-16 (or M8) mounting bolts (Figure 3-5). The panel can be bodirectly to a rigid structure or to mounting brackets and then clamped securely to a rigid stru



.

Figure 3-5. Display Panel Mounting Dimensions



3-5 DISPLAY BARRIER BOX INSTALLATION

Display barrier box installation consists of the following:

1. Mount the display barrier box (Section 3-5-1).

2. Ground the barrier box (Section 3-5-2).

3-5-1 Mount the Display Barrier Box

Mount the display barrier box in a non-hazardous area, using four 1/4-20 (or M6) mount-ing bolts (Figure 3-6). The barrier box can be bolted directly to a rigid structure or bolted to mounting brackets and then clamped securely to a rigid structure. Allow ample clear-ance above and below box for cable connections and in front of box for door to swing fully open.

Figure 3-6. Display Barrier Box Mounting Dimensions

3-5-2 Ground the Display Barrier Box

To ground the display barrier box, you will need the following:

• Grounding cable assembly or equivalent• For onshore installation only:

1) copper-clad grounding rod that is 8 feet long and 1/2-inch in diameter, and 2) 1/2-inch copper-clad ground clamp

NOTE

Grounding requirements may vary. Consult local electrical codes forspecific requirements.



Follow the steps below to earth ground the display barrier box.

1. Connect one end of grounding cable assembly, or equivalent, to display bar-rier box ground lug (Figure 3-7).

2. For offshore installation, make secure compression connection between cable assembly ground clamp and rig substructure.

For onshore installation, drive grounding rod into ground, leaving just enough of rod exposed for attachment of cable assembly ground clamp. Then make secure compression connection between grounding rod and 1/2-inch ground clamp.

Figure 3-7. Display Barrier Box Grounding

3-6 ALARM HORN INSTALLATION

Alarm horn installation consists of the following:

1. Mount the horn (Section 3-6-1)

2. Set horn tone and volume (Section 3-6-2).

3-6-1 Mount the Alarm Horn

The alarm horn must be mounted within 20 feet of the display panel and must be easily heard by the operator and rig floor personnel during normal rig operations. Mount the alarm horn using two 1/4-20 UNC (or M6) mounting bolts (Figure 3-8). The horn may be bolted directly to a rigid structure or bolted to mounting brackets and then clamped securely to a rigid structure.

CAUTION

All earth ground connections must be made in non-hazardous areas.Ensure that all connecting surfaces are bare metal and completely free ofgrease, paint or oxidation. Do not solder earth ground connections.



axi-

3-6-2 Adjust Alarm Horn Tone and Volume

The tone-selection DIP switch and volume control knob are identified in Figure 3-8. The recommended tone is a “fast whoop”, but any other may be used (Table 3-1). The mmum volume is 101 dB(A).

Figure 3-8. Alarm Horn Installation

6.02(152.9 mm)

5.27(133.9 mm)

5.27(133.9 mm)

M/D

TO

TC

OIN

ST

RU

ME

NT

AT

ION

TB10.32 (8.1 mm)

VOLUME CONTROL

TONE SELECTION DIP SWITCH

5.04(128.0 mm)



* 24 VDC supply via zener barrier ** Factory default/recommended

Table 3-1. Alarm Horn Tone Selections

Tone(sound level/current)*

Open Switch Positions (all other positions closed)

Continuous Tone800 Hz (101 dB(A)/21 mA)

1

Continuous Tone2400 Hz (105 dB(A)/32 mA)

1, 2, 3

Interrupted Tone800 Hz at 0.5 sec (98 dB(A)/17mA)

1, 2

Interrupted Tone2400 Hz at 0.5 sec (102 dB(A)/23mA)

1, 4

Alternate Two-Tone800/1000 Hz at 0.5 sec (101 dB(A)/23 mA)

1, 3

Alternate Two-Tone2400/2900 Hz at 0.5 sec (105 dB(A)/34 mA)

2, 3

Alternate Fast Two-Tone800/1000 Hz at 0.25 sec (101 dB(A)/23 mA)

3

Fast Whoop**500-1200 Hz at 0.1 sec (101 dB(A)/19 mA)

1, 2, 3, 4

Slow Whoop500-1200 Hz at 3 sec (101 dB(A)/23 mA)

1, 2, 4

Swept Frequency1200-5000 Hz at 1 sec (100 dB(A)/36 mA)

1, 3, 4

Sirenat 3 sec (100 dB(A)/22 mA)

2, 3, 4



3-7 CONNECT THE DAQ, DISPLAY BARRIER BOX, DISPLAY PANEL & ALARM HORN

Refer to Figure 3-9 & Figure 3-10 and use the cable assemblies listed below to connect the DAQ, display barrier box, display panel and alarm horn.

• 20-conductor, 18 gauge shielded cable to connect the DAQ to the display barrier box

• 20-conductor, 18 gauge shielded cable or cable assemblies to connect the display barrier box to the display panel

• 3-conductor, 18 gauge cable to connect the alarm horn to the display panel



Figure 3-9. Wiring: DAQ to Display Panel



Figure 3-10. View of Internal DAQ Wiring: 12 conductor cable to SIF PCB

SPECTRUM I/F (SIF) PCB

CABLE GLAND EXANE CABLE12 CONDUCTOR W/SHIELD

SCREW CLAMP PLUG-IN CONNECTORS



3-8 VIP WORKSTATION INSTALLATION

The VIP Workstation is pre-configured for Mini DRILLWATCH and automatically initializes VIP upon power-up. Follow the steps below and refer to Figure 3-11 to install a VIP Workstation. This procedure assumes that the keyboard and monitor are already connected according to the manufacturer’s instructions.

1. Connect 75 ohm BNC tee fitting to BNC connector on DAQ base (Figure 3-11) - OPTIONAL.

2. Connect RG59/U coaxial cable assembly (or equivalent) to BNC tee and to T-POT modem.

3. If PC is customer-supplied, install internal modem and install DCM communications board into appropriate PC expansion slot. Otherwise, proceed to Step 4.

4. Plug T-POT modem 9-pin connector into DCM communications board installed in PC.

5. Connect PC parallel port LPT1 to printer.

6. Install paper according to manufacturer’s instructions.

7. Connect ac power cord from PC to 115/230 VAC, 50-60 Hz surge-protected power outlet.

8. Connect ac power cord from printer to 115 VAC, 60 Hz surge-protected power outlet.

Figure 3-11. VIP Workstation Installation



3-9 SENSOR INSTALLATION

All Mini DRILLWATCH sensors supply input to the DAQ. The Mini DRILLWATCH system uses a UL DAQ with internal safety barriers. Sensor cables are routed and then connected directly to the DAQ field termination board. Table 4-4 and Table 4-5 list the default analog and digital connectors for each sensor.

3-9-1 DAQ Sensor Connections

All sensor cables are connected to the DAQ field termination board. The main features of this board are summarized below and identified in Figure 3-12. To connect sensor cables, use DAQ sensor cable screwdriver mounted in the DAQ to open the connector slot; then insert the wire.

• Analog Sensor Terminal Blocks - J1A through J23A; used to provide excitation voltage to and receive input from analog sensors, including mud flow, load, pressure, and torque sensors.

• Analog Sensor Voltage/Current Switches - located to the right of J1A through J23A, these red rocker switches are used to identify each analog sensor input as current or voltage and provide the corresponding excita-tion. For mud flow and rotary torque sensors, these switches should be set to “voltage” (i.e. pressed away from the center of the DAQ). For load, pressure, and top drive signals, these switches should be set to “current” (i.e. pressed toward the center of the DAQ).

• Digital Sensor Terminal Blocks - J1D through J14D; used to provide excitation voltage to and receive input from digital sensors, including the pump stroke and rotary rate sensors. These terminal blocks are also used if the DAQ is used to drive other instruments, such as chart recorders.

• Power-Out Terminal Blocks - J1P through J6P; supply power to other instruments. These terminal blocks are used in a typical Mini DRILL-WATCH system to power the external pump stroke sensor safety barriers.

• EDMS Input Terminal Blocks - J2S, J1R; used to connect an Electronic Depth Monitoring System to the DAQ. These terminal blocks are used to connect the drawworks encoder sensor (J1R) and EDMS calibration switch box (J1S) to the DAQ.

CAUTION

Be sure to connect each sensor to its default connector. Otherwise, theMini DRILLWATCH configuration must be modified to identify theconnectors used.



Figure 3-12. DAQ Field Termination Board



nd e r

3-9-2 Mud Flow Sensor Installation

Procedures for installing flow sensors are presented in the following paragraphs.

3-9-2-1 Installation Of Mud Flow Sensor P/n 270700-116

Follow the steps below to adjust and install this mud flow sensor.

1. Remove transmitter top cover (Figure 3-13). Disconnect and remove signal cable.

2. Check for the following resistances:

• 1.4 - 1.5 K ohms across terminals 1 and 2 with sensor paddle in position "A" and

• 3.5 - 4.5 K ohms across terminals 1 and 2 with sensor paddle in position "B"

3. If resistance from position “A” to “B” is out of tolerance, loosen bell crank set screw and connect digital resistance meter to termi-nals 1 and 2. With sensor paddle in position “A”, adjust drive shaft for reading of 1.4 - 1.5 K ohms across terminals 1 and 2 and tighten set screw.

If required resistance cannot be obtained, check for faulty electrical amechanical components, including potentiometer, resistor and linkagassembly between paddle and drive shaft. Refer to Manual 27-45A foadditional information.

4. Raise paddle from position “A” to position “B”; if reading decreases, swap positions of wires connected to terminals 1 and 3. Then raise paddle from position “A” to “B” and ensure that reading increases to 3.5 - 4.5 K ohms.



5. Ensure that mud pumps are shut down. Then proceed to Step 6.

6. Select a location on the flow line for installing the mud flow sen-sor. This location must meet the following criteria:

• slopes down toward the shaker pit• is accessible for servicing• is above spillover level of shale shaker• is away from bends in the flow line

7. Cut a 7.5 x 4.00 (190.5 mm x 101.6 mm) hole lengthwise in the flow line (Figure 3-14) and weld sensor base squarely onto flow line.

8. Determine flow line diameter and select appropriate paddle size.

9. Measure from top of flow flange to bottom of flow line to deter-mine where on sensor to mount paddle; attach using furnished screws. Ensure locking nuts for screws are on downstream side of paddle. Place paddle through hole in pipe, with concave side fac-ing upstream.

10. Ensure that when no mud is flowing and paddle is in down posi-tion, there is a 0.25–0.75-inch gap (6.3–19 mm) between paddle and base of pipe and there is no blockage (cement/cuttings) when sensor is mounted in its base. Bolt sensor squarely to base.

11. Position counterweights along counterweight shaft so that paddle returns to position “A” with no mud flow. Rotate counterweight support several times to ensure mechanism moves freely and returns to position “A”.

12. Remove transmitter cover and refer to Figure 3-12, 3-13, and 3-15 to connect sensor cable to sensor and to DAQ. Replace cover. Ensure cable is not in walkways, wet areas or near power cables.

NOTE

If a base is mounted to the flow line from a previous rig-up and meets theabove requirements, use it. Otherwise, proceed to Step 7.

WARNING

Be sure area is free of explosive vapors before using welding torch.



Figure 3-13. Flow Sensor Components: P/N 270700-116

Figure 3-14. Flow Sensor Installation: P/N 270700-116



Figure 3-15. Flow Sensor Wiring: P/N 270700-116 (DAQ with Internal Barriers)



3-9-3 Pump Stroke Sensor Installation

The pump stroke sensor assembly is designed to be mounted in the crosshead inspection plate of the mud pump. Sensor mounting dimensions are shown in Figure 3-16. Follow the steps below to install this sensor.

1. Remove crosshead inspection plate and gasket, if possible, from mud pump housing.

2. Rotate pump through one complete pump stroke by mechanical means or by bumping pump switch.

3. Measure linear distance traveled by crosshead in one complete stroke (Dimension A, Figure 3-17).

4. Determine minimum distance between inspection plate surface and crosshead in one complete pump stroke (Dimension B, Figure 3-17).

Figure 3-16. Pump Stroke Sensor Installation Dimensions

CAUTION

Be careful not damage crosshead inspection plate gasket.



Figure 3-17. Pump Stroke Sensor Mounting Methods



5. Drill a 7/8-inch (22.2 mm) mounting hole in inspection plate, locating hole so that sensor will be in best position for detecting pump strokes.

6. Determine distance between crosshead and inside edge of inspection plate by placing a straight edge across opening and measuring perpendicular distance. Allow 3/16–3/8-inch (5–10 mm) between sensor and part of crosshead being sensed (Dimension C, Figure 3-17).

7. Mount bulkhead union and tighten locknut (Figure 3-18).

8. Screw threaded pipe through bulkhead union until enough pipe extends through to connect adapter and sensor.

9. Thread sensor cable through pipe and out terminal housing; then connect adapter to pipe.

10. Ensure sensor head is within 3/8-inch (10 mm) of crosshead. Adjust sensor by loosening locknut and turning threaded pipe as follows: each 1-1/8 turn of the pipe moves the sensor 1/16-inch (1.6 mm).

Figure 3-18. Pump Stroke Sensor Installation

11. Connect sensor cable to sensor terminal strip and either directly to DAQ (Figure 3-12 and 3-19) or through sensor barrier box to DAQ (Figure 3-20). Ensure cable is not in walkways, wet areas or close proximity to power cables.

NOTE

A pilot hole approximately 3/8-inch (10 mm) provides accuracy for largerdrill.



Figure 3-19. Pump Stroke Sensor Wiring to DAQ

Figure 3-20. Pump Stroke Sensor Wiring to Barrierless DAQ

12. Use a voltmeter to ensure that sensor pulses when crosshead completes one full stroke. Supply power to sensor and connect meter to sensor as shown in Figure 3-21.



13. When no metal is within sensing range (i.e., further than 3/8-inch, or 10 mm, from sensor head), meter should read < 3.4 VDC.

14. Bump the pump with the switch or mechanically operate the pump until the sensor senses the crosshead; meter should read > 7.5 VDC.

15. If the required voltage is not observed, or if sensor does not respond to metal, remove signal cable, loosen locknut and turn threaded pipe until sensor responds as required. This procedure may have to be repeated several times until sensor is correctly positioned.

Figure 3-21. Pump Stroke Sensor Position Check



is to ssure raulic

routed e. The 4-1)

r third

3-9-4 Pressure Transducer Assembly

The Pressure Transducer Assembly is located within the drillers console. It’s purposeconvert hydraulic inputs from the Hook Load sensor (deadline anchor), the Pump Presensor (standpipe diaphragm), and the Power Tong sensor into 4-20mA signals. Hydsignals from the deadline anchor, standpipe diaphragm, and the power tong must beto the Pressure Transducer Assembly via high pressure tubing or high pressure hosfirst connection on the PT Assembly is the Hook Load connector. (Refer to Figure 2-

The middle connection is designated for the Pump Pressure signal and the bottom ois reserved for the Power Tong torque signal.

Figure 3-22. Pressure Transducer Assembly (P/N 220631-3660)

CAUTION

Make sure the Hook Load hydraulic signal is connected to the first pressureconnection on the Pressure Transducer Assembly. This connectionattaches to a 0-1000 psi transducer. Pump Pressure and Power Tong bothrequire 0-5000 psi transducers, located in the middle and third position.



3-9-4-1 Hook Load Sensor

Connecting the hook load channel requires routing stainless steel tubing or a high pressure hydraulic hose from the deadline anchor sensor to the Pressure Transducer Assembly (Section 3-9-4). The Hook Load transducer within the assembly will convert the hydraulic signal generated by the deadline sensor into a 4-20mA signal.

Since the driller relies on the weight indicator for Hook Load (and in some cases, the same hydraulic system may be used to run the automatic driller), any loss of hydraulic fluid or leaks caused during transducer connection would be extremely serious. Therefore, care must be taken to avoid loss of hydraulic fluid, introducing air into the system, or causing leaks by damaging any hydraulic lines or fittings. Additionally, the hydraulic tubing or hose must not interfere with the movement of either the dead line or the anchor. Always check for leaks in the hydraulic system after the transducer assembly is installed.

Figure 3-23. Hook Load Sensor Installation

3-9-4-2 Pump Pressure Sensor

The following installation procedure describes how to install a mud pump pres-sure diaphragm. If the rig already has a mud pump pressure diaphragm mounted on a standpipe, simply route high pressure stainless steel tubing or a high pres-sure hose to the Pressure Transducer Assembly (Section 3-9-4). Within the Transducer Assembly, a 5,000 PSI transducer will convert the hydraulic signal generated by the pump pressure diaphragm to a 4-20mA signal for the DAQ.

1. Connect diaphragm to hydraulic hand pump. Add hydraulic fluid while holding output valve open until all air is bled from line and diaphragm.



2. Release valve and continue pumping while observing bottom of diaphragm. Pumping should continue until diaphragm is almost totally collapsed. Do not overpressure diaphragm.

3. Connect diaphragm to standpipe.

4. Route high pressure tubing or hose from the diaphragm to the drillers console. Figure 3-25

5. Connect the tubing or hose to pressure input side of the Pressure Transducer Assembly. The pump pressure connection is located in the middle of the three possible connections. (Figure 2-4-1)

6. Recheck all hydraulic and electrical connections for security and ensure that installation does not interfere with normal rig operations.

Figure 3-24. Pump Pressure Sensor Installation

Figure 3-25. Pump Pressure Sensor to DAQ Wiring

WARNING

Ensure that the driller is aware of pending standpipe break and have drillerclose valve to point of connection to prevent escape of drilling mud.



3-9-4-3 Rotary RPM Sensor Installation

The rotary RPM sensor responds when ferrous metal is in close proximity to it when metal enters the sensing area, the circuit current drops and produces a pulse. For this installation, a target is attached to an exposed bolt located on the coupling located between the transmission and the rotary table. The coupling rotates a known number of times for each rotation of the rotary table. The sensor is installed so that the target passes within the sensing range of the probe when the rotary table is turning.

Figure 3-26. RPM Proximity Installation

Install the rotary RPM sensor as follows:

1. Remove the rig floor cover which covers the motor and transmis-sion drive for the rotary table.

2. Attach a 1" to 2" metal target to one of the exposed bolts on the coupling between the transmission and the rotary table. Refer to Figure 3-27.

Figure 3-27. Proximity Target Installation



3. Secure a bracket to the rig sub-floor and attach the sensor. Make sure to locate the bracket so that the sensor when attached will intersect the coupling target. Using the adjustment nuts on the sensor, adjust the sensor so that the sensing end passes within 3/16 to 3/8 inch of the target. Probe must be moved as close as possible to ensure accurate RPM counts. Refer to Figure 3-28.

Figure 3-28. Proximity Bracket Installation

4. Run signal cable and connect to rotary sensor and DAQ as shown in Figure 3-29.

5. Recheck all mechanical and electrical connections for security and ensure that installation does not interfere with normal rig operations. Replace the rig floor cover.

Figure 3-29. Rotary RPM Sensor to DAQ Wiring

NOTE

Sensor cable must not be run next to or near rig power cables. This couldcause the system to pickup erroneous signals and cause problems with therotary RPM channel.



3-9-4-4 Rotary Torque Sensor Installation

A current transducer is available for use as an electrical rotary torque sensor. When clamped around the correct DC motor leads, the split core transducer senses the amount of current used by the motor. The amount of current used varies in direct proportion to the amount of torque developed by the motor at any given time. The following procedure describes how to rig an electrical rotary torque channel using a current transducer

Use extreme caution when handling power cables and connectors. Power cables in electric drive motor circuits carry dangerously high voltages. When possible, shut off power before handling cables.

1. Install transducer by clamping two sections around positive motor lead with red dots pointing toward most positive segment current source of cable (not toward drive motor). Use electrical tape to prevent transducer from sliding along cable.

2. After installing transducer, run rotary torque signal cable from transducer to DAQ. Route cable away from walkway and sharp corners where excessive wear to cable insulation could occur. Avoid wet locations if possible and tie cable runs with plastic tie wraps.

3. Connect cables between transducer and DAQ as shown in Figure 3-30.

4. Recheck all electrical connections for security and ensure that installation does not interfere with normal rig operations.

NOTE

Do not install transducer on any cable carrying current used for reversingmotor direction as transducer only senses current flow in one direction.

NOTE

The transducer window hole is designed to fit a cable with a diameter upto two inches (50.8 mm). The transducer body red dots indicate positivepolarity and must face the most positive segment of the cable.



Figure 3-30. Rotary Torque Sensor to DAQ Wiring

3-9-5 EDMS Drawworks Encoder Sensor

The EDMS Drawworks Encoder sensor detects movement of the block via the drawworks. Refer to the below figures for installation information.

Figure 3-31. EDMS Drawworks Encoder Wiring



Figure 3-32. EDMS Drawworks Encoder Installation

NOTE:

Only (1) Encoder is required.



3-10 Mini DRILLWATCH DIGITAL OUTPUTS

The DAQ can be used to drive other instruments, such as chart recorders or meters, via the field termination board digital connectors (Figure 3-12). This output can be in the form of a 10 VDC alarm signal or it can operate an analog device with a 0-10 VDC pulse-width modulated level. Fig-ure 3-33 shows typical digital output wiring.

Figure 3-33. Typical Digital Output Wiring

NOTE

Each digital connector can be used for input or output, but not both.



3-11 SYSTEM POWER-UP

Follow the steps below to power-up a Mini DRILLWATCH system.

1. Open DAQ rear door.

2. Ensure ac power cord is plugged in to ac source and source is energized; then set power ON/OFF switch to ON position (Figure 3-4).

3. Ensure that the communications LED and analog processor LED on DAQ digital board are blinking (Figure 6-4).

4. Check for the following:

• The red LED’s D1 and D2 on the SIF PCB should flash continuously.• Data should be displayed on Mini DRILLWATCH display panel

5. Close DAQ rear door.

6. If a VIP Workstation is present, turn on power to PC and to printer. Verify that data displayed on workstation monitor is consistent with that on display panel.



4-1 INTRODUCTION

Configuration and Calibration Software is used to load the Mini DRILLWATCH configuration, edit the configuration (if necessary) and calibrate sensor inputs and digital output channels (if used). This chapter contains the following:

• Description of standard Mini DRILLWATCH configuration channels • Procedures for starting up the Configuration & Calibration software and loading

the Mini DRILLWATCH configuration• Procedures for editing the Mini DRILLWATCH configuration• Procedures for calibrating analog and digital sensor channels and outputs (if used)• Procedures for saving the configuration/calibration to disk

Figure 4-1 shows the recommended configuration and calibration procedure.

Figure 4-1. Recommended Mini DRILLWATCH Config and Cal Procedure

Initialize Configuration & Calibration Software (Paragraph 4-3)

Load the Mini DRILLWATCH Configuration from Disk (Paragraph 4-4)

Edit Mini DRILLWATCH Configuration to Match Rig Configuration, if necessary (Paragraph 4-5)

Calibrate Digital Sensor Channels (Paragraph 4-6-3)

Save Configuration & Calibration to Disk (Paragraph 4-7)

Calibrate Analog Sensor Channels (Paragraph 4-6-2)

Calibrate EDMS (Paragraph 4-6-3)


CHAPTER 4 MINI DRILLWATCHCONFIGURATION & CALIBRATION Manual XC-132

4-2 Mini DRILLWATCH CHANNELS

The standard Mini DRILLWATCH configuration contains 29 channels that either represent display fields (i.e., the RETURN FLOW channel represents the RETURN FLOW field) or are used to cal-culate display field values. Each channel is assigned a logical channel number, which the software uses to identify the channel.

Table 4-1 describes each Mini DRILLWATCH channel and Table 4-2 lists the default sensor type and required configured channels for each. Table 4-3 lists default Mini DRILLWATCH outputs, which can be used to drive other devices, such as chart recorders or meters. Table 4-4 and Table 4-5 list calibration defaults for standard Mini DRILLWATCH systems.

Table 4-1. Channel Descriptions: Standard Mini DRILLWATCH Configuration

Logical Channel # Channel Name Description

001 HOOK LOAD Total load suspended from the Hook. Displayed in KiloNewtons times 10.

002 BIT WEIGHT The weight on the Bit. Displayed in KiloNewtons times 10.

003 BIT ROP Rate of Penetration displayed in Meters per Minute or Meters per Hour.

005 DEPTH OF HOLE The distance between ground level and the bottom of the well bore.

011 PIPE TORQUE Rotary torque applied to the drill pipe. Displayed in KiloNewton Meters.

012 PIPE RPM Revolutions per minute of the drill pipe.

013 TONG TORQUE Force value generated by the Power Tong for "making" or "break-ing" drill pipe and casing. Displayed in KiloNewton Meters.

016 PUMP PRESS Force value for selected Pump 1 or Pump 2. Displayed in MPa.

020 COUNTER A The number of strokes of all active mud pumps in the indicator field labeled "COUNTER A".

022 SPM 1 The rate of Mud Pump 1, in strokes per minute

023 SPM 2 The rate of Mud Pump 2, in strokes per minute

029 TOTAL SPM The combined rate of all active mud pumps in the indicator field labeled TOTAL RATE

032 STROKES 1A The number of strokes of Mud Pump 1 since the STROKES 1A channel was activated. These pump strokes are included in the number of strokes displayed in the COUNTER A field.

033 STROKES 2A The number of strokes of Mud Pump 2 since the STROKES 2A channel was activated. These pump strokes will be included in the number of strokes displayed in the COUNTER A field.

055 RETURN FLOW The rate of mud flow leaving the hole, in percent of the flow line fill volume.


MINI DRILLWATCH CHAPTER 4Manual XC-132 CONFIGURATION & CALIBRATION

Table 4-2. Standard Mini DRILLWATCH Channel Configuration Information

Logical Channel # Channel Name Sensor Type Required Configured Channels

001 HOOK LOAD CURRENT LINES STRUNG

003 BIT ROP DERIVED SFM BITROP

005 HOLE DEPTH DERIVED BIT ON BOTTOM, BIT POSITION, HOLE DEPTH reset

011 PIPE TORQUE DERIVED DSI SELECT TD RT, TOP DRIVE TORQUE, ROTARY TORQUE

012 PIPE RPM DERIVED DSI SELECT TD RT, TOP DRIVE RPM, ROTARY RPM

013 TONG TORQUE CURRENT --

016 PUMP PRESS CURRENT --

020 COUNTER A DERIVED STROKES 1A, STROKES 2A, DRILL/TRIP, RETURN FLOW

022 SPM1 RATE --

023 SPM2 RATE --

029 TOTAL SPM DERIVED SPM 1, SPM 2

032 STROKES 1A EVENT --

033 STROKES 2A EVENT --

055 RETURN FLOW VOLTAGE --

Table 4-3. Mini DRILLWATCH Default Output Assignments: Standard Configuration

Channel Name DAQ Connector Output Type Low Scale High Scale

SPM1 J1D ANALOG (CHART) 0 300

SPM 2 J3D ANALOG (CHART) 0 300

PIPE TORQUE J6D ANALOG (CHART) 0 300

PIPE RPM J8D ANALOG (CHART) 0 300

ROTARY TORQUE J10D ANALOG (CHART) 0 300

RETURN FLOW J12D ANALOG (CHART) 0 100



.

4-3 CALCONFIG SOFTWARE START-UP

The Configuration & Calibration software is downloaded from a laptop PC’s hard drive to theDAQ. Follow the steps below to connect the laptop PC to the DAQ and initialize the software

1. Connect the calibration cable assembly between the laptop 9-pin serial port and the DAQ connector labeled “CAL.CONFIG” (Figure 4-2).

2. Turn the laptop PC on. Windows 95® will automatically load. Double-click on the CALCONF Icon.

3. The hard drive is accessed and checked for configuration units, and the Configuration and Calibration Main Menu is displayed (Figure 4-3).

Figure 4-2. Laptop PC Connection to DAQ

NOTE

The CALCONF screens shown in this manual are for example only.Channel names may be depicted which are not applicable to your system.



Figure 4-3. Configuration & Calibration Main Menu Screen

4-4 LOADING THE Mini DRILLWATCH CONFIGURATION FROM DISK

The Mini DRILLWATCH system configuration files are located on the hard drive of the laptop PC. These files provide a complete description of all system components, including sensors, algo-rithms and numerical constants used by Mini DRILLWATCH software.

For standard Mini DRILLWATCH systems (i.e., those that contain only the channels listed in Table 4-1), the system configuration files are named Mini DRILLWATCH. For non-standard Mini DRILLWATCH systems, the files are assigned a unique name, typically related to the rig or customer.

Upon initial start-up, follow the steps below to load the configuration files.

1. Select DISK: [LOAD ALL] from the Configuration and Calibration Main Menu screen (Figure 4-4). A submenu listing the configuration file(s) is displayed (Figure 4-5).

2. Highlight the name of the appropriate configuration and then press ENTER. Down-loading begins and a series of messages like those shown below is displayed.

3. When downloading is complete, the Configuration and Calibration Main Menu screen is redisplayed. Proceed to Section 4-5 if it is necessary to edit the configuration. Oth-erwise, proceed to Section 4-6 to calibrate the sensor channels.

DISK:



nd of

Figure 4-4. DISK: [LOAD ALL] Menu Screen

4-5 CONFIGURATION

The Mini DRILLWATCH configuration should only be edited if:

• The default channel output low and/or high scale values are not correct for the device used (or)

• The option channel must be configured.

The following procedure summarizes how to edit the system configuration if the first or secocondition listed above exists. To configure the option channel or for a thorough explanationhow to edit configurations, refer to Manual 60-40.

1. From the Main Menu screen, select TOOLS: [CONFIGURATION]. A submenu is dis-played (Figure 4-5).

2. Select SYSTEM/DAQ. The SYSTEM/DAQ CONFIGURATION screen (Figure 4-6) is displayed.

3. Select CHANNEL, SENSOR, & OUTPUT: [EDIT]; a submenu of channel names is displayed.

NOTE

The Mini DRILLWATCH configuration must be edited if it differs in any wayfrom the actual rig configuration. Erroneous data may result if theconfiguration is not updated to reflect the rig configuration.

DISK:



4. Select the name of the channel to edit. The Channel Configuration screen is displayed (Figure 4-7).

5. Edit the pertinent field(s) on the Channel Configuration screen.

6. When all edits have been made, press the [Esc] key, or highlight QUIT and press ENTER. The SYSTEM/DAQ CONFIGURATION screen is displayed. To edit another channel, repeat Step 4 and Step 5.

To exit Configuration mode, press the [Esc] key; the submenu is closed. Press the [Esc] key again. The following message is displayed:

7. To send the changes to the DAQ and overwrite the previous DAQ configuration, select SEND. The Main Menu screen is displayed when the new configuration has been sent to the DAQ.

To keep the existing DAQ configuration and exit to the CONFIGURATION submenu (Figure 4-5), select ABORT.

NOTE

If ABORT is selected, the configuration edits made in Step 5 are still storedin the calibration laptop, even though they have not been sent to the DAQ.



Figure 4-5. [CONFIGURATION] Submenu

Figure 4-6. SYSTEM/DAQ CONFIGURATION Screen

DISK:

DISK:



Figure 4-7. Typical Channel Configuration Screen

4-6 CALIBRATION

In standard Mini DRILLWATCH systems, the following sensor channels require analog calibra-tion:

• Hook Load channel• Pump pressure channels• Rotary torque channel• Top drive RPM channel• Top drive torque channel• The RETURN FLOW channel

The sensor channels listed below require digital calibration:

• Rotary table RPM channel• All active SPM channels• All active STROKES channels• EDMS system

The following paragraphs explain how to perform analog, digital, and EDMS calibration.



en any

nd re

4-6-1 Analog Sensor Channel Calibration

The output from the mud flow sensor is continuous and proportional to the quantity being measured. Analog calibration defines the relationship between sensor output and data val-ues in engineering units. This is accomplished by specifying the four values listed below:

• Raw Minimum - the number of sensor counts when the sensor is at mini-mum output

• Value Minimum - the engineering units value corresponding to Raw Minimum

• Raw Maximum - the number of sensor counts when the sensor is at max-imum output

• Value Maximum - the engineering units value corresponding to Raw Maximum

In the following procedure, Raw Minimum is determined first, then Value Minimum, thRaw Maximum, then Value Maximum. However, these values may be determined inorder.

Table 4-4 lists the default DAQ connector number and default Raw/Value Minimum aRaw/Value Maximum values for each analog sensor channel. Refer to this table befobeginning calibration.

Table 4-4. Calibration Defaults: Mini DRILLWATCH Analog Sensor Channels

Mini DRILLWATCH Defaults

ChannelName

DAQ Analog

Connector

Raw Min

(Counts)

Raw Max

(Counts)

Value Min

(Units)

Value Max

(Units) Units

HOOK LOAD J2A 0 10000 0 KNs

RETURN FLOW J3A 0 10000 0 100 %

PUMP PRESS 2 J4A 0 10000 0 5000 MPa

PUMP PRESS 1 J6A 0 10000 0 5000 MPa

POWER TONG J8A 0 10000 0 5000 KN M

TOP DRIVE RPM J9A 0 10000 0 UNITS

TOP DRIVE TORQUE

J11A 0 10000 0 KN M

ROTARY TORQUE (Sensor A)

J13A 0 10000 0 1000 UNITS

ERT POWER(Sensor A)

J15A 0 10000 0 1000 AMPS

ROTARY TORQUE(Sensor B)

J17A 0 10000 0 1000 UNITS

ERT POWER(Sensor B)

J19A 0 10000 0 1000 AMPS



Follow the steps below to calibrate the RETURN FLOW, HOOKLOAD, PUMP PRES-SURE, POWER TONG TORQUE and ROTARY TORQUE sensor channels.

1. Ensure sensor wires are connected to the default Mini DRILLWATCH DAQ connectors; if not, either reconnect the wires to agree with the defaults or modify the configuration (Section 4-5).

2. From the Configuration & Calibration Main Menu (Figure 4-3), select TOOLS: [CALIBRATION] and press ENTER. The SYSTEM CALIBRA-TION SOFTWARE screen (Figure 4-8) is displayed.

3. Highlight [CHANNELS] and press ENTER. A submenu of channels is dis-played (Figure 4-9).

4. Use the arrow keys to highlight the channel name and press ENTER. The Channel Calibration screen is displayed (Figure 4-10), with default minimum and maximum values listed.

The current sensor reading in raw counts and in engineering units is presented on the line labeled CURRENT READING. The CALIBRATION MIN and CALIBRATION MAX values are used to calculate the current sensor reading in engineering units.

5. Set the sensor to minimum output. For the mud flow sensor, this is with no mud flowing and the paddle down (position “A”, Figure 3-13).

Figure 4-8. SYSTEM CALIBRATION SOFTWARE Screen



Figure 4-9. CALIBRATION [CHANNELS] Submenu

Figure 4-10. Typical Analog Calibration Screen



M

-

ue is

6. With the sensor at minimum output, view the raw counts displayed next to CURRENT READING. When the reading stabilizes, or you have a good esti-mate of what the minimum raw counts should be, highlight RAW MIN and press ENTER. The “Raw Minimum” Calibration screen is displayed (Figure 4-11).

The CURRENT RAW MINIMUM VALUE field lists either raw counts from the previous calibration or the default minimum raw counts. The NEW RAW MINIMUVALUE field lists the sensor output, in raw counts, at the time RAW MIN was selected.

7. To accept the NEW RAW MINIMUM VALUE, press ENTER.

To enter a different NEW RAW MINIMUM VALUE, type in the value, up to 6 numbers, and press ENTER.

The Channel Calibration screen is displayed and the specified Raw Minimum valdisplayed on the CALIBRATION MIN line.

Figure 4-11. Typical “Raw Minimum” Calibration Screen

8. Select VALUE MIN from the Channel Calibration screen and press ENTER. The “Value Minimum” Calibration screen is displayed (Figure 4-12). The CURRENT MINIMUM VALUE lists either the value minimum from the pre-vious calibration or the default value minimum. The NEW MINIMUM VALUE field lists the current value sent from the DAQ, in engineering units, that corresponds with the raw minimum.



9. To accept the NEW MINIMUM VALUE, press ENTER.

To enter a different NEW MINIMUM VALUE, type in the new value and then press ENTER.

The Channel Calibration screen is displayed and the specified Value Minimum is dis-played on the CALIBRATION MIN line.

10. Set the sensor to its maximum output. For the mud flow sensor, this is when the paddle is up 90o from the down position, as illustrated by position “B” in Figure 3-13.

Figure 4-12. Typical "Value Minimum" Calibration Screen

11. With the sensor at maximum output, view the raw counts displayed next to CURRENT READING. When the reading stabilizes, or you have a good esti-mate of what the maximum reading should be, highlight RAW MAX and press ENTER. The “Raw Maximum” Calibration screen is displayed (Figure 4-13).

NOTE

Zero is the recommended Value Minimum for RETURN FLOW,HOOKLOAD, PUMP PRESSURE, and ROTARY TORQUE sensorchannels.



r-Max-

s dis-

The CURRENT RAW MAXIMUM VALUE field lists either the maximum raw counts from the previous calibration or the default maximum raw counts. The NEW RAW MAXIMUM VALUE field lists the sensor output, in raw counts, at the time RAW MAX was selected.

12. To accept the NEW RAW MAXIMUM VALUE, press ENTER.

To enter a different NEW RAW MAXIMUM VALUE, type in the value, up to 6 num-bers, and press ENTER.

The Channel Calibration screen is displayed and the specified Raw Maximum value is displayed on the CALIBRATION MAX line.

Figure 4-13. Typical "Raw Maximum" Calibration Screen

13. Select VALUE MAX from the Channel Calibration screen and press ENTER. The “Value Maximum” Calibration screen is displayed (Figure 4-14).

The CURRENT MAXIMUM VALUE field lists either the value maximum from theprevious calibration or the default. The NEW MAXIMUM VALUE field lists the curent value sent from the DAQ (in engineering units) that corresponds to the Raw imum.

14. To accept the NEW MAXIMUM VALUE, press ENTER.

To enter a NEW MAXIMUM VALUE, type in the new value and press ENTER.

The Channel Calibration screen is displayed and the specified Value Maximum iplayed on the CALIBRATION MAX line.



15. When the channel is calibrated, highlight QUIT and press ENTER. The SYSTEM CALIBRATION SOFTWARE [CHANNELS] submenu is dis-played (Figure 4-9).

16. Repeat Steps 4 through 15 to calibrate each analog sensor channel. Then pro-ceed to either digital calibration (Section 4-6-2) or exit calibration and save the configuration/calibration to disk (Section 4-7).

Figure 4-14. Typical "Value Maximum" Calibration Screen

4-6-2 Digital Sensor Channel Calibration

All standard Mini DRILLWATCH digital channels measure pump strokes and rotary table rotation. For each channel, one digital sensor output (pulse) represents one measured event (i.e. pump stroke). Table 4-5 lists the default DAQ connector number and units for each Mini DRILLWATCH digital sensor channel. Refer to this table before beginning calibra-tion.

Follow the steps below to calibrate digital sensor channels.

1. Ensure sensor channels are assigned to their default DAQ connector (Table 4-4 and Table 4-5). If not, either reconnect the wires to agree with the defaults or modify the configuration (Section 4-5).

NOTE

For the RETURN FLOW channel, Value Max should be 100%.



ue

ayed,

the

yed

2. From the CALIBRATION [CHANNELS] submenu (Figure 4-9), select the channel name and press ENTER. The Channel Calibration screen is displayed (Figure 4-10).

On this screen, the CURRENT CALIBRATION RATE and the NEW CALIBRATION RATE fields list either:

• the default number of pulses per unit, which is "1", or• the previous number of pulses per unit, if the channel was previously cali-

brated

3. To accept the NEW CALIBRATION RATE, press ENTER and proceed to Step 4.

To enter a rate different from the NEW CALIBRATION RATE, type-in the new valand press ENTER. Then proceed to Step 4.

If the NEW CALIBRATION RATE (pulses per unit) is unknown, follow Steps a through d below.

a. Verify that the CURRENT CALIBRATION RATE is one pulse per unit.

b. Run the monitored device at a known rate and record the channel value displin engineering units.

c. Divide the value displayed by the rate at which the device is running to obtainnumber of pulses per unit for the channel.

For example: If the device is running at a rate of 100 and the channel value displais 200, then the NEW CALIBRATION RATE is two pulses per unit.

d. Type-in the calculated value from Step c for NEW CALIBRATION RATE and press ENTER.

Table 4-5. Calibration Defaults: Mini DRILLWATCH Digital Sensor Channels

Mini DRILLWATCH Defaults

ChannelName

DAQ Digital Connector Rate Units

SPM 1 J1D 1 Strokes per minute

SPM 2 J3D 1 Strokes per minute

R/T RPM J7D 1 RPM



4. Repeat Steps 2 and 3 to calibrate each digital sensor channel. Then proceed to either analog calibration (Section 4-6-1) or exit calibration and save the con-figuration/calibration to disk (Section 4-7).

Figure 4-15. Typical Digital Calibration Screen

4-7 SAVE CONFIGURATION/CALIBRATION TO DISK

Follow the steps below to save configuration and calibration data to disk.

1. Select DISK: [SAVE ALL] from the Configuration and Calibration Main Menu screen (Figure 4-3). A message similar to the following is displayed, where Mini DRILL-WATCH is the name of the configuration loaded from disk:

2. Type in the new name (maximum of eight characters) to assign to the data file and press ENTER. The rig name is the recommended file name.



A series of messages is displayed as the configuration/calibration data file is copied to disk.

3. When all data is copied to disk, the Configuration and Calibration Main Menu screen is redisplayed.

4. Highlight [QUIT] and press ENTER to exit the Configuration and Calibration soft-ware.

4-8 EDMS CALIBRATION

Use the Full Calibration procedure to calibrate TOTAL DAQs with E-DEPTH under the following conditions:

• At initial system installation• When the number of lines strung has changed• After a cut-and-slip, if the zero block position on the drawworks drum changes

layers• When the line diameter has been changed

Use the Recalibration procedure under the following conditions:

• After each cut and slip, provided the zero block position on the drawworks drum is on the same layer as in Full calibration

• After power outages that deplete the E-DEPTH battery backup

NOTE

Always assign a new name to the modified data file.

NOTE

DAQ analog boards, E-DEPTH boards and calibration switch boxesthat are not properly tested may not function properly. This will resultin improper tracking of block height, depth, and bit position. Using theprocedures provided in Service Bulletin No. 222, verify that the DAQand E-DEPTH are functioning together properly.



at the

4-8-1 Setting Up the System for Full Calibration

The following items are required to perform a full calibration:

• Calibration switch box (P/N 219255-001) and calibration cable assembly (P/N 219344-003)

• 100-foot tape measure• Calibration Worksheet (Table 3 on the last page of this Service Bulletin)• Laptop PC and calibration cable assembly (P/N 220082)• CALCONF rig configuration disk

Complete the following steps to set the system up for the full calibration procedure:

1. Open the back side of the DAQ and identify the digital board (Figure 1). Ver-ify that position 2 of SW2 on the digital board is set to OFF and that all others are ON, as shown in Figure 2. If not, turn the DAQ power switch to OFF, change the switch position(s) as needed, then turn the power switch to ON. Close the DAQ.

2. Connect cable assembly P/N 219344-003 to the calibration switch box.

3. Open the front side of the DAQ and connect the free end of cable assemblyP/N 219344-003 to the DAQ field termination board J1S connector, as shown in Figure 4-18.

You may need to remove (cut) the connector from the free end of the cable so thindividual wires can be connected to the termination board J1S connector.

4. Verify that the calibration switch box is functioning properly by simulta-neously pressing the L/C START and CONNECTION buttons shown in Fig-ure 4-19. Verify that the red LED is on (lighted).

5. Press the L/C START and CONNECTION buttons again and verify that the red LED is off.

NOTE

Some international locations may require a Hot Work Permit to use thecalibration switch box in a hazardous (certified) area. Determine whatthe local codes require before performing the calibration proceduresdescribed in this document.

NOTE

Completing Step 4 below will put the system in calibration mode andwill “set” the BLOCK HEIGHT reference position. Make sure that youwill not disrupt current drilling operations before you begin testing thecalibration switch box.



If the LED fails to come on or to go out, check the connections between the calibration switch box and the DAQ. If the calibration switch box is still not functioning properly after checking the connections, replace the calibration switch box.

Figure 4-16. DAQ Digital Board

Figure 4-17. DAQ PCB Switch Positions



Figure 4-18. Calibration Switch Box Connections

4-8-2 Recommended Block Height Calibration Points

When completing the following procedure, use the BLOCK HEIGHT calibration points that are shown in Table 4-7. Using these calibration points will optimize system performance. Also, when calibrating rotary table applications, you will get the best results if you use as much drill string weight as possible (this is in addition to having the Kelly disconnected).

NOTE

The values in Table 4-7 represent typical block heights when going inand out of slips during drilling and tripping operations. Alternate blockheight calibration points may be used, however, this may adverselyaffect E-DEPTH accuracy.

Table 4-6. Block Heights

Block Height Point 1 Point 2 Point 3 Point 4

Rotary Table 2 ft. 47 ft. 77 ft. 95 ft.

Top Drive 2 ft. 8 ft. 33 ft. 95 ft.



4-8-3 E-depth Sensor Calibration Procedure

The following procedure provides the steps necessary to calibrate the block height sensor while at the calibration switch box. The procedure is broken up into stages which should be completed in sequential order.

STAGE 1

Lower the elevators or bales so that they are near the rig floor and attach a 100-foot (or metric equivalent) tape measure to the bottom. The tape may be tie-wrapped to the drill string in areas of high wind to minimize measurement errors.

STAGE 2

1. Raise the blocks so that the wirerope on the drawworks is at the end of the first layer and is just beginning to wrap onto the second layer of wirerope.

2. Begin calibration by simultaneously pressing the L/C START and CON-NECTION buttons on the calibration switch box (see Figure 4-19). The red LED will light (Figure 4-19), indicating that the DAQ has entered calibration mode.

Figure 4-19. Calibration Switch Box

STAGE 3

Lower the blocks to the Point 1 Block Height shown in Table 4-7. After lowering the blocks, complete the following:

NOTE

To make sure the calibration is accurate, make all layer changemeasurements to within 6 inches (152.4 mm) of actual wrap change.



cks

n

1. Press and hold the CONNECTION button on the calibration switch box until the red LED goes out. Release the CONNECTION button and the LED will light again.

2. Measure the height of the block above a selected reference point on the rig floor, in feet or meters, rounded to two decimal places. Record this value in the BLOCK POSITION column of the Calibration Worksheet. (For example, if the measured block height is 2 feet 3 inches, you would record 2.25 feet).

3. Record “BH” (block height) in the corresponding Calibration Worksheet col-umn labeled LAYER CHANGE/ BLOCK HEIGHT.

Raise the blocks until the wirerope on the drawworks changes layers, or until the bloreach Block Height Point 2 in Table 4-7 (whichever occurs first). Then, complete the following steps:

1. For a drawworks wirerope layer change, press the calibration switch box L/C START button. The red LED will blink.

For a block height calibration point, press the calibration switch box CONNECTION button. The red LED will blink.

2. For the second Block Height calibration point, measure the height of the block above the designated point on the rig floor and record this value (round to two decimal places) in the BLOCK POSITION column of the calibration worksheet.

3. For the second Block Height calibration point, record “BH” in the corresponding Calibration Worksheet column labeled LAYER CHANGE/BLOCK HEIGHT. For a layer change, record “LC” (see Table 4-7 for an example).

4. Repeat Step 2 above for the Point 3 and Point 4 Block Heights in Table 4-7.

5. End the sensor calibration procedure by simultaneously pressing L/C START and CONNECTION buttons on the calibration switch box. The red LED will go out.

Proceed to the following CALCONF PROCEDURE to complete the full calibratioprocedure for a DAQ with E-DEPTH system.

NOTE

To make sure the calibration is accurate, make all block heightmeasurements in this procedure from the same reference point on therig floor and round all measurements to two decimal places.

NOTE

Press the L/C START button for all layer changes, including the initialstart calibration layer change from STAGE 2, Step 1.



.

4-8-4 CALCONF Procedure

After completing the E-DEPTH Sensor Calibration procedure, you need to complete this procedure to fully calibrate the DAQ with E-DEPTH system.

1. At the DAQ, connect the calibration cable assembly (P/N 220082) to the lap-top PC 9-pin serial port and to the connector labeled “CAL CONFIG” on the base of the DAQ.

2. Turn the laptop PC on. Double-click the CALCONF Icon.

3. The hard drive is accessed and the Main Menu screen (Figure 4-20) is displayed

Figure 4-20. CALCONF Main Menu

WARNING

The laptop PC is not approved for use in hazardous areas. Make surethat the DAQ is in a non-hazardous area or that no hazardous gasesare present before connecting the laptop PC to the DAQ.

DISK:



4. Highlight [CALIBRATION] and press ENTER. The System Calibration Soft-ware screen (Figure 4-21) is displayed.

Figure 4-21. System Calibration Screen

5. Highlight [EDMS] and press ENTER. Data gathered by the DAQ in STAGE 3 of the E-DEPTH Sensor Calibration procedure are downloaded and displayed on the EDMS Calibration screen (Figure 4-22). Note that the block height measurements recorded in the BLOCK POSITION column of the Calibration Worksheet are not displayed on this screen.

6. Verify that the sequence of numbered BLOCK HEIGHT and LAYER CHANGE entries matches that on the Calibration Worksheet. For example, if entries 0, 2, 4 and 6 are designated as “BH” on the Calibration Worksheet, then on the EDMS Calibration screen, entries 0, 2, 4 and 6 must be labeled BLOCK HEIGHT. If the sequences do not match, redo the E-DEPTH Sensor Calibration procedure, starting with STAGE 1.

NOTE

The EDMS Calibration screen may label the UNUSED points asCALCULATED points.



7. Verify the following:

• The units selected for “Calibration Factors” are the units in which the block measurements were recorded on the Calibration Worksheet (feet or meters). To select the correct units, highlight Calibration Factors and press ENTER. Then highlight the correct units from the submenu and press ENTER.

• The correct values are entered for cable diameter, lines strung and counts per wrap. If shaft encoder P/N 219062 is used, the counts per wrap must be 2000. If encoder P/N H12321A is used, the counts per wrap must be 625. To enter the correct values, highlight the desired field and type in the value.

• Ten Point Table #4 is selected. If it is not, highlight “Output” and press ENTER. Then highlight TEN POINT TABLE #4 from the submenu and press ENTER.

8. For each BLOCK HEIGHT entry on the EDMS Calibration screen, enter the corresponding block height value from the Calibration Worksheet. To enter a block height, highlight the default value (999.00) and type in the correct value. Figure 4-23 shows the relationship between the BLOCK HEIGHT on the EDMS Calibration screen and Calibration Worksheet.

NOTE

Enter the counts per wrap parameter exactly as the encoder usedspecifies. Entering any other value will introduce significant errorswhen CALCONF computes the UNUSED, LAYER CHANGE, andCALCULATED points in the ten-point table.

NOTE

Only those measurements designated as “BH” (block height) on theCalibration Worksheet must be entered on the EDMS Calibrationscreen. Table 2 shows a calibration sheet with the example valuesused in this procedure.



Figure 4-22. EDMS Calibration Screen

Table 4-7. Sample Calibration Worksheet

Entry Block PositionLayer Change/Block Height

EDMS Counts

0 2.10 BH

1 LC

2 46.30 BH

3 LC

4 76.25 BH

5 LC

6 96.10 BH

7

8

9

NOTE

EDMS Counts should be added to the above worksheet. Reference thisdata during future calibrations. Block Position will not have to be re-measured.



Figure 4-23. Block Height Position Changes

9. After all block height measurements have been entered, highlight [CALCU-LATE] and press ENTER. The EDMS Calibration screen is redisplayed with updated values.

10. Exit EDMS calibration by highlighting [QUIT] and pressing ENTER. The system displays the following message:

11. Highlight SEND and press ENTER. Messages are displayed as the calibration data is sent to the DAQ.

12. Exit Calibration by highlighting [QUIT] and pressing ENTER. The Main Menu is redisplayed (Figure 4-20).

DAQ ACCESS> <

ATTENTION> <

WOULD YOU LIKE TO SEND CALIBRATION DATATO THE DAQ?

OPTIONS> <SEND ABORT



13. DISK: [SAVE ALL]. A message similar to the following is displayed, where "SMITH-1" is the name of the last configuration loaded.

14. Assign a new file name to the updated configuration by typing in the name (up to eight characters); the rig name with a configuration version designator is recommended, such as “SMITH-2”. Messages are displayed as the data is copied to disk.

15. To verify that the block position is accurate, press the F3 key. A CHANNEL VALUES screen similar to the one shown in Figure 4-24 is displayed.

Figure 4-24. Channel Values Screen

16. Bring the elevators or bales to a known height and verify that the value dis-played on the CHANNEL VALUES screen for the BLOCK POSITION chan-nel is within 0.1' (30.5 mm) of the known block position. For example, if the known height is 30.5', displayed values of 30.4' to 30.6' are acceptable.

17. Calibration is complete. Press the [Esc] key to return to the Main Menu.

18. Exit CALCONF by highlighting [QUIT] and pressing ENTER.

CAUTION

Always assign a new name to the modified configuration file.

MENU> <

Enter filename: _ SMITH-1



4-8-5 EDMS Re-Calibration

Follow the steps listed below to calibrate the EDMS system using the Two-Point Calibra-tion procedure.

1. Move block until the drawworks drum has one complete layer. (This occurs when the first layer begins to change to the second layer.)

2. To zero EDMS, press 96 on the Mini DRILLWATCH Keypad and then press the ENTER key. (Refer to Figure 4-25 and Figure 5-3)

3. Lower the block until the elevators touch the drill floor.

4. To set the block position to zero, press 95 on the Mini DRILLWATCH Key-pad, enter the current block position (this should be zero, if elevators are touching the floor). Then press the ENTER key. (Refer to Figure 4-25 and Figure 5-3)

5. This completes the re-calibration.

A Calibration Worksheet is provided in Table 4-8 on the following page.

Figure 4-25. Mini DRILLWATCH Instruction Label



Table 4-8. Calibration Worksheet

Entry Block PositionLayer Change/Block Height

0

1

2

3

4

5

6

7

8

9


a is

CHAPTER 5OPERATION

5-1 INTRODUCTION

This chapter describes the Mini DRILLWATCH display panel, including:

• Data display• Keypad operation• Display panel fields• Function codes

5-2 Mini DRILLWATCH DATA DISPLAY

The data display portion of the Mini DRILLWATCH display panel is shown in Figure 5-1. Datpresented in two ways:

• Numerically - Up to six digits can be displayed for each field. • Graphically - Vertical bar graphs display data ranging from 0% to 125% of the

user-specified high alarm limit. In the example below, the user-specified high alarm limit is 200 and the high bar scale value is 125% of 200, or 250.

FIGURE 2

TABLE 2


CHAPTER 5 MINI DRILLWATCHOPERATION Manual XC-132

Figure 5-1. Mini DRILLWATCH Data Display

GRAPHICAL

DATA DISPLAY

FIELD NAMES

ACTIVEINDICATORS

NUMERICALDATADISPLAY

DISPLAY UNITS

INDICATORSACTIVE

FUNCTION CODES


MINI DRILLWATCH CHAPTER 5Manual XC-132 OPERATION

f each

is a ecific

tions

5-2-1 Active Indicators

Active fields are those whose data values are used to calculate the value of a derived field. For example, if MUD PIT 1, MUD PIT 2 and MUD PIT 3 are the only active mud pits, then the value displayed in the TOTAL ACTIVE VOLUME field represents the volume in pits 1, 2 and 3 only, even if additional mud pits are present.

The display panel identifies active fields in one of two ways:

• A dash is displayed in the field. In the example below, only tanks 1, 2, 3 and 4 are active.

• The entire field lights up. In the example below, only PUMP 1 is active.

Figure 5-2. Example screen

5-2-2 Field Names and Units

The name of each display field is etched above the field and the engineering units ofield are etched below. For example, BARRELS are the units for the TOTAL ACTIVEVOLUME field.

5-2-3 Function Codes

Each display panel field has one or more associated function codes. A function codeone- or two-digit code entered by the user to perform a specific action affecting a spfield. Function codes are used to:

• Zero field values• Change field values• Set high and low alarm limits• Activate/deactivate fields• Specify drill, trip-in or trip-out mode• Set time and date• Turn backlighting on/off

Function codes are etched on the display next to their associated field. Refer to Section 5-3 for instructions on entering function codes and to Section 5-4 for descripof each code.



5-3 KEYPAD OPERATION

The display panel keypad is located to the right of the data display. It is shown in Figure 5-3 and the keys are summarized in Table 5-1. The following paragraphs explain how to use the keypad to execute function codes.

Figure 5-3. Mini DRILLWATCH Keypad

Table 5-1. Summary of Keypad Keys

Key Function

0-9, (.) Press these keys to specify function codes, field values, alarm limits, etc.

ENT Press this key after specifying field values, alarm limits, etc., to imple-ment the values.

CLR Press this key to disregard a data entry or cancel a function code.

ALARM ACK Press this key to temporarily disable the alarm horn for a field in alarm. Note that pressing this key does not prevent the alarm horn from sounding if the field in alarm returns to normal and then later exceeds its alarm limits, or if a different field goes into alarm.

START ROP Press this key to start rate of penetration measurement.

ZEROBIT WT

Press this key to immediately set the value for BIT WEIGHT to zero.



5-3-1 Zero a Field Value

Follow the steps below to zero a field value.

1. Key in the function code for the affected field. The following occurs:

• The function code is displayed in the KEYBOARD CODE field.• The KEYBOARD ENTRY field displays the current value of the field

being zeroed.• The window of the affected field flashes.

2. Press the ENT key. The following occurs:

• The KEYBOARD CODE field clears.• The KEYBOARD ENTRY field displays the time.• The window of the affected field stops flashing.• The field value is set to zero.

For example: To zero COUNTER A STROKES:

1. Press the 1 key.

2. Press the ENT key.

5-3-2 Change Field Value

Follow the steps below to change a field value.


• The function code is displayed in the KEYBOARD CODE field.• The KEYBOARD ENTRY field displays the current field value.• The window of the affected field flashes.

2. Key in the new value. The KEYBOARD ENTRY field displays the new value.


• The KEYBOARD CODE field clears.• The KEYBOARD ENTRY field displays the time.• The window of the affected field stops flashing.• The new value is displayed.

For example: To change the value of COUNTER A STROKES:

1. Key in 10.

2. Key in the new value.


5-3-3 Change/View Alarm Limits

Follow the steps below to change or view a field’s high/low alarm limits.




D

are

• The function code is displayed in the KEYBOARD CODE field.• The KEYBOARD ENTRY field displays the current high or low limit.• The affected field flashes.

2. If the current alarm limit is satisfactory, press CLR to cancel the function.

If the current alarm limit is not satisfactory, key-in the new value. The KEYBOARENTRY field displays the new value.


• The KEYBOARD CODE field clears.• The KEYBOARD ENTRY field displays the time.• The affected field stops flashing.• The new alarm limit is now in effect.

For example: To change the high limit of PUMP RATE 1:

1. Key in 44.

2. Key in the new value.


5-3-4 Activate/Deactivate Fields

The procedures for activating/deactivating PUMP STROKES and PUMP SPM fieldspresented in the following paragraphs.

5-3-4-1 Activate/deactivate Pump Strokes/Pump SPM

1. Key in the appropriate function code. The following occurs:

• The function code is displayed in the KEYBOARD CODE field.

• The KEYBOARD ENTRY field clears.• The associated field flashes.

2. Press the ENT key to toggle the active status. The following occurs:

• The KEYBOARD CODE field clears.• The KEYBOARD ENTRY field displays the time.• The selected field is changed from active to inactive, or vice-

versa.For example: To change the active status of PUMP 1 for COUNTER A:

1. Key in 11.


5-3-5 Set Date and Time

Follow the steps below to set either the date or time.

1. Key in function code 98 (date) or 99 (time). The following occurs:

• The function code is displayed in the KEYBOARD CODE field.• The KEYBOARD ENTRY field clears.



2. Key in the date as MM DD YY or time as HH MM, based upon a 24-hour clock. The date/time is displayed in the KEYBOARD ENTRY field, as entered.

3. Press the ENT key. The date/time is set.

For example: To set the date:

1. Key in 98.

2. Key in the date. For example, key in 020193 for February 1, 1993.


For example: To set the time:

1. Key in 99.

2. Key in the time. For example, key in 1409 for 2:09 pm.


5-3-6 Switch Backlighting ON/OFF

Follow the steps below to switch the LCD backlighting on or off.

1. Key in 97. The function code is displayed in the KEYBOARD CODE field and the KEYBOARD ENTRY field clears.

2. Press the ENT key. Backlighting is changed from on to off, or vice versa.

5-4 DISPLAY PANEL FIELDS

The following paragraphs describe each display panel field and its related indicators and function codes. The fields are grouped by function, so that all fields related to tank volume are described as one group, all those that relate to SPM are described as another group, and so on.

5-4-1 Keyboard Fields

There are two KEYBOARD fields (Figure 5-4). The KEYBOARD CODE field displays the function code entered by the operator. The KEYBOARD ENTRY field typically dis-plays the following:

• Data regarding the status of the channel affected by the function code, at the time the code was entered. This may be the channel value, high or low alarm limit, tank number, etc.

• New values entered by the operator for the affected channel. This may include new channel values, high or low alarm limits, etc.

• The current time



Figure 5-4. KEYBOARD Fields

5-4-2 Return Flow

RETURN FLOW is used during drilling to monitor the rate of mud leaving the hole, in units of percent of the flow line fill volume. Under normal drilling conditions, RETURN FLOW should remain fairly constant.

RETURN FLOW is displayed numerically and graphically (Figure 5-5). The indicator field labeled RETURNS lights up whenever the RETURN FLOW exceeds 3%.

5-4-2-1 Function Code 53: SET HIGH

Enter this code to specify the maximum allowed RETURN FLOW. This value will depend upon whether the rig is in drill, trip in or trip out mode. If RETURN FLOW reaches this value, the RETURN FLOW bar graph and numerical display flash and the alarm horn sounds. Refer to Section 5-3-3 to set the high limit.

5-4-2-2 Function Code 54: SET LOW

Enter this code to specify the minimum allowed RETURN FLOW. This value will depend upon whether the rig is in drill, trip in or trip out mode. If RETURN FLOW reaches this value, the RETURN FLOW bar graph and numerical display flash and the alarm horn sounds, unless it is disabled (Section 5-4-4-1). Refer to Section 5-3-3 to set the low limit.



Figure 5-5. RETURN FLOW Fields

5-4-3 Counter A

COUNTER A (Figure 5-6) is used during drilling to continuously monitor pump strokes. The value displayed in the COUNTER A field represents the total number of strokes made by the pump(s) designated as "active" in the COUNTER A indicator field.

During tripping, these counters are used to monitor the number of pump strokes required to fill all or a part of the hole or to perform a particular task. They do this by counting strokes only while the RETURN FLOW is less than 3% (i.e., the RETURNS indicatoris on).

5-4-3-1 Function Code 1: SET ZERO

Enter these codes to zero the number of strokes counted by Counters A. When either code is entered, the corresponding counter is zeroed and then starts count-ing. Refer to Section 5-3-1 to zero a field.

5-4-3-2 Function Code 10: PRESET

Enter these codes to specify a starting number of strokes for Counters A; subsequent strokes will be added to this value. Refer to Section 5-3-2 to preset (change) the field value.

5-4-3-3 Function code 15: SET COUNTER ALARM

Enter these codes to specify the maximum number of strokes allowed for the pump(s) being monitored by Counter A. If the number of strokes reaches this value, the COUNTER field flashes and the alarm horn sounds. Refer to Section 5-3-3 to set the alarm value.



5-4-3-4 Function Codes 11 & 12: PUMP 1 & 2

Enter codes 11 or 12, to change the "active" status of pumps 1 or 2 for COUNTER A. The strokes of active pumps are included in the associated COUNTER field. For example, if COUNTER A is currently counting strokes for pump 2 and function code 11 is entered, COUNTER A will stop counting strokes for pump 2 and begin counting strokes for pump 1. Additionally the PUMP 2 indicator field will darken. Refer to Section 5-3-4-1 to change the "active" status of pumps.

Figure 5-6. COUNTER A Field

5-4-4 Pump Rates/Total Pump Rate

The PUMP RATE fields (Figure 5-7) are used during drilling to monitor the rate of each mud pump. The TOTAL RATE field is used during drilling to monitor the combined rate of all mud pumps designated as "active" in the TOTAL RATE indicator field. Individual and total pump rates should remain fairly constant during drilling.

5-4-4-1 Function Code 47: SET LOW FLOW ALARM DISABLE

Use this function code to enter a TOTAL RATE value below which the RETURN FLOW low alarm is disabled. This prevents the RETURN FLOW low alarm from sounding due to low or 0% RETURN FLOW when the pumps are slowed or stopped. Refer to Section 5-3-3 to set the LOW FLOW ALARM DIS-ABLE pump rate.

ACTIVE PUMP INDICATORSFOR COUNTER A



Figure 5-7. PUMP RATE Fields

5-4-5 Depth Of Hole

The Depth of Hole field us used to display the current depth of the hole. Units are in feet.

5-4-5-1 Function Code 65: SET DEPTH OF HOLE

Enter this code to allow you to set the depth of the hole. Use the keypad to enter the depth of the hole.

Figure 5-8. Depth of Hole Field

ACTIVE PUMPINDICATORSFOR TOTAL RATE





6-1 INTRODUCTION

This chapter contains periodic inspection procedures for Mini DRILLWATCH devices and sen-sors, a troubleshooting table and list of initialization codes for the Mini DRILLWATCH system. For parts lists and illustrations depicting component locations, refer to Chapter 7 or to the related device manual.

6-2 PERIODIC INSPECTION OF Mini DRILLWATCH DEVICES

Perform the following checks weekly. Always complete these checks before performing more extensive repairs.

• Verify that primary power is supplied to all units and that it is the power required by the unit (Table 2-1).

• Check for loose, crushed, frayed, cut or otherwise damaged cables.• Check wiring connections for loose or broken leads.• Ensure that all ground connections are secure and free of corrosion.• Ensure all component mounting bolts are securely fastened.• Verify that all components are properly interconnected and seated in their mating

connector or socket.• Check all enclosures for moisture ingression; correct as needed.

6-3 PERIODIC INSPECTION OF Mini DRILLWATCH SENSORS

Perform the following sensor checks as recommended.

• Ensure that all strain reliefs are secure and that all strain relief connections are not stressed.

• For mud flow sensors, periodically perform the following:1. Flush out the flow pipe to prevent mud build-up, as this can cause sensor mal-

function or result in incorrect readouts.

2. Verify that the paddle arm swings full span under no-flow conditions. If it does not, remove flow sensor from base and flush out all lodged-in cuttings or other obstructions.


CHAPTER 6 MINI DRILLWATCHMAINTENANCE Manual XC-132

6-4 TROUBLESHOOTING TABLE: Mini DRILLWATCH SYSTEM

Table 6-1 lists problems that might be observed in a Mini DRILLWATCH system. For each prob-lem, the table lists the probable cause(s) and corrective action(s), in order of most likely to least likely. The paragraphs following Table 6-1 contain information needed to perform the corrective action(s).

Table 6-1. Troubleshooting Table: Mini DRILLWATCH System

Observed Problem Probable Cause Corrective Action

DAQ not functioning 1. No power to system 1. Check and correct AC power source.

2. Blown fuse 2. Replace fuse.

3. Defective power supply 3. Check power supply according to procedure in Section 6-4-1.

Display panel blank, dim, or displays blinking 8’s

1. Defective DAQ power supply.

1. Check power supply according to procedure in Section 6-4-1.

2. Incorrect jumper setting on SIF board.

2. Compare configuration of SIF I/O board jumpers with Table 6-2; correct if needed.

3. SIF board failure 3. Verify that +16V is present on JP6-3. Replace board if needed.

4. Incorrect or faulty wiring between DAQ and dis-play panel.

4. Verify wiring per Figure 3-9 and cor-rect if needed.

5. Display panel power barrier failure

5. Check H10992A-768P barrier by dis-connecting it from the circuit and verifying 150-185 ohms between terminals 1 and 3 and terminals 2 and 4. Replace barrier if needed.

6. ISMI module failure. 6. Check display panel controller boards (Figure 6-3) for +6 V mini-mum between TB1-1 and TB1-2. Replace ISMI module, if needed (Figure 7-3).

7. Display controller board failure

7. Replace display controller board or display board, as required.

Display panel displays dashes or bars

1. No communication between SIF and DAQ

1. If red T-POT communications LED D1 on the SIF (Figure 6-2) is not flashing, perform checks 2 through 7 below. If LED is flashing, go to check 8.

2. DAQ not configured for Spectrum Interface

2. Connect laptop PC to DAQ and use Manual 60-40 to check SYSTEM DAQ configuration and Spectrum Interface configuration; correct if nec-essary.


MINI DRILLWATCH CHAPTER 6Manual XC-132 MAINTENANCE

3. Incorrect SIF device I.D. 3. Ensure that SIF device I.D. designated by jumper settings on JP3 of SIF board (Figure 6-2) is same as that assigned to spectrum interface in DAQ configuration software. Correct jumpers if needed. (see Table 6-3)

4. Incorrect T-POT net-work baud rate

4. Ensure that T-POT network baud rate designated by jumper JP4 on SIF board is same baud rate that DAQ is configured. (see Table 6-4)

5. Faulty DAQ power supply

5. Check power supply according to Section 6-4-1.

6. Incorrect or faulty wir-ing between DAQ and display

6. Verify wiring per Figure 3-9 and cor-rect if needed.

7. Incorrect jumper setting on SIF board

7. Verify jumper settings per Table 6-3; correct if needed.

8. SIF processor malfunc-tion

8. Press reset push button S1 on SIF. Refer to Table 6-7 and verify the INIT Code displayed in the display panel KEYBOARD DATA field.

9. Display panel commu-nication barrier failure

9. Check both H10992A-787S barriers by disconnecting them from the circuit, then verifying 300-340 ohms between terminals 1 and 3 and veri-fying that the diode return channel between terminals 4 (anode) and 2 (cathode) is functional. Replace barriers if needed.

10. Display panel ISMI mod-ule failure

10. Move communication connector in J2 to backup circuit J3. If this corrects the problem, replace the ISMI mod-ule (Figure 7-3).

11. Display panel controller board malfunction

11. Check controller board SW1 settings (Figure 6-3); correct if needed.

12. If SW1 settings are correct and problem persists, replace SIF board. If problem persists, replace faultydisplay controller board or display board.

Table 6-1. Troubleshooting Table: Mini DRILLWATCH System (Continued)




Display panel values are erratic or incorrect, or one field shows dashes.

1. Incorrect SIF device I.D. 1. Check to see if SIF device I.D desig-nated by jumper JP3 (Figure 6-2) is same as that assigned to SIF in DAQ configuration software. Correct jump-ers if needed (see Table 6-3).

2. Incorrect Spectrum con-figuration.

2. Connect laptop PC to DAQ and use Manual 60-40 to check SYSTEM DAQ configuration and SIF configu-ration; correct if needed.

3. DAQ analog processor malfunction

3a. Check DAQ digital board “analog processor” LED (Figure 6-4). If LED is off or on steady (not blinking) pro-ceed to Step 3b. If LED is blinking, proceed to Step 4.

3b. Press analog processor reset (SW4, Figure 6-4). If problem persists, pro-ceed to Step 3c.

3c. Press main and analog processor resets, SW1 and SW4. If problem persists, go to Step 3d.

3d. Place position 8 on SW2 to OFF. Press both processor resets, SW1 and SW4; then place SW2 position 8 to ON. If problem persists, replace DAQ analog board and reload Mini DRILLWATCH configuration to DAQ.

4. DAQ digital processor malfunction

4a. Check DAQ digital board “watch-dog timer” LED. If LED is off or not blink-ing steady, go to Step 4b. If LED is blinking steady, go to Step 5.

4b. Turn main power to DAQ off and wait 5 seconds; then turn main power to DAQ on. If problem persists, go to Step 4c.

4c. Place position 8 on SW2 of digital board to OFF. Press both processor resets, SW1 and SW4; then place SW2 position 8 to ON. If problem persists, replace DAQ digital board and reload Mini DRILLWATCH configuration to DAQ.





Display panel values are erratic or incorrect, or one field shows dashes (Continued)

5. Faulty channel config-uration or calibration.

5. Compare sensor channel raw counts to engineering units. If raw counts OK and corresponding engineering units do not mimic raw counts, check channel configuration and correct if needed. If problem persists, recali-brate sensor channel.

6. Voltage/current rocker switch on DAQ field termination board set incorrectly

6. Verify if rocker switch setting agrees with sensor output (Figure 3-12); cor-rect if needed.

7. Faulty sensor connec-tion

7. Ensure all sensor connections are secure and correct. Correct if needed; then reconfigure and recali-brate sensor channel.

8. Faulty connector on DAQ field termination board

8. Connect sensor to a different con-nector; then reconfigure and recali-brate sensor channel.

9. Sensor malfunction 9. Replace sensor.

No backlighting on display panel

1. Backlighting turned off by software

1. Enter function code 97 at display keypad. Replace SIF board if needed.

2. Insufficient voltage from SIF PC Board

2. Verify +24V is present at TB6-1 of SIF board. If +24 VDC not present, check DAQ 28 volt power supply and connection between power supply and SIF board. If power supply and connections are not faulty, check SIF board. Replace if needed.

3. Incorrect jumper setting on SIF board.

3. Check configuration of jumpers according to Table 6-3 and correct if needed.

4. Faulty wiring between DAQ and display panel

4. Check wiring per Figure 3-9 and cor-rect if needed.

5. Display panel back-lighting barrier failure

5. Check both H10992A-779P barriers and verify 300-340 ohms between terminals 1 and 3 and terminals 2 and 4. Replace barriers if needed.





6-4-1 DAQ Power Supply Checkout Procedure

Follow the steps below to test both DAQ power supply outputs and associated wiring. Fig-ure 6-1 is a schematic of DAQ DC power distribution, including interfaces, connector pins, signal names and wire color coding.

1. Open DAQ and remove power supply cover (Figure 3-3).

2. Using digital voltmeter (DVM), measure voltages from power supply connec-tors to chassis ground as follows:

3. If required voltages are not present, replace associated power supply. If required voltages are present, measure voltages as follows:

4. If DAQ contains an EDMS board, measure voltages as follows:

5. If required voltages are not present, repair or replace wiring between power supply and associated connector

Connector/Pins Volts DC

From (+) To (-)

P4-6 Gnd -15

P4-1 Gnd +15

P14-1 Gnd +28

P4-2 Gnd +5


From (+) To (-)

P8-1 Gnd +5

P8-2 Gnd +15

P11-1 Gnd +28

P11-5 Gnd +15

P11-8 Gnd -15


From (+) To (-)

P8-1 Gnd +5

P11-8 Gnd -15



6-4-2 Spectrum I/F Board

The Spectrum I/F (SIF) board is shown in Figure 6-2. Jumper settings from Mini DRILL-WATCH are listed in Table 6-2.

Figure 6-1. DAQ DC Power Distribution Wiring



Figure 6-2. Spectrum I/F (SIF) Board

Table 6-2. SIF Board Jumpers

Jumper Mini DRILLWATCH

Default Jumper Setting

General Description

JP1 Not Applicable Not currently used.

JP2 Installed between pins 15 and 16 for 42.8K baud

Used to select the T-Pot network baud rate (default = 42.8K).

JP3 Not installed Used to select the SIF device ID.

JP4 Installed between pins 1 and 2 for 42.8k baud

Used to select the SIF processor baud rate (default = 42.8K).

JP5 Installed between pins 1 and 2 for 24V relay power.

Used to select relay power: 24V for IS sys-tems and 12V for non-IS systems

JP6 Installed between pins 2 and 3 for 16V display power.

Used to select display power: 16V for IS sys-tems and 10V for non-IS systems.



Table 6-3. JP3 - SIF Board Jumper Settings

SIF 3-4 5-6 7-8

0

1 X

2 X

3 X X

4 X

5 X X

6 X X

7 X X X

Table 6-4. JP4 - Communication Baud Rate

BAUD 1-2 3-4

9600

31K X

42.8K X

125K X X

Table 6-5. JP5 - Relay Power

1-2 2-3

+12V X

+24V X

Table 6-6. JP6 - Display Power

1-2 2-3

+10V X

+16V X



6-4-3 Display Panel Controller Boards

The controller board attached to each panel display board contains a DIP switch labeled SW1 (Figure 6-3). For each board, SW1 is used to set the controller board address so that the correct data is displayed in the correct fields on that board. For controller board 1, which is connected to the keypad, all SW1 positions should be open (up). For controller board 2, position 1 should be closed (down) and all other positions open.

Figure 6-3. Display Panel Controller Boards

FT

B1

SW1SW1

OP

EN

OP

EN

OP

EN

OP

EN

1 2 3 4

OP

EN

OP

EN

OP

EN

1 2 3 4

CLO

SE

DCONTROLLER BOARD 1

CONTROLLER BOARD 2

DISPLAYBOARD 2

DISPLAYBOARD 1



6-4-4 DAQ Digital Board

The DAQ digital board is shown in Figure 6-4. As shown, this board contains two DIP switches, SW2 and SW3. Positions 5 and 6 of SW2 are used to specify the DAQ device I.D. For most Mini DRILLWATCH systems, which contain only one DAQ, positions 5 and 6 should both be set to ON. Position 2 must be set to OFF for EDMS communications. All other SW2 positions should be set to ON during normal operation. SW3 is currently not used.

Figure 6-4. DAQ Digital Board



6-4-5 VIP Workstation Communications Board

The DCM communications board is shown in Figure 6-5. This board contains three DIP switches, which should be set as follows:

• SW1 - position 2 is ON (closed) and all other positions are OFF (open). This selects the IRQ to the host PC from the 68HC11 processor as 5.

• SW2 - positions 1 through 6 are OFF (open). This allows the VIP Work-station device I.D. to be set and/or changed using the Configuration/Cali-bration software (Chapter 4).- position 7 is OFF (open) and position 8 is ON (closed). This sets the baud rate to the default network baud rate of 42.8K.

• SW3 - positions 3, 6, 7 and 8 are ON (closed) and all other positions are OFF (open). This sets the dual port RAM address space and interrupt request from the host PC to the 68HC11 processor.

Figure 6-5. DCM Communications Board

NOTE

Baud rate must be the same for all network devices.



6-5 INIT CODES

During Mini DRILLWATCH system initialization, one of six initialization codes (INIT codes) may be displayed in the display panel KEYBOARD DATA field. These codes inform the operator of SIF initialization conditions and are typically displayed for 2-5 seconds. Table 6-7 summarizes each INIT code. The T-Pot communications LED is the red LED on the SIF PC board labeled D1.

CAUTION

If any INIT code is displayed for longer than ten seconds, reset the SIFboard by pressing push button switch S1.

NOTE

Always check for faulty wiring and power before replacing the SIF board.

Table 6-7. Mini DRILLWATCH INIT Codes

Code Explanation Required Action

INIT 1 When displayed for 2-5 seconds, INIT 1 indicates one of the following conditions:

1. Normal DAQ power-up initialization. None

2. Normal SIF initialization after pressing SIF reset button (Figure 6-13)

None

When displayed for longer than ten seconds and accompanied by flashing T-POT communications LED, the SIF is faulty.

Press SIF reset button (Figure 6-2). If problem persists, replace SIF.

When displayed for longer than ten seconds and accompanied by non-flashing T-POT communica-tions LED, there is no communication between SIF and T-POT network.

Perform the checks required when INIT 2 is displayed.

INIT 2 There is no communication between SIF and T-POT network. Accompanied by non-flashing T-POT communications LED.

Check: 1) T-POT modem connections with SIF PCB, 2) designated baud rate and SIF device I.D. (Table 6-3 and Table 6-4). If problem persists, see Manual 60-10.

INIT 3 SIF is re-initializing due to incorrect record received from T-POT network during initialization.

None

INIT 4 There is a SIF software problem. Contact M/D Totco.



INIT 5 SIF is re-initializing due to incorrect record received from T-POT network during normal SIF operation.

None

INIT 6 SIF is re-initializing due to partial device or screen config received from T-POT network.

None

Table 6-7. Mini DRILLWATCH INIT Codes

Code Explanation Required Action


se On s-gned AQ nents


7-1 INTRODUCTION

This chapter contains an Illustrated Parts Breakdown (IPB) and recommended spare parts inven-tory for Mini DRILLWATCH. The IPB consists of component illustrations and accompanying parts lists. IPBs of the DAQ, pit level sensor P/N H10924A-series and both mud flow sensors are presented in their respective manuals. Features of the IPB are described below.

7-2 ILLUSTRATIONS

On the illustrations, stand-alone parts and assemblies are assigned index numbers. If an assembly is detailed in a separate figure, its index number is circled.

7-3 PARTS LIST

Parts list contents are described in the following paragraphs.

7-3-1 Find Number

This column lists the figure and index number of each illustrated item.

7-3-2 Part Number

This column lists the M/D Totco part number of each item.

7-3-3 Description

This column contains the name and description of each item.

7-3-4 Units Per Assembly

This column lists the number of items required for one next higher assembly (NHA).

7-3-5 Use On Code

This column is used only when the illustrated assembly has more than one configuration. Each configuration is assigned a Use On Code (A, B, etc.) and, thereafter, only its constit-uent parts are assigned the same Use On Code. For example, in the parts list for Figure 7-1, a Mini DRILLWATCH system containing a DAQ with internal barriers is assigned a Use On Code of “A”, whereas a system containing a barrierless DAQ is assigned a UCode of “B”. Thereafter, all Mini DRILLWATCH components that are used only in sytems containing a DAQ with internal barriers (for example, the junction box) are assia Use On Code of "A"; components used only in systems containing a barrierless D(for example, the sensor barrier box) are assigned a Use On Code of "B"; and compoused in both systems are assigned a Use On Code of "A, B".


CHAPTER 7 MINI DRILLWATCHABBREVIATIONS Manual XC-132

7-4 ABBREVIATIONS

Table 7-1 contains standard abbreviations used in parts lists.

Table 7-1. Parts List Abbreviations

Abbreviation Explanation Abbreviation Explanation

AP Attaching Parts NHA Next Higher Assembly

AR As Required NPT National Pipe Thread

ASSY Assembly NP Not Procurable

AWG American Wire Gauge NYL Nylon

BDGH Binding Head OD Outer Diameter

BRS Brass PCB Printed Circuit Board

CSK Countersunk PHHD Phillips Head

CT Count PN Part Number

CTN Carton PNHD Pan Head

EXT External POS Position

FILH Fillister Head PT Point

FLHD Flat Head RD Root Diameter

GA Gauge RDHD Round Head

HD Head REF Reference

HDW Hardware SHLD Shield

HX Hexagonal SLFLKG Self-Locking

ID Inner Diameter SLTD Slotted

INS Inside SST Stainless Steel

INTL Internal ST Self-Tapping

IS Intrinsically Safe STD Standard

LCD Liquid Crystal Display THD Thread

LED Light-Emitting Diode UNC Unified Coarse Thread

LG Length UNF Unified Fine Thread

M/F Male/Female UNS Unified Straight Thread

MTG Mounting


MINI DRILLWATCH CHAPTER 7Manual XC-132 ABBREVIATIONS

Figure 7-1. Mini DRILLWATCH System Components

1

4

5

21

22

27

28

26

25

29



FIGURE UNITS USE & PART PER ONINDEX NO. NUMBER DESCRIPTION ASSY CODE

7-1 N/A Mini DRILLWATCH w/ DAQ with internal barriers . . . N/A N/A

1 220492-005 DAQ UL, SIF, Mini DRILLWATCH . . . . . . . . . . . . . . . . . . . 1

4 E6830-310 Mini DRILLWATCH, barrels (see Figure 7-2 on page 5) . . 1

5 220450-001 DISPLAY BARRIER BOX(see Figure 7-4 on page 8). . . . 1

21 219607-001 COMPUTER SYSTEM, VIP WORKSTATION. . . . . . . . . . 1

22 935419-010 PRINTER, VIP WORKSTATION . . . . . . . . . . . . . . . . . . . . 1

21 & 22 E7298-500 VIP DATA ANALYSIS MODULE . . . . . . . . . . . . . . . . . . . . 1

25 270700-111 MUD FLOW SENSOR (Manual 27-44). . . . . . . . . . . . . . . 1

26 232389 PUMP STROKE SENSOR (see Figure 7-5 on page 9) . . 3

27 219062-003 POSITION SENSOR, DRAWWORKS, ENCODER . . . . . 1

28 218041-002 TORQUE SENSOR, ROTARY TORQUE . . . . . . . . . . . . . 2

29 220631-3660 PRESSURE TRANSDUCER ASSEMBLY . . . . . . . . . . . . 1

NS 219255-001 CALIBRATION SWITCH BOX . . . . . . . . . . . . . . . . . . . . . 1

NS 219916-001 DCM MODEM, VIP WORKSTATION . . . . . . . . . . . . . . . . 1

NS 220893 LAPTOP PC, CAL/CONFIG . . . . . . . . . . . . . . . . . . . . . . . 1

NS 220451-001 ALARM HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

NS E7298-300 RIG-UP KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

NS 999263-002 GROUNDING ROD, 8’ x 1/2-inch, Copper-Clad . . . . . . . AR

NS 999264-001 GROUNDING CLAMP, 1/2-inch . . . . . . . . . . . . . . . . . . . AR



Figure 7-2. Mini DRILLWATCH Display Panel

1 1




7-2 E6830-310 Mini DRILLWATCH Display Panel, barrels . . . . . . . .N/A N/A

1 A11313A-14 COVER/ENCLOSURE ASSY . . . . . . . . . . . . . . . . . . . .1

2 220042 BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3 A11212A-114A LENS ASSY, Barrels. . . . . . . . . . . . . . . . . . . . . . . . . . . .1

4 H11062A KEYBOARD ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

10 220065 GASKET, Lens/Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . .1

11 220066 GASKET, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

12 220034 FRAME, Display Mounting . . . . . . . . . . . . . . . . . . . . . . .1

13 N/A TERMINAL BLOCK (see Figure 7-3 on page 7). . . . . . .1

14 999449-180 SCREW, Pnhd, 10-32 X .75, cres. . . . . . . . . . . . . . . . . 24

15 B10449A GASKET, PCB Isolator . . . . . . . . . . . . . . . . . . . . . . . . . .4

16 PCB287A-01 PCB ASSY, Display with Backlight . . . . . . . . . . . . . . . . .2

17 999449-066 SCREW, Pnhd, 6-32 x .38, cres . . . . . . . . . . . . . . . . . . .8

18 G241-1 WASHER, Flat, #6 fiber . . . . . . . . . . . . . . . . . . . . . . . . .8

19 J841-4RN SCREW, Rdhd, 4-40 x .25, nylon . . . . . . . . . . . . . . . . . .6

20 PCB295A PCB, Display Controller . . . . . . . . . . . . . . . . . . . . . . . . .2

21 999335-009 SCREW, Flhd, 6-32 x .38, cres. . . . . . . . . . . . . . . . . . . .8

23 M10072A-080006 STANDOFF, 6-32 x .50 m/f, .38 cres, hx. . . . . . . . . . . . .8

24 G180A-01943 WASHER, #6 Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

25 J827-1CS NUT, 6-32, hx cres . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

NS B10448A NAMEPLATE, Keypad . . . . . . . . . . . . . . . . . . . . . . . . . .1

NS B10511A NAMEPLATE, Mini DRILLWATCH . . . . . . . . . . . . . . . . .1

NS M10368A STANDOFF, .38 Hx, m/f, 6-32 x 1.25 . . . . . . . . . . . . . . .6

NS 999449-072 SCREW, 6-32 X .50, pnhd, cres . . . . . . . . . . . . . . . . . . .6

NS H12007A-02 CONNECTOR, Screw Term, 2-socket, .2" . . . . . . . . . . .2

* Not shown



Figure 7-3. Terminal Block Detail: Display Panel


7-3 N/A TERMINAL BLOCK DETAIL, Display Panel . . . . . . .N/A N/A

1 220035 BAR, Terminal Block, ISMI master mounting . . . . . . . . .2

3 H12101A-09 TERMINAL BLOCK ASSY . . . . . . . . . . . . . . . . . . . . . . .1

4 M10073A-60004 STANDOFF, 4-40 X .38, m/f, .25 hx, cres . . . . . . . . . . . .8

5 J841-4FS SCREW, 4-40 x .25, flhd, cres . . . . . . . . . . . . . . . . . . . .2

6 J812-2TS SCREW, 10-32 x .25, trusshd, cres . . . . . . . . . . . . . . . .2

7 999449-026 SCREW, 4-40 x .25, pnhd, cres . . . . . . . . . . . . . . . . . . .2

8 G180A-01042 WASHER, Flat, #4, cres . . . . . . . . . . . . . . . . . . . . . . . . .4

9 999449-034 SCREW, 4-40 x .50, pnhd, cres . . . . . . . . . . . . . . . . . . .6

10 H12031A-02 CONNECTOR, Screw Term, 2-socket, .3" . . . . . . . . . . .1






Figure 7-4. Display Barrier Box


7-4 220450-001 DISPLAY BARRIER BOX . . . . . . . . . . . . . . . . . . . . . .N/A N/A

1 H12292A-06 BARRIER BOX, 6 Position . . . . . . . . . . . . . . . . . . . . . . .1

2 H10992A-768P BARRIER, I.S., 22V/22V . . . . . . . . . . . . . . . . . . . . . . . .1

3 H10992A-787S BARRIER, I.S., 28V/28V . . . . . . . . . . . . . . . . . . . . . . . .3

4 H10992A-779P BARRIER, I.S., 28V/28V . . . . . . . . . . . . . . . . . . . . . . . .2

5 995706-007 CONN, Cord, nyl, .75 NPT, .38-.50. . . . . . . . . . . . . . . . .4

6 J10481A-02 HUB, Conduit, .75 NPT . . . . . . . . . . . . . . . . . . . . . . . . .4

7 J10009A-000400 REDUCER, .75 NPT to .5 NPT . . . . . . . . . . . . . . . . . . .4

5

7

6

1

2

3

4



Figure 7-5. Pump Stroke Sensor

FIGURE UNITS USE &‘ PART PER ONINDEX NO. NUMBER DESCRIPTION ASSY CODE’

7-5 232389 PUMP STROKE SENSOR . . . . . . . . . . . . . . . . . . . . . .N/A N/A

1 955220-013 CONDUIT OUTLET BODY . . . . . . . . . . . . . . . . . . . . . . .1

2 955701-009 CONN, Cord, stl, 1/2’ NPT, .25-.38 . . . . . . . . . . . . . . . . .1

3 978915-001 GASKET, Cond. outlet, neoprene. . . . . . . . . . . . . . . . . .1

4 999298-002 NUT, Seal, 1/4’ NPS, sst. . . . . . . . . . . . . . . . . . . . . . . . .3

5 220379 REDUCER BUSHING, 1/2’ NPT x 1/4’ NPS. . . . . . . . . .1

6 232397 PIPE, Threaded, 1/4’ NPS . . . . . . . . . . . . . . . . . . . . . . .1

7 232399 BULKHEAD UNION, 1/4’ NPS, sst . . . . . . . . . . . . . . . . .1

8 951508-004 TERMINAL BLOCK, 4 term, dbl row . . . . . . . . . . . . . . .1

9 999298-004 NUT, Seal, 1/2’ NPS, sst. . . . . . . . . . . . . . . . . . . . . . . . .1

10 932814-005 PROXIMITY SENSOR, 10 mm Range . . . . . . . . . . . . . .1

11 230118 ADAPTER, 1/4’ NPS, proximity sensor. . . . . . . . . . . . . .1



Figure 7-6. VIP Workstation

FIGURE UNITS USE& PART PER ON

INDEX NO. NUMBER DESCRIPTION ASSY CODE

7-6 E7298-500 VIP WORKSTATION, WITH PC, PRINTER . . . . . . . . .N/A

2 219497 PCB ASSY, DCM Communications Board, TOTAL. . . . .1

3 219916-001 T-POT MODEM, DCM, TOTAL . . . . . . . . . . . . . . . . . . . .1

6 219607-001 COMPUTER SYSTEM, with PC, printer, paper . . . . . . .1

8 935419-010 PRINTER, Color Graphics . . . . . . . . . . . . . . . . . . . . . . .1



Table 2-1. Recommended Spare Parts Inventory

MANUAL/FIG-URE & INDEX

NO

PART NUMBER DESCRIPTION QUANTITY

Manual 60-10 938203-021 Fuse, 3 A, 250 V, slo-blo 5

Manual 60-10 935676-006 AC Protector, 240 Vac, 1A 1

Manual 60-10 220251-005 Power Supply, +5/+15/-15 Vdc 1

Manual 60-10 220251-006 Power Supply, +28 Vdc 1

Manual 60-10 219916 T-POT Modem 1

Manual 60-10 219493 Digital PCB 1

Manual 60-10 219506 Analog PCB 1

Manual 60-10 932312-410 Switch Contact Block 1

7-3-2 H12010A ISMI Master Module 1

7-2-16 PCB287A-01 Display PCB, with Backlight 1

7-2-20 PCB295A Display Controller PCB 1

7-2-4 H11062A Keypad Assembly 1

7-9-2 219497 DCM Communications PCB 1

7-9-3 219916-001 T-POT Modem, DCM 1

7-9-10 999384-004 Paper, 1-Ply, 11 x 14.87 1

Not Shown 221034-001 SIF PCB, MW 1




next to alues.

hod of ielded

APPENDIX ASHIELDED CABLE GUIDELINES

A-1 INTRODUCTION

This appendix provides guidelines for connecting sensor signal cables.

A-2 GUIDELINES FOR PREVENTING CABLE DAMAGE

Observe the following practices when routing sensor signal cables.

• Route cables so that they are out of walkways and vehicle traffic and are not exposed to sharp corners that could wear through insulation.

• Plan signal cable runs to avoid wet areas and close proximity to power cables.• Use nylon (land rig) or stainless steel (offshore rig) tie wraps to dress, secure and

support cables.• Protect splices from moisture and excessive strain.

A-3 ELECTRICAL INTERFACE

Use shielded cable whenever signal cables must be run in cable trays or otherwise located electrical power cables. This prevents induced noise from causing erratic sensor channel v

A-4 SHIELDED CABLE SPLICING

Sensor cables must typically be spliced in the field. Figure A-1 shows the recommended metusing butt splices to join two pieces of shielded cable or a length of shielded cable and a shcable pigtail assembly.

Follow the guidelines below when splicing shielded cable:

• When joining two cables, cut individual conductors (Figure A-1).• Stagger butt splices along length of cable splice.• Observe color code when cutting and splicing conductors.• Use a crimping tool and apply enough pressure on each butt splice connector to

ensure a good compression connection between conductor and connector.• Always seal and protect each splice with a strip of mastic tape that extends up the

cable about one inch past both sides of splice and wrap mastic tape securely with black electrical tape.

WARNING

Plan each rig-up so that splices are not located in hazardous areas.

March 10, 1999 Page A-1M/D Totco

Appendix A MINI DRILLWATCHSHIELDED CABLE GUIDELINES Manual XC-132

A-5 CONNECTING DEVICES

Follow the guidelines below when connecting two devices with shielded cable.

• Connect shield to ground at only one end of cable. When connecting a DAQ and sensor, connect shield to ground only at DAQ end.

• When using butt splice connectors to fabricate a length of shielded cable, splice cable to shield only in pigtail connected to DAQ. At other end of cable, cut off shield even with cable insulation; do not connect shield to any other shield or device.

Figure A-1. Recommended Method of Splicing Shielded Cable

CAUTION

If the shield is connected to ground at both ends of the cable, the shield willattract electrical interference, rather than shield against it.

Page A-2 March 10, 1999M/D Totco

APPENDIX BCONVERSION DATA

B-1 INTRODUCTION

This chapter contains the following conversion information:

• Methods for converting temperature from degrees Fahrenheit (oF) to degrees Cen-tigrade (oC) and vice versa

• Conversion factors for commonly used units

B-2 TEMPERATURE CONVERSIONS

To convert from degrees Fahrenheit (oF) to degrees Centigrade (oC), subtract 32 from the degreesFahrenheit, then multiply by 0.556, as shown below:

oC = [ oF - 32 ] x 0.556 (EQ 1)

To convert from degrees Centigrade (oC) to degrees Fahrenheit (oF), multiply the degrees Centi-grade by 1.7985, then add 32, as shown below:

oF = [ oC x 1.8 ] + 32 (EQ 2)

B-3 CONVERSION FACTORS

Conversion factors for commonly used units are presented in Table B-1.

March 10, 1999 Page B-1M/D Totco

Appendix B MINI DRILLWATCHCONVERSION FACTORS Manual XC-132

Table B-1. Conversion Factors

MULTIPLY BY TO OBTAIN

atmospheres (atm) 101.325 kiloPascal (kPa) absolute

atmospheres (atm) 14.7059 pounds per square inch (psi)

barrels (bbl) of petroleum 5.615 cubic feet (ft3)

barrels (bbl) of petroleum 0.159 cubic meters (m3)

barrels (bbl) of petroleum 42 gallons, U.S. liquid

barrels of petroleum per inch (bbl/in) 0.626 cubic meters per centimeter (m3/cm)

bars 14.5138 pounds per square inch (psi)

centimeters 0.394 inches (in)

centimeters per second (cm/sec) 0.0328 feet per second (ft/sec)

cubic feet (ft3) 7.4805 gallons, U.S. liquid

cubic feet (ft3) 28.32 liters

cubic feet (ft3) 0.178 barrels (bbl) of petroleum

cubic meters (m3) 6.289 barrels (bbl) of petroleum

cubic meters (m3) 264.2 gallons, U.S. liquid

cubic meters per centimeter (m3/cm) 1.597 barrels of petroleum per inch (bbl/in)

decaNewtons (daN) 2.248 pounds

feet (ft) 0.3048 meter (m)

feet per hour (ft/hr) 0.3048 meters per hour (m/hr)

feet per minute (ft/min) 0.01829 kilometers per hour (km/hr)

feet per minute (ft/min) 0.3048 meters per minute (m/min)

feet per second (ft/sec) 30.48 centimeters per second (cm/sec)

feet per second (ft/sec) 18.29 meters per minute (m/min)

foot-pound 1.4882 kilogram-meter (kg-m)

foot-pound 1.3558 Newton-meter

gallons, U.S. liquid 0.0238 barrels (bbl) of petroleum

gallons, U.S. liquid 0.13368 cubic feet (ft3)

gallons, U.S. liquid 0.003785 cubic meters (m3)

gallons, U.S. liquid 3.7854 liter

grams per cubic centimeter (g/cm3) 8.345 pounds per U.S. liquid gallon (lb/gal)

inch (in) 2.54 centimeter (cm)

inches Hg (Mercury) 0.4912 pounds per square inch (psi)

inches H20 (Water) 0.0361 pounds per square inch (psi)

kilograms (kg) 2.2046 pounds

kilogram-meters (kg-m) 0.67196 foot-pound

kilograms per cubic meter (kg/m3) 0.00835 pounds per U.S. liquid gallon (lb/gal)

kilograms per meter (kg/m) 0.672 pounds per foot

kilograms per square centimeter (kg/cm3) 14.2227 pounds per square inch (psi)

kilometers (km) 0.6215 miles

Page B-2 March 10, 1999M/D Totco

(Continued)

MINI DRILLWATCH Appendix BManual XC-132 CONVERSION FACTORS

)

kilometers per hour (km/hr) 54.6747 feet per minute (ft/min)

kiloPascals (kPa) 0.0099 atmospheres (atm)

kiloPascals (kPa) absolute 0.145 pounds per square inch (psi)

liters (l) 0.0353 cubic feet (ft3)

liters (l) 0.2642 gallon, U.S. liquid

liters per minute (lpm) 2.1186 standard cubic feet per hour (scfh)

meters 3.281 feet (ft)

meters per hour (m/hr) 3.2808 feet per hour (ft/hr)

meters per minute (m/min) 3.2808 feet per minute (ft/min)

meters per minute 0.0547 feet per second (ft/sec)

miles 1.609 kilometers (km)

Newtons 0.2284 pounds

Newton-meters 0.7376 foot-pounds

pounds (lb) 0.4448 decaNewtons (daN)

pounds (lb) 0.4536 kilograms (kg)

pounds (lb) 0.000454 metric tons

pounds (lb) 4.448 Newtons (N)

pounds (lb) 0.0005 U.S. tons

pounds per foot (lb/ft) 1.488 kilograms per meter (kg/m)

pounds per gallon (lb/gal) 0.119826 grams per cubic centimeter (g/cm3)

pounds per gallon (lb/gal) 119.826 kilograms per cubic meter (kg/m3)

pounds per square inch (psi) 0.0680 atmospheres (atm)

pounds per square inch (psi) 0.0689 bars

pounds per square inch (psi) 2.0358 inches of Hg (Mercury)

pounds per square inch (psi) 27.6778 inches of H20 (Water)

pounds per square inch (psi) 0.0703 kilograms per square centimeter (kg/cm2

pounds per square inch (psi) 6.895 kiloPascals (kPa)

square centimeters (cm2) 0.155 square inch (in2)

square feet (ft2) 0.0929 square meter (m2)

square inch (in2) 6.4516 square centimeter (cm2)

square meter (m2) 10.764 square feet (ft2)

standard cubic feet per hour (scfh) 0.472 liters per minute (lpm)

tons, metric 2205 pounds

tons, metric 1.1025 U.S. tons

tons, U.S. 0.907 metric tons

tons, U.S. 2000 pounds

metric ton-kilometers (tonne-km) 0.6853 U.S.ton-miles

U.S.ton-miles 1.4593 metric ton-kilometers (tonne-km)

MULTIPLY BY TO OBTAIN

March 10, 1999 Page B-3M/D Totco

Appendix B MINI DRILLWATCHCONVERSION FACTORS Manual XC-132

Page B-4 March 10, 1999M/D Totco

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