60-30.pdf

Part Number 60-30
Revision A
INSTALLATION, OPERATION, MAINTENANCE

&
ILLUSTRATED PARTS BREAKDOWN
MUDWATCH SYSTEM
TOTAL SYSTEM 4
Manufacturers of Precision Instruments
Printed in U.S.A. April 30, 1999

Manual 60-30 contains 158 pages as follows:
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999

i through Iv . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Table of Contents . . . . . . . . . . . . . . . . . . . . . April 1999
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . April 1999
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Chapter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Chapter 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Chapter 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Chapter 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Chapter 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Chapter 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Chapter 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
Appendix C . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999
All product, brand, or trade names used in this publication are the trademarks or registered trade-
marks of their respective owners.
Information in this manual is subject to change without notice.

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.
April 30, 1999 iii

M/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 LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
Martin-Decker Totco (“Company”) warrants to Buyer (“Purchaser”) of new products manufactured or supplied
by the Company 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 which has been repaired or altered in such a way, in the Company's judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.
B. Any product which has, in the Company's judgement, been subject to negligence, accident, or improper
storage.
C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.
D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.
The Company'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 to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.
The cost of labor for installing a repaired or replacement part shall be borne by Buyer. 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. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.
B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.
No deviations from the Company's standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.
EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.
IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.
iv April 30, 1999

M/D Totco
Table Of Contents
CHAPTER 1
INTRODUCTION
1-1 INTRODUCTION .............................................................................................................................1-1
1-2 SCOPE OF MANUAL......................................................................................................................1-1
1-3 INTENDED AUDIENCE...................................................................................................................1-1
1-4 PERSONNEL QUALIFICATIONS ...................................................................................................1-1
1-5 NOTES, CAUTIONS AND WARNINGS ..........................................................................................1-2
1-6 RELATED DOCUMENTS................................................................................................................1-2
CHAPTER 2
DESCRIPTION
2-1 INTRODUCTION .............................................................................................................................2-1
2-2 FUNCTION ......................................................................................................................................2-1
2-3 MAIN COMPONENTS .....................................................................................................................2-1
2-3-1 DAQ .....................................................................................................................................2-3
2-3-2 MUDWATCH Display Panel ................................................................................................2-4
2-3-3 Display Barrier Box ..............................................................................................................2-5
2-3-4 I.S. Alarm Horn ....................................................................................................................2-5
2-3-5 Connecting Cables ..............................................................................................................2-5
2-4 OPTIONAL COMPONENTS............................................................................................................2-6
2-4-1 Sensor Barrier Box ..............................................................................................................2-6
2-4-2 Basic Cable Kit ....................................................................................................................2-7
2-4-3 Quick Rig-Up Kits ................................................................................................................2-7
2-4-4 Laptop PC ............................................................................................................................2-8
2-4-5 VIP Workstation ...................................................................................................................2-8
2-5 SENSORS .......................................................................................................................................2-9
2-5-1 Pit Level Sensors .................................................................................................................2-9
2-5-1-1 Pit Level Sensor P/N 272819-series ........................................................................2-9
2-5-1-2 Pit Level Sensor P/N H10924A-series ...................................................................2-10
2-5-2 Mud Flow Sensors .............................................................................................................2-11
2-5-2-1 Mud Flow Sensor P/N MFTX4A-5 ..........................................................................2-11
2-5-2-2 Mud Flow Sensor P/N 270700-116 ........................................................................2-12
2-5-3 Pump Stroke Sensor ..........................................................................................................2-13
2-6 MUDWATCH SPECIFICATIONS ..................................................................................................2-13
CHAPTER 3
INSTALLATION
3-1 INTRODUCTION .............................................................................................................................3-1
3-2 INSTALLATION LOCATION REQUIREMENTS.............................................................................3-1
3-3 DAQ INSTALLATION .....................................................................................................................3-3
3-3-1 Mount the DAQ ....................................................................................................................3-3
3-3-2 Ground the DAQ ..................................................................................................................3-4
3-3-3 Connect AC Power Cable to DAQ .......................................................................................3-5
3-4 DISPLAY PANEL INSTALLATION.................................................................................................3-6
3-5 DISPLAY BARRIER BOX INSTALLATION....................................................................................3-7
3-5-1 Mount the Display Barrier Box .............................................................................................3-7
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MUDWATCH - System 4
Table of Contents Manual 60-30
3-5-2 Ground the Display Barrier Box ...........................................................................................3-8
3-6 ALARM HORN INSTALLATION ...................................................................................................3-10
3-6-1 Mount the Alarm Horn ........................................................................................................3-10
3-6-2 Adjust Alarm Horn Tone and Volume ................................................................................3-10
3-7 CONNECT THE DAQ, DISPLAY BARRIER BOX, DISPLAY PANEL & ALARM HORN ............3-11
3-8 SENSOR BARRIER BOX INSTALLATION ..................................................................................3-14
3-9 JUNCTION BOX INSTALLATION ................................................................................................3-15
3-10 VIP WORKSTATION INSTALLATION..........................................................................................3-17
3-11 SENSOR INSTALLATION ............................................................................................................3-18
3-11-1 DAQ Sensor Connections ..................................................................................................3-18
3-11-2 Pit Level Sensor Installation ..............................................................................................3-20
3-11-2-1 Installation Of Pit Level Sensor P/N 272819-series ...............................................3-20
3-11-2-2 Installation Of Pit Level Sensor P/N H10924A-series ............................................3-22
3-11-3 Mud Flow Sensor Installation .............................................................................................3-25
3-11-3-1 Installation Of Mud Flow Sensor P/N 270700-116 .................................................3-25
3-11-3-2 Installation Of Mud Flow Sensor P/N MFTX4A-5 ...................................................3-29
3-11-4 Pump Stroke Sensor Installation .......................................................................................3-32
3-12 MUDWATCH DIGITAL OUTPUTS................................................................................................3-37
3-13 SYSTEM POWER-UP ...................................................................................................................3-38
CHAPTER 4
CONFIGURATION & CALIBRATION
4-1 INTRODUCTION .............................................................................................................................4-1
4-2 MUDWATCH CHANNELS ..............................................................................................................4-2
4-3 CONFIGURATION & CALIBRATION SOFTWARE START-UP ....................................................4-7
4-4 LOADING THE MUDWATCH CONFIGURATION FROM FLOPPY ...............................................4-8
4-5 CONFIGURATION ..........................................................................................................................4-9
4-6 CALIBRATION ..............................................................................................................................4-14
4-6-1 Mud Pit Volume Calculations .............................................................................................4-14
4-6-2 Analog Sensor Channel Calibration ...................................................................................4-15
4-6-3 Digital Sensor Channel Calibration ....................................................................................4-22
4-7 SAVE CONFIGURATION/CALIBRATION TO DISK ....................................................................4-25
CHAPTER 5
OPERATION
5-1 INTRODUCTION .............................................................................................................................5-1
5-2 MUDWATCH DATA DISPLAY........................................................................................................5-1
5-2-1 Active Indicators ..................................................................................................................5-3
5-2-2 Field Names and Units ........................................................................................................5-3
5-2-3 Function Codes ....................................................................................................................5-3
5-3 KEYPAD OPERATION ...................................................................................................................5-4
5-3-1 Zero Field Value ..................................................................................................................5-5
5-3-2 Change Field Value .............................................................................................................5-5
5-3-3 Change/View Alarm Limits ...................................................................................................5-6
5-3-4 Activate/Deactivate Fields ...................................................................................................5-6
5-3-4-1 Activate/deactivate Pump Strokes/pump SPM .........................................................5-6
5-3-4-2 Activate/De-Activate Tanks ......................................................................................5-7
5-3-5 Specify Drill, Trip-In or Trip-Out Mode .................................................................................5-7
5-3-6 Set Date and Time ...............................................................................................................5-8
5-3-7 Switch Backlighting ON/OFF ...............................................................................................5-8
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M/D Totco
MUDWATCH - System 4
Manual 60-30 Table of Contents
5-4 DISPLAY PANEL FIELDS ..............................................................................................................5-9

5-4-1 Keyboard Fields ...................................................................................................................5-9
5-4-2 Return Flow .......................................................................................................................5-10
5-4-2-1 Function Code 54: Set High ...................................................................................5-10
5-4-2-2 Function Code 55: Set Low ....................................................................................5-10
5-4-3 Total Active Volume/Active Tanks .....................................................................................5-11
5-4-3-1 Function Code 63: Set High ..................................................................................5-11
5-4-3-2 Function Code 64: Set Active Tanks ......................................................................5-11
5-4-4 Gain/Loss ...........................................................................................................................5-12
5-4-4-1 Function Code 6: Set Zero ....................................................................................5-12
5-4-4-2 Function Code 61: Set Gain ...................................................................................5-12
5-4-4-3 Function Code 62: Set Loss ...................................................................................5-12
5-4-5 Trip Volume/Tank Volume .................................................................................................5-13
5-4-5-1 Trip Vol ...................................................................................................................5-13
5-4-5-2 Tank Vol .................................................................................................................5-13
5-4-5-3 Mode ......................................................................................................................5-13
5-4-5-4 Function Code 66: Set Mode .................................................................................5-13
5-4-5-5 Function Code 67: Set Tank No. ...........................................................................5-13
5-4-5-6 Function Code 68: Select Active ...........................................................................5-13
5-4-5-7 Function Code 69: Select Trip ................................................................................5-13
5-4-5-8 Function Code 65: Set High ...................................................................................5-14
5-4-6 Counter A/Counter B .........................................................................................................5-15
5-4-6-1 Function Codes 1 and 2: Set Zero ........................................................................5-15
5-4-6-2 Function Codes 10 and 20: Preset .........................................................................5-15
5-4-6-3 Function codes 15 and 25: Set Counter Alarm .....................................................5-15
5-4-6-4 Function Codes 11, 12, 13, 21, 22, 23: Pump 1, 2, 3 ............................................5-15
5-4-7 Pump Rates/Total Pump Rate ...........................................................................................5-17
5-4-7-1 Function Codes 44, 45, 46: Set High ....................................................................5-17
5-4-7-2 Function Codes 41, 42, 43: Pump 1, Pump 2, Pump 3 .........................................5-17
5-4-7-3 Function Code 47: Set Low Flow Alarm Disable ....................................................5-17
5-4-8 Option ................................................................................................................................5-18
5-4-8-1 Function Code 51: Set Low Alarm .........................................................................5-18
5-4-8-2 Function Code 52: Set High Alarm .........................................................................5-18
5-4-8-3 Function Code 53: Preset .....................................................................................5-18
CHAPTER 6
MAINTENANCE
6-1 INTRODUCTION .............................................................................................................................6-1
6-2 PERIODIC INSPECTION OF MUDWATCH DEVICES ...................................................................6-1
6-3 PERIODIC INSPECTION OF MUDWATCH SENSORS .................................................................6-1
6-4 TROUBLESHOOTING TABLE: MUDWATCH SYSTEM................................................................6-2
6-4-1 DAQ Power Supply Checkout Procedure ............................................................................6-7
6-4-2 Spectrum "SUPER" I/F Board ..............................................................................................6-8
6-4-3 Display Panel Controller Boards ........................................................................................6-11
6-4-4 DAQ Digital Board .............................................................................................................6-12
6-4-5 VIP Workstation Communications Board ...........................................................................6-13
6-5 INIT CODES ..................................................................................................................................6-15
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M/D Totco
MUDWATCH - System 4
Table of Contents Manual 60-30
CHAPTER 7
7-1 INTRODUCTION .............................................................................................................................7-1
7-2 ILLUSTRATIONS ............................................................................................................................7-1
7-3 PARTS LIST ....................................................................................................................................7-1
7-3-1 Figure & Index Number ........................................................................................................7-1
7-3-2 Part Number ........................................................................................................................7-1
7-3-3 Description ...........................................................................................................................7-1
7-3-4 Units Per Assembly .............................................................................................................7-1
7-3-5 Use On Code .......................................................................................................................7-1
7-4 ABBREVIATIONS ...........................................................................................................................7-2
Appendix A
SHIELDED CABLE GUIDELINES
A-1 INTRODUCTION ............................................................................................................................ A-1
A-2 GUIDELINES FOR PREVENTING CABLE DAMAGE................................................................... A-1
A-3 ELECTRICAL INTERFACE............................................................................................................ A-1
A-4 SHIELDED CABLE SPLICING ...................................................................................................... A-1
A-5 CONNECTING TWO DEVICES WITH SHIELDED CABLE........................................................... A-2
Appendix B
CONVERSION DATA
B-1 INTRODUCTION ............................................................................................................................ B-1
B-2 TEMPERATURE CONVERSIONS ................................................................................................. B-1
B-3 CONVERSION FACTORS ............................................................................................................. B-1
Appendix C
WORKSHEET DRAWINGS
C-1 INTRODUCTION ............................................................................................................................ C-1
C-2 HOW TO DOCUMENT A SYSTEM ................................................................................................ C-1
C-3 CONTENTS OF THIS APPENDIX.................................................................................................. C-1
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M/D Totco
List of Figures
CHAPTER 2
DESCRIPTION
Figure 2-1. Typical MUDWATCH System ......................................................................................... 2-2
Figure 2-2. DAQ (Data Acquisition Unit) ........................................................................................... 2-3
Figure 2-3. MUDWATCH Display Panel ........................................................................................... 2-4
Figure 2-4. Display Barrier Box ......................................................................................................... 2-5
Figure 2-5. I.S. Alarm Horn ............................................................................................................... 2-5
Figure 2-6. Sensor Barrier Box ......................................................................................................... 2-6
Figure 2-7. Quick Rig-Up Kit Junction Box ....................................................................................... 2-8
Figure 2-8. Pit Level Sensor (P/N 272819-series) ............................................................................ 2-9
Figure 2-9. Pit Level Sensor (P/N H10924A-series) ....................................................................... 2-10
Figure 2-10. Flow Sensor (P/N MFTX4A-5) ...................................................................................... 2-11
Figure 2-11. Mud Flow Sensor (P/N 270700-116) ............................................................................ 2-12
Figure 2-12. Pump Stroke Sensor .................................................................................................... 2-13
CHAPTER 3
INSTALLATION
Figure 3-1. Installation Location Requirements: MUDWATCH System ............................................ 3-2
Figure 3-2. DAQ Installation Dimensions .......................................................................................... 3-3
Figure 3-3. DAQ Power Supply Cover .............................................................................................. 3-5
Figure 3-4. DAQ ac Power Connections ........................................................................................... 3-6
Figure 3-5. Display Panel Mounting Dimensions .............................................................................. 3-7
Figure 3-6. Display Barrier Box Mounting Dimensions ..................................................................... 3-8
Figure 3-7. Display Barrier Box Grounding ....................................................................................... 3-9
Figure 3-8. Alarm Horn Installation ................................................................................................. 3-10
Figure 3-9. Wiring: DAQ to Display Panel....................................................................................... 3-12
Figure 3-10. View of Internal DAQ Wiring: 12 conductor cable to SIF PCB...................................... 3-13
Figure 3-11. Sensor Barrier Box Mounting Dimensions.................................................................... 3-14
Figure 3-12. Junction Box Mounting Dimensions ............................................................................. 3-15
Figure 3-13. Junction Box Internal Wiring ......................................................................................... 3-16
Figure 3-14. VIP Workstation Installation.......................................................................................... 3-17
Figure 3-15. DAQ Field Termination Board ...................................................................................... 3-19
Figure 3-16. Pit Level Sensor Installation (P/N 272819-series) ........................................................ 3-21
Figure 3-17. Pit Level Sensor Wiring (P/N 272819-2XX) DAQ with Barriers Only............................ 3-21
Figure 3-18. Pit Level Sensor Installation (P/N H10924A-series) ..................................................... 3-24
Figure 3-19. Pit Level Sensor Wiring (P/N H10924A-series) ............................................................ 3-24
Figure 3-20. Flow Sensor Components: P/N 270700-116 ............................................................... 3-27
Figure 3-21. Flow Sensor Installation: P/N 270700-116 ................................................................... 3-28
Figure 3-22. Flow Sensor Wiring: P/N 270700-116 (DAQ with Internal Barriers) ............................. 3-28
Figure 3-23. Mud Flow Sensor Installation: P/N MFTX4A-5 ............................................................. 3-30
Figure 3-24. Mud Flow Sensor Calibration: P/N MFTX4A-5 ............................................................. 3-30
Figure 3-25. Mud Flow Sensor MFTX4A-5 Wiring to DAQ with Internal Barriers ............................. 3-31
Figure 3-26. Mud Flow Sensor MFTX4A-5 Wiring to Barrierless DAQ ............................................. 3-31
Figure 3-27. Pump Stroke Sensor Installation Dimensions............................................................... 3-32
Figure 3-28. Pump Stroke Sensor Mounting Methods ...................................................................... 3-33
Figure 3-29. Pump Stroke Sensor Installation .................................................................................. 3-34
Figure 3-30. Pump Stroke Sensor Wiring to DAQ with Internal Barriers........................................... 3-35
Figure 3-31. Pump Stroke Sensor Wiring to Barrierless DAQ .......................................................... 3-35
Figure 3-32. Pump Stroke Sensor Position Check ........................................................................... 3-36
Figure 3-33. Typical Digital Output Wiring ........................................................................................ 3-37
April 30, 1999 Page LOF -1

M/D Totco
MUDWATCH - System 4
List of Figures Manual 60-30
CHAPTER 4
Figure 4-1. Recommended MUDWATCH Configuration and Calibration Procedure........................ 4-1
Figure 4-2. Laptop PC Connection to DAQ....................................................................................... 4-7
Figure 4-3. Configuration & Calibration Main Menu Screen.............................................................. 4-7
Figure 4-4. DISK: [LOAD ALL] Menu Screen................................................................................... 4-8
Figure 4-5. [CONFIGURATION] Submenu ....................................................................................... 4-9
Figure 4-6. SYSTEM/DAQ CONFIGURATION Screen................................................................... 4-10
Figure 4-7. [EDIT] Channel Pull-Down............................................................................................ 4-10
Figure 4-8. Typical Channel Configuration Screen ......................................................................... 4-11
Figure 4-9. SYSTEM CONFIGURATION AND CALIBRATION Screen.......................................... 4-16
Figure 4-10. SYSTEM CALIBRATION SOFTWARE Screen ............................................................ 4-16
Figure 4-11. CALIBRATION SENSOR Channel Submenu............................................................... 4-17
Figure 4-12. Typical System Channel Calibration Screen ................................................................ 4-17
Figure 4-13. “USE CURRENT” Min Screen ...................................................................................... 4-18
Figure 4-14. "CALIBRATION MIN" Manual Entry ............................................................................. 4-18
Figure 4-15. "CALIBRATION MIN" and "VALUE MIN"...................................................................... 4-19
Figure 4-16. "USE CURRENT" Max Screen ..................................................................................... 4-20
Figure 4-17. "CALIBRATION MAX" Manual Entry ............................................................................ 4-20
Figure 4-18. "CALIBRATION MAX" and "VALUE MAX" .................................................................. 4-21
Figure 4-19. Typical Digital Calibration Screen................................................................................. 4-22
Figure 4-20. Digital "CALIBRATION RATE" Screen ......................................................................... 4-23
Figure 4-21. Digital "DEBOUNCE RATE" Screen............................................................................. 4-24
Figure 4-22. DISK: [SAVE ALL] Screen ............................................................................................ 4-25
Figure 4-23. Enter New FILENAME Screen ..................................................................................... 4-25
CHAPTER 5
OPERATION
Figure 5-1. MUDWATCH Data Display ............................................................................................. 5-2
Figure 5-2. Example screen .............................................................................................................. 5-3
Figure 5-3. MUDWATCH Keypad ..................................................................................................... 5-4
Figure 5-4. KEYBOARD Fields ......................................................................................................... 5-9
Figure 5-5. RETURN FLOW Fields................................................................................................. 5-10
Figure 5-6. ACTIVE VOLUME Fields .............................................................................................. 5-11
Figure 5-7. GAIN/LOSS Fields........................................................................................................ 5-12
Figure 5-8. TRIP VOLUME/TANK VOLUME Fields ........................................................................ 5-14
Figure 5-9. COUNTER Fields ......................................................................................................... 5-16
Figure 5-10. PUMP RATE Fields ...................................................................................................... 5-17
Figure 5-11. OPTION Field ............................................................................................................... 5-18
CHAPTER 6
MAINTENANCE
Figure 6-1. DAQ DC Power Distribution Wiring ................................................................................ 6-8
Figure 6-2. Spectrum I/F (Super SIF) Board ..................................................................................... 6-9
Figure 6-3. Display Panel Controller Boards................................................................................... 6-11
Figure 6-4. DAQ Digital Board ........................................................................................................ 6-12
Figure 6-5. DCM Communications Board ....................................................................................... 6-14
Page LOF-2 April 30, 1999

M/D Totco
MUDWATCH - System 4
Manual 60-30 List of Figures
CHAPTER 7
Figure 7-1. MUDWATCH System Components ................................................................................ 7-3
Figure 7-2. MUDWATCH Display Panel ........................................................................................... 7-5
Figure 7-3. Terminal Block Detail: Display Panel............................................................................. 7-7
Figure 7-4. Display Barrier Box ......................................................................................................... 7-8
Figure 7-5. Sensor Barrier Box ......................................................................................................... 7-9
Figure 7-6. Junction Box ................................................................................................................. 7-10
Figure 7-7. Pit Level Sensor ........................................................................................................... 7-12
Figure 7-8. Pump Stroke Sensor .................................................................................................... 7-14
Figure 7-9. VIP Workstation ............................................................................................................ 7-15
Appendix A
Figure A-1. Recommended Method of Splicing Shielded Cable ...................................................... A-3
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MUDWATCH - System 4
List of Figures Manual 60-30
Page LOF-4 April 30, 1999

M/D Totco
List of Tables
CHAPTER 2
DESCRIPTION
Table 2-1. MUD WATCH Specifications .......................................................................................2-14
CHAPTER 3
INSTALLATION
Table 3-1. Alarm Horn Tone Selections .........................................................................................3-11

Table 3-2. Measurable Tank Depths: Pit Level Sensors P/N 272819-series ................................3-20
Table 3-3. Measurable Tank Depths: Pit Level Sensors P/N H10924A-series ..............................3-23
CHAPTER 4
Table 4-1. Channel Descriptions: Standard MUDWATCH Configuration .......................................4-2

Table 4-2. Channel Name and Channel Type .................................................................................4-4
Table 4-3. Standard MUDWATCH Channel Configuration Information ..........................................4-5
Table 4-4. MUDWATCH Default DAQ Output Assignments ............................................................4-6
Table 4-5. Field Descriptions for Channel Configuration Screen .................................................4-12
Table 4-6. Calibration Defaults: MUDWATCH Analog Sensor Channels .....................................4-15
Table 4-7. Calibration Defaults: MUDWATCH Digital Sensor Channels ......................................4-23
CHAPTER 5
OPERATION
Table 5-1. Summary of Keypad Keys ..............................................................................................5-4
CHAPTER 6
MAINTENANCE
Table 6-1. Troubleshooting Table: MUDWATCH System ...............................................................6-2

Table 6-2. Spectrum I/F Board Jumpers ..........................................................................................6-9
Table 6-3. JP3 - SIF Board Jumper Settings .................................................................................6-10
Table 6-4. JP4 - Communication Baud Rate .................................................................................6-10
Table 6-5. JP5 - Relay Power ........................................................................................................6-10
Table 6-6. JP6 - Display Power .....................................................................................................6-10
Table 6-7. MUDWATCH INIT Codes .............................................................................................6-15
April 30, 1999 Page LOT-1

M/D Totco
MUDWATCH - System 4
List of Tables Manual 60-30
CHAPTER 7
Table 7-1. Parts List Abbreviations ..................................................................................................7-2

Table 7-2. Recommended Spare Parts Inventory .........................................................................7-16
APPENDIX B
CONVERSION DATA
Table B-1. Conversion Factors ....................................................................................................... B-2
Page LOT-2 April 30, 1999

M/D Totco
CHAPTER 1
INTRODUCTION
1-1 INTRODUCTION
This manual contains installation, operation, maintenance, configuration, calibration and parts
information for the MUDWATCH system, a mud-monitoring system manufactured by M/D Totco.
Information in this manual should enable qualified personnel to install, operate, calibrate and
maintain a MUDWATCH system.
1-2 SCOPE OF MANUAL

This manual is divided into the following chapters:
q Chapter 1 - Introduction to manual
q Chapter 2 - Description of the MUDWATCH system, its main components,

optional components and sensors; list of system specifications
q Chapter 3 - Installation of main components, optional components and sensors
q Chapter 4 - Configuration and calibration of sensor channels
q Chapter 5 - Operation of display panel keypad, description of display panel

fields and function codes
q Chapter 6 - Maintenance and troubleshooting
q Chapter 7 - Illustrated parts breakdown and recommended spare parts inventory
q Appendix A - Guidelines for working with shielded cable
q Appendix B - Conversion data
q Appendix C - General information/schedule sheets, block diagrams and intercon-

nect drawings for the five most common MUDWATCH systems
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 iii of this manual and who are fully qualified and trained to perform the
procedures herein.
April 30, 1999 Page 1-1

M/D Totco
CHAPTER 1 MUDWATCH - System 4
INTRODUCTION Manual 60-30
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.
NOTE
Provides additional information about the current topic.
CAUTION
Provides information to prevent equipment malfunction or damage that
could result in interruption of service.
WARNING
Provides information to prevent equipment malfunction or damage that

could result in serious or fatal injury to personnel or major property loss.
1-6 RELATED DOCUMENTS

M/D TOTCO documents related to the use of this manual are listed below:
• Manual 60-11: Data Acquisition Unit (DAQ) and Sensors
• Manual 60-41: TOTAL System 4 Configuration and Calibration software
• Manual 28-31: VIP (Visulogger Interface Program)
• Manual TW1022: Pit Level Sensors H10924A-series
• Manual TW658: Mud Flow Sensor MFTX4A-5
• Manual 27-45A: Mud Flow Sensor 270700-series
• Manual 27-44A: Mud Flow Sensor 270700-series Illustrated Parts Breakdown
Page 1-2 April 30, 1999

M/D Totco
CHAPTER 2
DESCRIPTION
2-1 INTRODUCTION
This chapter describes the MUDWATCH system, including its main components, optional compo-
nents and sensors. Figure 2-1 is a typical MUDWATCH system. System specifications are listed in
Table 2-1.
2-2 FUNCTION
MUDWATCH is a mud-monitoring system that collects, processes, displays and monitors the fol-
lowing data:
• active mud tank volume, trip tank volume, and gain/loss
• return mud flow
• pump rate and pump strokes
• customer-selected optional channel
If alarm conditions are reached, MUDWATCH alerts the operator via audible and visual alarms.
MUDWATCH data can be output to a VIP Workstation for real-time and historical data display and
hardcopy printouts.
FIGURE 1
2-3 MAIN COMPONENTS

The main components of a MUDWATCH system are listed below and described in the paragraphs
that follow. These components are required in all MUDWATCH configurations.
• Data Acquisition Unit (DAQ)
• MUDWATCH display panel
• Display barrier box
• I.S. alarm horn
• Cable for connecting the DAQ and to a laptop PC for configuration and calibration
WARNING
Only UL-approved and CENELEC-approved MUDWATCH components

are recommended for use in hazardous locations.
WARNING
April 30, 1999 Page 2-1

M/D Totco
April 30, 1999
Manual 60-30
MUDWATCH - System 4
PUMP STROKE
SENSOR
JUNCTION
BOX SENSOR
BARRIER BOX VIP WORKSTATION
Figure 2-1. Typical MUDWATCH System

DAQ
MUD LEVEL
SENSOR
M/D Totco
CAL/CONFIG CABLE
ASSEMBLY MUDWATCH
DISPLAY PANEL
PIT LEVEL
SENSOR AC POWER DISPLAY
BARRIER BOX
HORN
ALARM
DESCRIPTION
CHAPTER 2
Page 2-2
MUDWATCH - System 4 CHAPTER 2
Manual 60-30 DESCRIPTION
2-3-1 DAQ
The DAQ (Figure 2-2) is the data acquisition and processing device for MUDWATCH. Its
functions are summarized below.
• Powers rig sensors
• Receives and processes rig sensor data and transmits this data to the
MUDWATCH display panel
• Receives and processes data entered by the operator using the display
panel keypad
• Transmits data to the optional VIP Workstation for real-time and histori-
cal data display and hardcopy printouts
• Configures the system and calibrates sensor channels, when connected to
a laptop PC running configuration/calibration software
Two DAQ models are available: one with internal safety barriers for applications requiring
UL-certification and one without internal safety barriers for applications requiring CEN-
ELEC certification. If a barrierless DAQ is used, then a sensor barrier box (Paragraph 2-4-
1) is required.
For a thorough description of the DAQ, refer to Manual 60-11.
Figure 2-2. DAQ (Data Acquisition Unit)
April 30, 1999 Page 2-3

M/D Totco
DESCRIPTION Manual 60-30
2-3-2 MUDWATCH Display Panel

The MUDWATCH 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.
Mud volume data can be presented in barrels or cubic meters.
O PT IO N K E Y B O A RD E N T R Y
9 9 -S E T TIME
0
RE TURN FLOW G AI N / LO S S KE Y BOA RD
CO UNT ER A RETU RNS P ERCENT BA RRE LS CODE
COUNTE R A 6 4 -S E T
A CT I V E T A NK S
1 2 3 4 5 6
1 2 3
S TR O KE S 7 8 1 0 11 1 2 4 5 6
9
LI G H T-SE LE C TE D
CO UNT ER B 2 -S E T Z E R O COUNTE R B T O T A L A CT I V E V O L UM E
7 8 9
CL R
0 ENT
0
STRO KES BA RRE LS
LIG H T-S E LE C TE D PUMP 1 RAT E P U MP 2 R A T E MOD E T RIP VO L

1
820821A
2
SPM S P M BA RRE LS
T O T A L R A T E P U MP 3 R A T E
T A N K T AN K VO L
82 082 1A
0
LI GH T -S E L E C T E D S P M S P M
N O BARRELS T RI P
Figure 2-3. MUDWATCH Display Panel
Page 2-4 April 30, 1999

M/D Totco
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 six barriers, which are used
for communication (2), display panel power (1), display panel backlighting (2) 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
2-3-5 Connecting Cables

All MUDWATCH 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
Additional cables required for MUDWATCH installation may be supplied by the customer
or by M/D Totco as a basic cable kit (Paragraph 2-4-2).
April 30, 1999 Page 2-5

M/D Totco
2-4 OPTIONAL COMPONENTS

Optional components for alternate MUDWATCH configurations are listed and described below.
• Sensor barrier box
• Basic cable kit
• Quick rig-up kits
• Laptop PC
• VIP Workstation
2-4-1 Sensor Barrier Box

For CENELEC certification requirements, a sensor barrier box (Figure 2-6) is required to
ensure safe energy levels of all power supplied to sensors by the barrierless DAQ. The box
contains up to 16 barriers that can be used for pit level and flow sensors and up to 3 barri-
ers that can be used for pump stroke sensors.
Figure 2-6. Sensor Barrier Box
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2-4-2 Basic Cable Kit

The MUDWATCH basic cable kit (P/N 220452-005) consists of the following:
• Cable - one 260-foot, 12-conductor 18-gauge shielded cable for connect-
ing the DAQ, display barrier box and display panel
• Cable - one 70-foot, 3-conductor 18-gauge cable for supplying ac power
to the DAQ and for connecting the alarm horn to the display panel
• Grounding assemblies - two 5-foot #8 AWG cables with clamps for
grounding the DAQ and display barrier box
2-4-3 Quick Rig-Up Kits

Two MUDWATCH rig-up kits are available for expediting rig-up/rig-down. The contents
of each kit are described below.
Quick rig-up kit (P/N 220452-006) is used instead of the basic cable kit. The kit consists
of the following components:
• Cable assembly - a 250-foot, 12-conductor, 18-gauge shielded cable with
16-socket plug for connecting the display barrier box and display panel
• Cable assembly - a 5-foot, 12-conductor, 18-gauge shielded cable with
16-pin receptacle for connecting the display barrier box and display panel
• Grounding assemblies - two 5-foot #8 AWG cables with clamps for
grounding the DAQ and display barrier box
• Cable - a 10-foot, 12-conductor, 18-gauge shielded cable for connecting
the DAQ and display barrier box
• Cable - a 70-foot, 3-conductor, 18-gauge cable for supplying ac power to
the DAQ and for connecting the alarm horn to the display panel
• Quick disconnects - a 16-socket in-line plug and 16-pin in-line recepta-
cle that can be inserted into the cable assembly connecting the display
barrier box and display panel
Quick rig-up kit P/N 220452-004 can be used to marshall the many sensor cables into one
multicore cable to the DAQ. Two or three of these kits are often used in a typical MUD-
WATCH system. Each kit contains the following:
• Junction box - a pre-wired junction box with eight input connectors,
wired to a 36-pin terminal block and a 37-pin output receptacle
(Figure 2-7)
• Cable assembly - connects the junction box to the DAQ; a 250-foot 12-
pair shielded cable with 37-socket receptacle which connects to the junc-
tion box for easy rig-up/rig-down
• Quick-disconnects - a 37-socket in-line plug and 37-pin in-line recepta-
cle that can be inserted into the cable assembly to speed rig-up/rig-down
April 30, 1999 Page 2-7

M/D Totco
M / D TO TC O
I N S TR U ME N TA TI ON
Figure 2-7. Quick Rig-Up Kit Junction Box
2-4-4 Laptop PC
A laptop PC is used to calibrate MUDWATCH sensor channels and modify the MUD-
WATCH system configuration using configuration and calibration software (Chapter 4). It
connects to the DAQ via the nine-pin CAL/CONFIG cable assembly supplied with all
MUDWATCH systems (Figure 2-1).
2-4-5 VIP Workstation

The VIP Workstation is used to run VIP (Visulogger Interface Program). It consists of an
IBM-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
• Data files can be accessed at the rig site and off-site locations and can be
reformatted for import to spreadsheet or database applications programs
• Compare data values for each channel to user-specified alarm limits
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2-5 SENSORS
The MUDWATCH display panel displays data supplied by:
• Pit level sensors
• Mud flow sensors
• Pump stroke sensors
• Customer-specified optional sensor
2-5-1 Pit Level Sensors

Pit level sensors are used to measure the volume in surface mud tanks so that volume
increases or decreases can be detected. They are powered by +5 VDC from the DAQ and
output a voltage signal that is proportional to the mud level in the tank. The DAQ uses this
signal to calculate individual tank volume, total volume and gain/loss for all active mud
tanks and trip tanks.
Two types of pit level sensors are available. They are described in the following para-
graphs.
2-5-1-1 Pit Level Sensor P/N 272819-series
These pit level sensors (Figure 2-8) are used in MUDWATCH systems contain-
ing a DAQ with internal barriers.
A tubular stainless steel probe containing a staggered series of switches that
make up a voltage divider is mounted vertically in the tank and is connected to
the DAQ. A float attached to the probe moves with the mud level. Magnets in
the float cause the switches to close. Thus, as mud level varies, a voltage propor-
tional to the mud level is supplied to the DAQ.
Figure 2-8. Pit Level Sensor (P/N 272819-series)
April 30, 1999 Page 2-9

M/D Totco
2-5-1-2 Pit Level Sensor P/N H10924A-series
These pit level sensors (Figure 2-9) are used in MUDWATCH systems contain-
ing an external sensor barrier box.
A tubular stainless steel probe containing a slider is mounted vertically in a
bracket attached to the tank bottom. The slider is connected to the drive gear of a
potentiometer, located in a housing at the top of the probe. A float attached to
the probe moves with the mud level, and a magnet inside the float attracts the
slider. Thus, as mud level varies, the slider moves, and the potentiometer output
varies proportionally.
For a detailed description of this sensor, refer to Manual TW1022.
Figure 2-9. Pit Level Sensor (P/N H10924A-series)
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M/D Totco
2-5-2 Mud Flow Sensors

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.
Two flow sensors are available for use with MUDWATCH. They are described in the fol-
lowing paragraphs.
2-5-2-1 Mud Flow Sensor P/N MFTX4A-5
This sensor (Figure 2-10) is approved for use in all MUDWATCH systems. The
paddle on this sensor drives a potentiometer, which outputs a dc analog signal
proportional to the angle of deflection of the paddle.
Refer to Manual TW658 for details on this sensor.
Figure 2-10. Flow Sensor (P/N MFTX4A-5)
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2-5-2-2 Mud Flow Sensor P/N 270700-116
This sensor (Figure 2-11) is approved for use in MUDWATCH systems contain-
ing a DAQ with internal safety barriers. The sensor contains an electric transmit-
ter whose output signal is proportional to the angle of deflection of the paddle.
For details on this sensor, refer to Manual 27-45A.
Figure 2-11. Mud Flow Sensor (P/N 270700-116)
Page 2-12 April 30, 1999

M/D Totco
2-5-3 Pump Stroke Sensor

Pump stroke sensors are used to detect individual strokes of the mud pump. The MUD-
WATCH pump stroke sensor (Figure 2-12) 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 signal 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 2-12. Pump Stroke Sensor
2-6 MUDWATCH SPECIFICATIONS

Specifications for MUDWATCH system components are listed in Table 2-1. For certification infor-
mation not listed, contact M/D TOTCO Engineering.
NOTE
All specifications are subject to change without notice.
April 30, 1999 Page 2-13

M/D Totco
TABLE 1
Table 2-1. MUD WATCH Specifications
Parameter Requirements/Limits
Electrical:
DAQ
Primary Power 85 to 265 VAC (Y Power)
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 50 mA, typical
Backlighting Power +12 VDC (nominal)
Current 140 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
Sensor Barrier Box
Pit Level Sensor Power +5 VDC Input, +4 VDC Output
Mud Flow Sensor Power +5 VDC Input, +4 VDC Output
Pump Stroke Sensor Power +12 VDC Input, +8 VDC Output (from power barrier output)
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M/D Totco
Table 2-1. MUD WATCH Specifications (Continued)
Environmental:
DAQ
Operating Temperature -20oC to +60oC (-4oF to +140oF)
Storage Temperature -30oC to +85oC (-22oF to +185oF)
Internal Humidity 5% to 90% non-condensing
Display Panel
Display Barrier Box:
Alarm Horn
Internal Humidity 95% maximum at 40oC (104oF)
Sensor Barrier Box:
(Continued)
April 30, 1999 Page 2-15

M/D Totco
Mechanical:
DAQ
Enclosure Stainless steel, NEMA 4X (IP 65)
Dimensions - inches (mm) 21.5 L x 19.0 W x 8.5 D (546 mm x 482 mm x 216 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) @ 90 o arc
Weight 57 lb (126 kg)
Display Panel
Enclosure Stainless steel, NEMA 4X (IP 56)
Dimensions - inches (mm) 18.14 L x 24.52 W x 5.20 D (460.7 mm x 622.8 mm x 132.0 mm)
Mounting Hole Separations 19.40 L x 15.02 W (492.8 mm x 381.5 mm)
Mounting Hole Diameter 0.44 (11.2 mm)
Weight 47 lb (21.3 kg)
Display Barrier Box
Enclosure Sheet steel, zinc-sprayed and painted, NEMA 4 (IP67)
Dimensions - inches (mm) 9.38 L x 6.00 W x 5.70 D (238.2 mm x 152.4 mm x 145.0 mm)
Alarm Horn
Enclosure Molded ABS, NEMA 4 (IP55)
Dimensions - inches (mm) 5.27 L x 5.27 W x 5.04 H (133.9 mm x 133.9 mm x 128.0 mm)
Mounting Hole Separations 6.02 (153 mm)
Mounting Hole Diameter 0.31 (8 mm)
Weight 1.5 lb (0.7 kg)
Page 2-16 April 30, 1999

M/D Totco
Sensor Barrier Box
Enclosure Sheet steel, zinc-sprayed and painted, NEMA 4 (IP67)
Weight 33 lb (15 kg)
Junction Box
Enclosure Stainless steel, NEMA 4X (IP66)
Suitable for Area:
DAQ NEC Class 1 Div 2, IEC Zone 2
MUDWATCH Display Panel CENELEC Zone 0, 1, 2
Display Barrier Box Non-hazardous
Alarm Horn CENELEC Zone 0, 1, 2
Sensor Barrier Box Non-hazardous
Junction Box Hazardous area
Pit Level Sensor NEC Class 1 Div 1, IEC Zone 0, 1, 2
(P/N 272819-series)
Pit Level Sensor NEC Class 1 Div 1, IEC Zone 0, 1, 2, CENELEC Zone 0, 1, 2
(P/N H10924A-series)
Mud Flow Sensor NEC Class 1 Div 1, IEC Zone 0, 1, 2
(P/N 270700-116)
Mud Flow Sensor NEC Class 1 Div 1, IEC Zone 0, 1, 2
(P/N MFTX4A-5)
Pump Stroke Sensor NEC Class 1 Div 1, IEC Zone 0, 1, 2, CENELEC Zone 0, 1, 2
April 30, 1999 Page 2-17

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M/D Totco
CHAPTER 3
INSTALLATION
3-1 INTRODUCTION
This chapter contains procedures for the following:
• Main component installation
• Optional component installation
• Sensor installation
For block diagrams and point-to-point wiring diagrams at the system level, refer to Appendix C.
3-2 INSTALLATION LOCATION REQUIREMENTS

Figure 3-1 shows location requirements for MUDWATCH main components, optional components
and sensors.
WARNING
Install MUDWATCH components in accordance with the procedures in this

chapter and use only replacement parts listed in the spare parts inventory
(Table 7-2). Incorrect installation could result in explosion or fire hazard.
April 30, 1999 Page 3-1

M/D Totco
INSTALLATION Manual 60-30
Figure 3-1. Installation Location Requirements: MUDWATCH System
Page 3-2 April 30, 1999

M/D Totco
Manual 60-30 INSTALLATION
3-3 DAQ INSTALLATION

To install the DAQ, follow the steps below.
1. Mount the DAQ (Paragraph 3-3-1).
2. Earth ground the DAQ (Paragraph 3-3-2).
3. Connect ac power cable to DAQ (Paragraph 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
April 30, 1999 Page 3-3

M/D Totco
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 and 1/2-inch in diameter, and 2) 1/2-inch copper clad ground clamp
NOTE
Grounding requirements may vary. Consult local electrical codes for
specific requirements.
CAUTION
All earth ground connections must be made in non-hazardous areas.
Ensure that all connecting surfaces are bare metal and completely free of
grease, paint or oxidation. Do not solder earth ground connections.
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 rod
exposed for attachment of cable assembly ground clamp. Then make secure compres-
sion connection between grounding rod and 1/2-inch ground clamp.
Page 3-4 April 30, 1999

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3-3-3 Connect AC Power Cable to DAQ

To connect the AC power cable to the DAQ, follow the steps below.
CAUTION
Ensure ground wire is properly installed before connecting ac power cable
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
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
April 30, 1999 Page 3-5

M/D Totco
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.
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 bolted
directly to a rigid structure or to mounting brackets and then clamped securely to a rigid structure.
Page 3-6 April 30, 1999

M/D Totco
0 .44 (11.2 mm)
.63 (16.0 mm)
OP TION K E Y BO A R D EN T R Y
9 9- S E T TI ME
0
R E T U RN F L O W G AI N/ L OS S KE Y BOA RD
RETU RNS PERC ENT BARR ELS CODE

COU NTE R A
COUNTE R A 6 4 - S ET
A CT IV E TA NK S
1 2 3 4 5 6
1 2 3
18.14
19.40 L IG H T - S E L E C T E D
C O U NT E R B 2- S E T Z E R O
ST RO KE S
COUNTE R B
7 8 9 10
T O T A L A C T IV E V O L U M E
11 12 4
7
5
8
6
9
(460.7 mm)
(492.8 mm) S T RO K E S
0
CL R 0 ENT
B AR R EL S
LIGH T-S E LE C TE D P UM P 1 R ATE P U MP 2 R A T E M ODE T RI P VO L

1
8 20 8 21 A
SPM S P M B A RR E L S
TOTAL RATE PU MP 3 RA T E
T A N K T A NK V O L
8 2 08 2 1 A
0
LIGH T-S E LE C TE D S P M S P M N O BARR ELS T R IP
0.87
4.75 5.20
(22.1 mm)
(120.6 mm) (132.0 mm)
15.02
(381.5 mm)
24.52
(622.8 mm)
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 (Paragraph 3-5-1).
2. Ground the barrier box (Paragraph 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.
April 30, 1999 Page 3-7

M/D Totco
0.39 (10.0 mm)
M/D TOTCO
INSTRUMENTATION
5.90
(149.9 mm)
9.38
(238.2 mm)
0.50
(12.7 mm)
6.00 5.70
(152.4 mm) (145.0 mm)
7.00
(177.8 mm)
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 for
specific requirements.
Page 3-8 April 30, 1999

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CAUTION
All earth ground connections must be made in non-hazardous areas.
Ensure that all connecting surfaces are bare metal and completely free of
grease, paint or oxidation. Do not solder earth ground connections.
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 compres-
sion connection between grounding rod and 1/2-inch ground clamp.
Figure 3-7. Display Barrier Box Grounding
April 30, 1999 Page 3-9

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3-6 ALARM HORN INSTALLATION

Alarm horn installation consists of the following:
1. Mount the horn. (Paragraph 3-6-1)
2. Set horn tone and volume. (Paragraph 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.
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 maxi-
mum volume is 101 dB(A).
0.32 (8.1 mm) TB1
6.02
(152.9 mm)
5.27
M /D TO TCO
I NS TRUM E NTATI O N
(133.9 mm)
5.04
5.27 (128.0 mm)
(133.9 mm)
VOLUME CONTROL
TONE SELECTION
DIP SWITCH
Figure 3-8. Alarm Horn Installation
Page 3-10 April 30, 1999

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Table 3-1. Alarm Horn Tone Selections
Tone Open Switch Positions (all

(sound level/current)* other positions closed)
Continuous Tone 1
800 Hz (101 dB(A)/21 mA)
Continuous Tone 1, 2, 3
2400 Hz (105 dB(A)/32 mA)
Interrupted Tone 1, 2
800 Hz at 0.5 sec (98 dB(A)/17mA)
Interrupted Tone 1, 4
2400 Hz at 0.5 sec (102 dB(A)/23mA)
Alternate Two-Tone 1, 3
800/1000 Hz at 0.5 sec (101 dB(A)/23 mA)
Alternate Two-Tone 2, 3
2400/2900 Hz at 0.5 sec (105 dB(A)/34 mA)
Alternate Fast Two-Tone 3
800/1000 Hz at 0.25 sec (101 dB(A)/23 mA)
Fast Whoop** 1, 2, 3, 4
500-1200 Hz at 0.1 sec (101 dB(A)/19 mA)
Slow Whoop 1, 2, 4
500-1200 Hz at 3 sec (101 dB(A)/23 mA)
Swept Frequency 1, 3, 4
1200-5000 Hz at 1 sec (100 dB(A)/36 mA)
Siren 2, 3, 4
at 3 sec (100 dB(A)/22 mA)
* 24 VDC supply via zener barrier
** Factory default/recommended
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.
• 12-conductor, 18 gauge shielded cable to connect the DAQ to the display barrier box
• 12-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
April 30, 1999 Page 3-11

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14
TB3
Figure 3-9. Wiring: DAQ to Display Panel
Page 3-12 April 30, 1999

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SPECTRUM I/F (SIF) PCB
SCREW CLAMP
PLUG-IN
CONNECTORS
EXANE JACKET
AND SHIELD
STRIPPED OFF
CABLE GLAND EXANE CABLE

(USER SPECIFIED) 12 CONDUCTOR W/SHIELD
Figure 3-10. View of Internal DAQ Wiring: 12 conductor cable to SIF PCB
April 30, 1999 Page 3-13

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3-8 SENSOR BARRIER BOX INSTALLATION

Install the sensor barrier box in a non-hazardous location using four 3/8-16 UNC (or M8) mount-
ing bolts (Figure 3-11). 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 adequate clearance above
and below box for cable connections. Allow adequate clearance in front of box for door to swing
fully open.
Ground the barrier box according to the procedure in Paragraph 3-5-2 before connecting the box to
sensors and to the DAQ. Instructions for connecting sensors through the sensor barrier box to the
DAQ are described in the installation procedure for each sensor in this chapter.
18.50
(469.9 mm) M/D TO TC O
I N S T R U ME N T A T I O N
12.00
0.39 (10.0 mm)
(304.8 mm)
5.68
(144.3 mm)
0.50
(12.7 mm) 15.00
(381.0 mm)
16.00
(406.4 mm)
Figure 3-11. Sensor Barrier Box Mounting Dimensions
Page 3-14 April 30, 1999

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3-9 JUNCTION BOX INSTALLATION

Install the junction box using four 1/4-20 UNC (or M6) mounting bolts (Figure 3-12). The junction
box can be bolted directly to a rigid structure or bolted to mounting brackets and then clamped
securely to a rigid structure. Allow ample clearance on the sides and bottom for cables.
The junction box is pre-wired. This internal wiring is illustrated in Figure 3-13.
10.30
(261.6 mm)
8.00 0.37 (8.4 mm)

(203.2 mm)
12.75
(323.8 mm)
M / D T O TC O
IN ST RU MEN TA TI ON
12.00
(304.8 mm)
0.31 (7.8 mm)
6.15
(156.2 mm)
J2 J1
Figure 3-12. Junction Box Mounting Dimensions
April 30, 1999 Page 3-15

M/D Totco
J109 TB2 TB1 J101

A BLK 19 1 BLK A
B WHT 20 2 WHT B
D GRA 21 3 GRA D
C RED 22 4 RED C
J111 J103
C RED 23 5 RED C
D GRA 24 6 GRA D
A BLK 25 7 BLK A
B WHT 26 8 WHT B
27 9
J113 J105
A BLK 28 1 0 BLK A
B WHT 29 1 1 WHT B
D GRA 30 1 2 GRA D
C RED 31 1 3 RED C
J115 J107
C RED 32 W H T /B L K /R E D 14 RED C
D GRA 33 15 GRA D
O R N /G R N
B L U /W H T
W H T /R E D
BLK 34 16 BLK
B L U /R E D
A A
B WHT 35 17 WHT B
R E D /W H T
B L K /W H T
O R N /B L K
R E D /B L K
36 18
W HT
BLU
GRN
R E D /B L K /W H T
B L K /W H T /R E D
R E D /G R N
O R N /R E D
G R N /W H T
B L K /R E D
G R N /B L K
W H T /B L K
B L U /B L K
RED
ORN
BLK
GRA
GRA
GRA
GRA
GRA
GRA
GRA
GRA
GRA
GRA
GRA
GRA
36 34 32 30 28 26 24 22 20 2 4 6 8 10 12 14 16 18
J1
35 33 31 29 27 25 23 21 19 1 3 5 7 9 11 13 15 17
Figure 3-13. Junction Box Internal Wiring
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3-10 VIP WORKSTATION INSTALLATION

The VIP Workstation is pre-configured for MUDWATCH and automatically initializes VIP upon
power-up. Follow the steps below and refer to Figure 3-14 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 3-14) - 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 3-14. VIP Workstation Installation
April 30, 1999 Page 3-17

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3-11 SENSOR INSTALLATION

All MUDWATCH sensors supply input to the DAQ. In systems using a DAQ with internal safety
barriers, sensor cables can be routed through a junction box (optional) and then connected to the
DAQ field termination board. In systems using a barrierless DAQ, sensor cables can be routed
through a junction box (optional), then through a sensor barrier box (required) and connected to
the field termination board. Tables 4-4 and 4-5 list the default analog and digital connectors for
each sensor.
CAUTION
Be sure to connect each sensor to its default connector. Otherwise, the
MUDWATCH configuration must be modified to identify the connectors
used.
3-11-1 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 3-15. 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
MUDWATCH pit level and mud flow 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 MUDWATCH pit level sensors and mud flow sensor, these
switches should be set to "voltage" (i.e., depressed away from 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
MUDWATCH pump stroke 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 MUDWATCH
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 not
used in a typical MUDWATCH system.
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Figure 3-15. DAQ Field Termination Board
April 30, 1999 Page 3-19

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3-11-2 Pit Level Sensor Installation

Procedures for installing MUDWATCH pit level sensors are presented in the following
paragraphs.
3-11-2-1 Installation Of Pit Level Sensor P/N 272819-series
1. Refer to Table 3-2 to ensure pit level sensor is correct length for tank.
NOTE
Probe length does not equal the maximum measurable tank depth.
2. If float is not already installed, loosen set screws in retaining col-

lar, remove collar from end of probe and slide float on. Replace
retaining collar, as follows: if 8-inch spherical float is used (Fig-
ure 3-16), align top of collar with lowermost line etched on
probe; if 20-inch disk float is used, align top of collar with upper
etched line.
3. Identify area of least turbulence in tank. Attach mounting clamp
to tank edge or on cross-member over tank.
WARNING
Pit level probe must not contact mud pit agitator. Severe equipment
damage could result.
4. Adjust extension bracket over tank.

5. Place probe assembly in area of least turbulence in tank and, with
probe vertical, move probe assembly in circular pattern to ensure
float movement will not be hampered as mud level changes.
6. Place probe in clamp and tighten clamp bolts, keeping probe vertical.
7. Remove sensor cover; run sensor cable through strain relief connector.
8. Refer to Figures 3-15, 3-16 and 3-17 to connect sensor cable to
sensor and to DAQ. Replace cover. Ensure cable is not in walk-
ways, wet areas or close proximity to power cables.
Table 3-2. Measurable Tank Depths: Pit Level Sensors P/N 272819-series
Sensor Part Number Sensor Description Maximum Measurable Tank Depth
272819-229 6-foot probe 4.2 feet (1.3 m)
272819-225 8-foot probe 6.2 feet (1.9 m)
272819-226 10-foot probe 8.2 feet (2.5 m)
272819-227 15-foot probe 14.9 feet (4.5 m)
272819-228 20-foot probe 19.9 feet (6.0 m)
Page 3-20 April 30, 1999

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Figure 3-16. Pit Level Sensor Installation (P/N 272819-series)
Figure 3-17. Pit Level Sensor Wiring (P/N 272819-2XX) DAQ with Barriers Only
April 30, 1999 Page 3-21

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3-11-2-2 Installation Of Pit Level Sensor P/N H10924A-series
1. Refer to Table 3-3 to ensure pit level sensor is correct length for
tank.
NOTE
Probe length does not equal the maximum measurable tank depth
2. Slide float onto stem.

3. Identify area of least turbulence in tank. Position bracket on tank
bottom so that probe is vertical when seated in bracket; ensure
float movement will not be hampered as mud level changes.
Secure bracket in place on tank bottom by welding or bolting.
WARNING
Pit level probe must not contact mud pit agitator. Sever equipment damage
could result.
4. Attach mounting clamp to tank edge or on cross-member over

tank.
5. Place probe assembly in bracket on tank bottom. Adjust extension
bracket over tank so that probe is vertical.
6. Place probe in clamp and tighten clamp bolts, keeping probe ver-
tical.
7. Remove sensor cover (Figure 3-18) and run sensor cable through
strain relief connector.
8. Refer to Figures 3-15 and 3-19 to connect sensor cable to sensor
and to DAQ. Replace cover. Ensure cable is not in walkways, wet
areas or close proximity to power cables.
Page 3-22 April 30, 1999

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Table 3-3. Measurable Tank Depths: Pit Level Sensors P/N H10924A-series
Sensor Part Number Probe Length (feet) Maximum Measurable Tank Depth
H10924A-06 6 4.5 feet (1.4 m)
H10924A-07 7 5.5 feet (1.7 m)
H10924A-08 8 6.5 feet (2.0 m)
H10924A-09 9 7.5 feet (2.3 m)
H10924A-10 10 8.5 feet (2.6 m)
H10924A-11 11 9.5 feet (2.9 m)
H10924A-12 12 10.5 feet (3.2 m)
H10924A-13 13 11.5 feet (3.5 m)
H10924A-15 15 13.5 feet (4.1 m)
H10924A-16 16 14.5 feet (4.4 m)
H10924A-18 18 16.5 feet (5.0 m)
H10924A-19 19 17.5 feet (5.3 m)
H10924A-20 20 18.5 feet (5.6 m)
H10924A-22 22 20.5 feet (6.2 m)
H10924A-30 30 28.5 feet (8.7 m)
April 30, 1999 Page 3-23

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Figure 3-18. Pit Level Sensor Installation (P/N H10924A-series)
Figure 3-19. Pit Level Sensor Wiring (P/N H10924A-series)
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3-11-3 Mud Flow Sensor Installation

Procedures for installing MUDWATCH flow sensors are presented in the following para-
graphs.
3-11-3-1 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 3-20). 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 and
mechanical components, including potentiometer, resistor and linkage
assembly between paddle and drive shaft. Refer to Manual 27-45A for
additional 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
NOTE
If a base is mounted to the flow line from a previous rig-up and meets the
above requirements, use it. Otherwise, proceed to Step 7.
April 30, 1999 Page 3-25

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WARNING
Be sure area is free of explosive vapors before using welding torch.
7. Cut a 7.5 x 4.00 (190.5 mm x 101.6 mm) hole lengthwise in the

flow line (Figure 3-21) 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 Figures 3-15, 3-20, and 3-
22 to connect sensor cable to sensor and to DAQ. Replace cover.
Ensure cable is not in walkways, wet areas or near power cables.
Page 3-26 April 30, 1999

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Figure 3-20. Flow Sensor Components: P/N 270700-116
April 30, 1999 Page 3-27

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Figure 3-21. Flow Sensor Installation: P/N 270700-116
Figure 3-22. Flow Sensor Wiring: P/N 270700-116 (DAQ with Internal Barriers)
Page 3-28 April 30, 1999

M/D Totco
3-11-3-2 Installation Of Mud Flow Sensor P/N MFTX4A-5
Follow the steps below to install and calibrate this mud flow sensor.
1. Select a location on the flow line for installing the mud flow
sensor. This location must meet the following criteria:
• slopes down toward shaker pit
• is accessible for servicing
• is above spillover level of shale shaker
• is away from bends in the flow line
NOTE
If a base mounted to the flow line from a previous rig-up meets the above
requirements, it can be used. Otherwise, proceed to Step 2.
WARNING
Be sure area is free of explosive vapors before using welding torch.
2. Cut a 9.25" x 2.50" (235 mm x 63.5 mm) hole lengthwise in return flow
line (Figure 3-23) and weld sensor base squarely onto flow line. Be
sure base containing three holes is upstream from other end.
3. Determine flow line diameter and select appropriate paddle size.
4. Measure from top of flow flange to bottom of flow line to deter-
mine where on sensor to mount paddle, then attach using furnished
screws. Ensure locking nuts for screws are on downstream side of
paddle arm. Place paddle through hole in pipe, with concave side
facing upstream.
5. 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, adjust paddle using holes in paddle
arm, if necessary.
6. Ensure base has sufficiently cooled from welding; then position
neoprene gasket on face of base.
7. Rotate flow sensor approximately 90o to place paddle through opening;
then rotate it back to align body with base and bolt to base.
8. Remove potentiometer housing cover (Figure 3-24). Set sensor
zero point by holding paddle in down position. Loosen two
screws and slide potentiometer assembly until 150-250 ohms is
present between terminals 1 and 2 on TB1. Tighten screws.
9. Connect sensor cable to TB1 and then either directly to DAQ
(Figures 3-15 and3-25) or through sensor barrier box to DAQ
(Figure 3-26). Replace cover.
April 30, 1999 Page 3-29

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Figure 3-23. Mud Flow Sensor Installation: P/N MFTX4A-5
Figure 3-24. Mud Flow Sensor Calibration: P/N MFTX4A-5
Page 3-30 April 30, 1999

M/D Totco
Figure 3-25. Mud Flow Sensor MFTX4A-5 Wiring to DAQ with Internal Barriers
Figure 3-26. Mud Flow Sensor MFTX4A-5 Wiring to Barrierless DAQ
April 30, 1999 Page 3-31

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3-11-4 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 3-27. Follow the
steps below to install this sensor.
1. Remove crosshead inspection plate and gasket, if possible, from mud pump
housing.
CAUTION
Be careful not damage crosshead inspection plate gasket.
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 (Dimen-
sion A, Figure 3-28).
4. Determine minimum distance between inspection plate surface and crosshead
in one complete pump stroke (Dimension B, Figure 3-28).
Figure 3-27. Pump Stroke Sensor Installation Dimensions
Page 3-32 April 30, 1999

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Figure 3-28. Pump Stroke Sensor Mounting Methods
April 30, 1999 Page 3-33

M/D Totco
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.
NOTE
A pilot hole approximately 3/8-inch (10 mm) provides accuracy for larger
drill.
6. Determine distance between crosshead and inside edge of inspec-

tion plate by placing a straight edge across opening and measur-
ing perpendicular distance. Allow 3/16 - 3/8-inch (5-10 mm)
between sensor and part of crosshead being sensed (Dimension
C, Figure 3-28).
7. Mount bulkhead union and tighten locknut (Figure 3-29).
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 3-29. Pump Stroke Sensor Installation
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11. Connect sensor cable to sensor terminal strip and either directly
to DAQ (Figures 3-15 and 3-30) or through sensor barrier box to
DAQ (Figure 3-31). Ensure cable is not in walkways, wet areas or
close proximity to power cables.
Figure 3-30. Pump Stroke Sensor Wiring to DAQ with Internal Barriers
Figure 3-31. Pump Stroke Sensor Wiring to Barrierless DAQ
April 30, 1999 Page 3-35

M/D Totco
12. Use a voltmeter to ensure that sensor pulses when crosshead com-
pletes one full stroke. Supply power to sensor and connect meter
to sensor as shown in Figure 3-32.
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 3-32. Pump Stroke Sensor Position Check
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3-12 MUDWATCH 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 3-15). 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.
NOTE
Each digital connector can be used for input or output, but not both.
Figure 3-33. Typical Digital Output Wiring
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3-13 SYSTEM POWER-UP

Follow the steps below to power-up a MUDWATCH 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 main processor LED and analog processor LED on DAQ digital board are
blinking (Figure 6-4).
4. Check for the following:
5. The red LED’s D1 and D2 on the SIF PCB should flash continuously.
6. Data should be displayed on MUDWATCH display panel
7. Close DAQ rear door.
8. 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.
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CHAPTER 4
4-1 INTRODUCTION
Configuration and Calibration Software is used to load the MUDWATCH configuration, edit the
configuration (if necessary) and calibrate sensor inputs and digital output channels (if used). This
chapter contains the following:
• Description of standard MUDWATCH configuration channels
• Procedures for starting up the Configuration & Calibration software and loading
the MUDWATCH configuration
• Procedures for editing the MUDWATCH configuration
• Procedures for calibrating analog and digital sensor channels and outputs (if used)
• Procedures for saving the configuration/calibration to floppy
Figure 4-1 shows the recommended configuration and calibration procedure.
Initialize Configuration & Calibration Software

(Section 4-3)
Load the MUDWATCH Configuration

from Disk (Section 4-4)
Edit MUDWATCH Configuration to Match

Rig Configuration, if necessary (Section 4-5)
Calculate Pit Volumes (Section 4-6-1) &

Calibrate Analog Sensor Channels (Section 4-6-2)
Calibrate Digital Sensor Channels

(Section 4-6-3)
Save Configuration & Calibration to Floppy

(Section 4-7)
Figure 4-1. Recommended MUDWATCH Configuration and Calibration Procedure
April 30, 1999 Page 4-1

M/D Totco
CONFIGURATION & CALIBRATION Manual 60-30
4-2 MUDWATCH CHANNELS

The standard MUDWATCH configuration contains 42 channels that either represent display fields
(i.e., the RETURN FLOW channel represents the RETURN FLOW field) or are used to calculate
display field values (i.e., MUD PIT 1 is used to calculate the value displayed in the TOTAL
ACTIVE VOLUME field). Each channel is assigned a logical channel number, which the software
uses to identify the channel.
Table 4-1 describes each MUDWATCH channel and Table 4-3 lists the default sensor type and
required configured channels for each. Table 4-4 lists default MUDWATCH outputs, which can be
used to drive other devices, such as chart recorders or meters. Table 4-6 and Table 4-7 list calibra-
tion defaults for standard MUDWATCH systems.
Table 4-1. Channel Descriptions: Standard MUDWATCH Configuration
Channel # Channel Name Description

001 SYNCH A synchronization channel that VIP software uses in place of the
DEPTH channel
007 FLOW OUT % The rate of mud flow leaving the hole, in percent of the flow line fill
volume
010 - 021 MUD PIT 1 through The volume of mud in Pits 1 through 12, in barrels*
MUD PIT 12
022 TRIP TANK 1 The volume of mud in Trip Tank 1, in barrels*
023 TRIP TANK 2 The volume of mud in Trip Tank 2, in barrels*
037 TANK NUMBER The number of the mud or trip tank whose volume is displayed in
the TANK VOLUME field
039 TANK VOLUME The volume of the selected mud or trip tank (i.e., the tank whose
number is displayed in the TANK NUMBER field)
047 STROKES 1B The number of strokes of Mud Pump 1 since the STROKES 1B
channel was activated. These pump strokes are included in the
number of strokes displayed in the COUNTER B field.
054 PUMP SPM 1 The rate of Mud Pump 1, in strokes per minute
The number of strokes of Mud Pump 1 since the STROKES 1A
055 STROKES 1A channel was activated. These pump strokes are included in the
number of strokes displayed in the COUNTER A field.
057 STROKES 2A channel was activated. These pump strokes will be included in
the number of strokes displayed in the COUNTER A field.
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Manual 60-30 CONFIGURATION & CALIBRATION
Table 4-1. Channel Descriptions: Standard MUDWATCH Configuration (Continued)
Channel # Channel Name Description

059 STROKES 3A channel was activated. These pump strokes will be included in
the number of strokes displayed in the COUNTER A field.
063 COUNTER B The number of strokes of all active mud pumps in the indicator
field labeled "COUNTER B”
069 OPTION An operator-specified sensor channel
070 DRILL/TRIP A manual channel that specifies drilling mode or tripping mode
077 TOTAL SPM The combined rate of all active mud pumps in the indicator field
labeled TOTAL RATE
078 COUNTER A The number of strokes of all active mud pumps in the indicator
field labeled "COUNTER A"
083 MUD VOLUME The total volume of mud in all active mud pits, in barrels*
084 GAIN/LOSS The gain or loss in the volume of mud monitored by the TOTAL
VOLUME channel, in barrels*
086 TRIP TOT VOL The volume of mud in all active trip tanks, in barrels
189 SPM TRIGGER A user-specified SPM value below which the LOW RETURN
FLOW ALARM is disabled. The purpose of this channel is to pre-
vent the alarm from sounding due to low or zero return flow when
the pumps are stopped.
200 MASTER DAQ The version number of DAQ software
201 UNIT 1 VER. The version number of MUDWATCH software
348 MUDWATCH.CHN The name of the current configuration
* If the display panel presents volume in cubic meters, the MUDWATCH configuration must be modified.
Refer to Paragraph 4-5 for instructions on modifying the configuration.
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Table 4-2. Channel Name and Channel Type
Channel # Channel Name Channel Type

001 Synch
007 Flow Out % MUD FLOW OUT PERCE
010 - 021 Mud Pit 1 Through MUD TANK VOLUME 1 -
Mud Pit 12 MUD TANK VOLUME 12
022 Trip Tank 1 TRIP VOLUME 1
023 Trip Tank 2 TRIP VOLUME 2
037 Tank Number DSI SEL TANK NO
039 Tank Volume STANDARD
047 Strokes 1B PUMP COUNT B 1
054 Pump SPM 1 PUMP SPM 1
055 Strokes 1A PUMP COUNT A 1
063 Counter B STANDARD
069 Option STANDARD
070 Drill/Trip DSI DRILL TRIP
077 Total SPM DSI TOTAL SPM
078 Counter A STANDARD
083 Mud Volume TOTAL VOLUME
084 Gain/Loss GAIN LOSS
086 Trip Tot Vol TRIP TOT VOL
189 SPM Trigger DSI SPM TRIGGER
200 Master DAQ VERSION NUMBER 1
201 Unit 1 Ver. VERSION NUMBER 2
348 Mudwatch.chn Config Channel
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Table 4-3. Standard MUDWATCH Channel Configuration Information
Channel # Channel Name Sensor Type Required Configured Channels

001 SYNCH MANUAL --
007 FLOW OUT % VOLTAGE (0-5) --
010 MUD PIT 1 VOLTAGE (0-5) --
022 TRIP TANK 1 VOLTAGE (0-5) --
023 TRIP TANK 2 VOLTAGE (0-5) --
037 TANK NUMBER MANUAL --
039 TANK VOLUME DERIVED TANK NUMBER and the tank indicated by
TANK NUMBER
047 STROKES 1B EVENT DRILL/TRIP, RETURN FLOW
054 PUMP SPM 1 RATE --
055 STROKES 1A EVENT DRILL/TRIP, RETURN FLOW
063 COUNTER B DERIVED STROKES 1B, STROKES 2B, STROKES
3B, DRILL/TRIP, RETURN FLOW
069 OPTION CURRENT --
070 DRILL/TRIP MANUAL --
077 TOTAL SPM DERIVED SPM 1, SPM 2, SPM 3
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Table 4-3. Standard MUDWATCH Channel Configuration Information (Continued)
Channel # Channel Name Sensor Type Required Configured Channels

078 COUNTER A DERIVED STROKES 1A, STROKES 2A, STROKES
3A, DRILL/TRIP, RETURN FLOW
083 MUD VOLUME DERIVED All active MUD PIT channels
084 GAIN/LOSS DERIVED TOTAL VOLUME
086 TRIP TOT VOL DERIVED All active TRIP TANK channels
189 SPM TRIGGER MANUAL --
200 MASTER DAQ MANUAL --
201 UNIT 1 VER. MANUAL --
348 MUDWATCH.CHN N/A N/A
Table 4-4. MUDWATCH Default DAQ Output Assignments
Channel Name DAQ Connector Output Type Low Scale High Scale
PUMP SPM1 J2D ANALOG (CHART) 0 300
PUMP SPM 2 J4D ANALOG (CHART) 0 300
PUMP SPM 3 J6D ANALOG (CHART) 0 300
TOTAL SPM J10D ANALOG (CHART) 0 300
GAIN/LOSS J12D ANALOG (CHART) -50 50
MUDVOLUME J11D ANALOG (CHART) 0 1000
FLOW OUT % J9D ANALOG (CHART) 0 100
TRIP VOLUME J13D ANALOG (CHART) 0 100
OPTION J14D ANALOG (CHART) 0 100
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4-3 CONFIGURATION & CALIBRATION SOFTWARE START-UP

The Configuration & Calibration software is downloaded from a laptop PC’s hard drive to the
DAQ. 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.
The hard drive is accessed and checked for configuration units, and the Configuration and Calibra-
tion Main Menu is displayed (Figure 4-3)
Figure 4-2. Laptop PC Connection to DAQ
Figure 4-3. Configuration & Calibration Main Menu Screen
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4-4 LOADING THE MUDWATCH CONFIGURATION FROM FLOPPY

The MUDWATCH 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, algorithms and
numerical constants used by MUDWATCH software.
For standard MUDWATCH systems (i.e., those that contain only the channels listed in Table 4-1),
the system configuration files are named MUDWATCH. For non-standard MUDWATCH 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 from disk.
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 Paragraph 4-5 if it is necessary to edit the configuration.
Otherwise, proceed to Paragraph 4-6 to calibrate the sensor channels.
Figure 4-4. DISK: [LOAD ALL] Menu Screen
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4-5 CONFIGURATION
The MUDWATCH configuration should only be edited if:
• volumes are displayed in cubic meters (instead of barrels) on the MUDWATCH
display panel, or-
• the default channel output low and/or high scale values are not correct for the
device used, or-
• the option channel must be configured.
NOTE
The MUDWATCH configuration must be edited if it differs in any way from
the actual rig configuration. Erroneous data may result if the configuration
is not updated to reflect the rig configuration.
The following procedure summarizes how to edit the system configuration if the first or second
condition listed above exists. To configure the option channel or for a thorough explanation of how
to edit configurations, refer to Manual 60-41.
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 is displayed.
Figure 4-5. [CONFIGURATION] Submenu
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3. Select CHANNEL & SENSOR: [EDIT] and press ENTER. Refer to Figure 4-6.
Figure 4-6. SYSTEM/DAQ CONFIGURATION Screen
4. A submenu of channel names is displayed (Figure 4-7). Select the name of the channel
to edit and press ENTER.
Figure 4-7. [EDIT] Channel Pull-Down
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5. The Channel Configuration screen is displayed (Figure 4-8). Edit the necessary field(s) on
the Channel Configuration screen. Refer to Table 4-5 for Field description information.
Figure 4-8. Typical 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 Steps 4 and 5.
To exit Configuration mode, press the [Esc] key; the submenu is closed. Press the [Esc] key
again.
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, select
ABORT.
NOTE
If ABORT is selected, the configuration edits made in Step 5 are still stored
in the calibration laptop, even though they have not been sent to the DAQ.
The fields on the Channel Configuration Screen are summarized in Table 4-5.
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Table 4-5. Field Descriptions for Channel Configuration Screen
Field Description
Channel Name The channel name (up to 12 characters, including blanks). This
is the label used when a channel is displayed.
Name (part 1) The first part of the channel name displayed on VIP print/plots.
Name (part 2) The second part of the channel name displayed on VIP print/
plots.
Units The engineering units (maximum of eight characters) that will
be used for display.
Precision The number of digits that can be displayed to the right of the
decimal point. A maximum of 7 numbers, including decimal
points, can be displayed.
Algorithm Type Specifies whether to use an internal algorithm, external algo-
rithm or no algorithm to calculate the channel value. Internal
algorithms are those most commonly used by all channels;
they are burned into the DAQ EPROM and cannot be viewed
or edited. External algorithms are not often used; they can be
viewed and edited by selecting ALGORITHMS from the SYS-
TEM/DAQ Configuration screen. For a summary of all algo-
rithms, refer to Appendix C.
Algorithm The name of the algorithm used to calculate the channel value,
For a summary of all algorithms, refer to Appendix C.
Filter Value The value, in percent, by which raw input data is filtered before
it is used in the algorithm. Each raw data value is averaged
with the previously filtered data value.
The larger the Filter Value, the more the new data value is
affected by the previous value; a Filter Value of 0 results in no
filtering. The maximum allowable filter value is 99.9.
Rate The frequency at which the channel value will be updated
Channel Type The type of channel; The algorithms use the channel type, not
the channel name, to locate input data for their calculations;
consequently, the channel type assigned to a channel should
not be changed.
Sensor Type The sensor type used for the channel.
Connector The number of the connector that the channel sensor is con-
nected to. For analog sensors, select from 1A to 23A; for digital
sensors, select a from 1D to 14D.
Conversion Factor/Con- Used by the DAQ to convert the channel to some unit other
version Addition than English units. The channel value that the DAQ sends out
to the display devices and CalConf will be the English channel
value multiplied by the conversion factor and then added to the
conversion addition.
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Table 4-5. Field Descriptions for Channel Configuration Screen (Continued)
Field Description
Function Configures a function to execute when a digital interrupt
occurs.
Operator can/cannot Not used by the MUDWATCH system.
modify channel
zero channel
activate channel
Channel is / is not ini- This field tells if the channel is currently active. If the field reads
tially active “Channel is initially active”, then algorithms may use the chan-
nel’s data values to compute values for derived channels. If the
field reads “Channel is not initially active”, then the channel’s
data values are not used to compute values for derived chan-
nels.
Channel value cannot This field is used for channels whose values cannot be nega-
be negative tive; channel values that would be negative are set to zero.
SPECTRUM ALGO- Not used by the MUDWATCH system.
RITHM FLAG
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4-6 CALIBRATION
In standard MUDWATCH systems, the following sensor channels require analog calibration:
• All active MUD PIT channels
• All active TRIP TANK channels
• The FLOW OUT % channel
• The OPTION channel, if a sensor is connected
The sensor channels listed below require digital calibration:
• All active SPM channels
• All active STROKES channels
The following paragraphs explain how to calculate pit volume and perform analog and digital cali-
bration.
4-6-1 Mud Pit Volume Calculations

Before calibrating the MUD PIT and TRIP TANK channels, follow the steps below to cal-
culate the volume of rectangular mud pits with constant cross-section.
1. Determine height of mud column that sensor can measure as follows:
a. Record height (in feet or meters) of float when pit is empty. Measure from center
of the float.
b. Record height (in feet or meters) of float when pit is full. Measure from center of
the float.
c. Subtract height recorded in Step a from that in Step b to obtain height of mud
column that can be measured.
2. Measure length and width of pit.
3. Use dimensions from Steps 1 and 2 to calculate pit volume as follows:
mud column height (ft.) x pit length (ft.) x pit width (ft.) x 0.178 = volume in barrels (EQ 1)
or
mud column height (m) x pit length (m) x pit width (m)= volume in m3
(EQ 2)
4. Use volume calculated in Step 3 for VALUE MAX and VALUE MIN in
analog calibration.
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4-6-2 Analog Sensor Channel Calibration

The output from pit level and mud flow sensors is continuous and proportional to the
quantity being measured. Analog calibration defines the relationship between sensor out-
put and data values in engineering units. This is accomplished by specifying the four val-
ues listed below:
• CALIBRATION MIN - the value of raw counts when the sensor is at
minimum output
• VALUE MIN - the value (from step 3 of Section 4-6-1) corresponding to
CALIBRATION MIN
• CALIBRATION MAX - the value of raw counts when the sensor is at
maximum output
• VALUE MAX - the value (from step 3 of Section 4-6-1) corresponding to
CALIBRATION MAX
In the following procedure, CALIBRATION MIN is determined first, then VALUE MIN-
IMUM, then CALIBRATION MIN, then VALUE MAXIMUM. However, these values
may be determined in any order.
Table 4-4 lists the default DAQ connector number and default CALIBRATION/Value
Minimum and CALIBRATION/Value Maximum values for each analog sensor channel.
Refer to this table before beginning calibration.
Table 4-6. Calibration Defaults: MUDWATCH Analog Sensor Channels
MUDWATCH Defaults
DAQ Raw Raw Value Value
Channel
Analog Min Max Min Max Units
Name
Connector (Counts) (Counts) (Units) (Units)
MUD PIT 1 J2A 0 4095 0 100 BBLS
MUD PIT 2 J4A 0 4095 0 100 BBLS
MUD PIT 3 J6A 0 4095 0 100 BBLS
MUD PIT 4 J8A 0 4095 0 100 BBLS
MUD PIT 5 J10A 0 4095 0 100 BBLS
MUD PIT 6 J12A 0 4095 0 100 BBLS
MUD PIT 7 J14A 0 4095 0 100 BBLS
MUD PIT 8 J16A 0 4095 0 100 BBLS
MUD PIT 9 J18A 0 4095 0 100 BBLS
MUD PIT 10 J20A 0 4095 0 100 BBLS
MUD PIT 11 J22A 0 4095 0 100 BBLS
MUD PIT 12 J23A 0 4095 0 100 BBLS
TRIP TANK 1 J5A 0 4095 0 100 BBLS
TRIP TANK 2 J7A 0 4095 0 100 BBLS
FLOW OUT % J3A 0 4095 0 100 %
OPTION J1A 0 4095 0 100 UNITS
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Follow the steps below to calibrate the MUD PIT, TRIP TANK and RETURN FLOW
sensor channels.
1. Ensure sensor wires are connected to the default MUDWATCH DAQ con-
nectors; if not, either reconnect the wires to agree with the defaults or modify
the configuration (Paragraph 4-5).
2. From the Configuration & Calibration Main Menu (Figure 4-9), select
TOOLS: [CALIBRATION] and press ENTER. The SYSTEM CALIBRA-
TION SOFTWARE screen (Figure 4-9) is displayed.
Figure 4-9. SYSTEM CONFIGURATION AND CALIBRATION Screen
3. Highlight SENSORS: [CAL] and press ENTER (Figure 4-10.) A submenu of

channels is displayed (Figure 4-11).
Figure 4-10. SYSTEM CALIBRATION SOFTWARE Screen
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Figure 4-11. CALIBRATION SENSOR Channel Submenu
4. Use the arrow keys to highlight the channel name and press ENTER. The
Channel Calibration screen is displayed (Figure 4-12), with minimum and
maximum values displayed.
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.
Figure 4-12. Typical System Channel Calibration Screen
5. Set the sensor to minimum output. For pit level sensors, this is where the float
rests when the pit is empty. For the mud flow sensor, this is with no mud flow-
ing and the paddle down (position “A”, Figure 3-20).
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6. With the sensor at minimum output, view the raw counts displayed next to CUR-
RENT READING. When the reading stabilizes, highlight [USE CURRENT]
CALIBRATION MIN: and press ENTER. The CURRENT RAW READING will
be captured and placed in the CALIBRATION MIN (Figure 4-13).
The CURRENT READING field displays either raw counts from the previous
calibration or the default minimum raw counts. The new CALIBRATION MIN value
field displays the sensor input, in raw counts, at the time CALIBRATION MIN was
selected.
Figure 4-13. “USE CURRENT” Min Screen
7. To enter a different CALIBRATION MIN value, highlight CALIBRATION

MIN and type in the value (up to 4 numbers) and press ENTER. Refer to
Figure 4-14
Figure 4-14. "CALIBRATION MIN" Manual Entry
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The Channel Calibration screen is displayed and the specified CALIBRATION MIN
value is displayed on the CALIBRATION MIN line.
8. Highlight, then enter a new value for VALUE MIN that corresponds with the
CALIBRATION MIN.
Figure 4-15. "CALIBRATION MIN" and "VALUE MIN"
9. To accept the new CALIBRATION MIN value, press ENTER.
NOTE
Zero is the recommended Value Minimum for MUD PIT and TRIP TANK
sensor channels, if Ultrasonic Sensors are used. For other pit probe
sensor types, use the actual value of volume at 6 inches for Value Minimum.
10. Set the sensor to its maximum output. For pit level sensors, this is where the
float rests when the pit is full. For the mud flow sensor, this is when the paddle
is up 90o from the down position, as illustrated by position “B” in Figure 3-20.
11. With the sensor at maximum output, view the raw counts displayed next to CUR-
RENT READING. When the reading stabilizes, highlight [USE CURRENT]
CALIBRATION MAX: and press ENTER. The CURRENT "raw" READING
will be captured and placed in the CALIBRATION MAX (Figure 4-16).
The CURRENT READING field displays either raw counts from the previous
calibration or the default minimum raw counts. The new CALIBRATION MAX value
field displays the sensor input, in raw counts, at the time CALIBRATION MAX was
selected.
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Figure 4-16. "USE CURRENT" Max Screen
12. To enter a different CALIBRATION MAX value, highlight CALIBRATION

MAX and type in the value (up to 4 numbers) and press ENTER. Refer to
Figure 4-17.
The Channel Calibration screen is displayed and the specified CALIBRATION MAX
value is displayed on the CALIBRATION MAX line.
Figure 4-17. "CALIBRATION MAX" Manual Entry
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13. Highlight the dash (-), then enter a new value for VALUE MAX that coorresponds
with the CALIBRATION MAX.
Figure 4-18. "CALIBRATION MAX" and "VALUE MAX"
NOTE
For MUD PIT and TRIP TANK channels, Value Max should be the mud pit
volume calculated in Paragraph 4-6-1. For the RETURN FLOW channel,
Value Max should be 100%.
14. When the channel is calibrated, highlight EXIT and press ENTER. The
SYSTEM CALIBRATION SOFTWARE [CHANNELS] submenu is displayed.
15. Repeat Steps 4 through 15 to calibrate each analog sensor channel. Then pro-
ceed to either digital calibration (Paragraph 4-6-3) or exit calibration and save
the configuration/calibration to floppy (Paragraph 4-7).
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4-6-3 Digital Sensor Channel Calibration

All standard MUDWATCH digital channels measure pump strokes. For each channel, one
digital sensor output (pulse) represents one measured event (i.e., pump stroke). Table 4-7
lists the default DAQ connector number and units for each MUDWATCH digital sensor
channel. Refer to this table before beginning calibration.
Follow the steps below to calibrate digital sensor channels.
1. Ensure sensor channels are assigned to their default DAQ connector
(Table 4-7). If not, either reconnect the wires to agree with the defaults or
modify the configuration (Paragraph 4-5).
2. From the SYSTEM CALIBRATION SOFTWARE screen, highlight CAL and
press enter. Refer to Figure 4-10.
3. From the CALIBRATION [CHANNELS] submenu (Figure 4-11), select a
digital channel name and press ENTER. The Channel Calibration screen is
displayed (Figure 4-19).
On this screen, the CALIBRATION RATE and the DEBOUNCE RATE fields are
displayed.
Figure 4-19. Typical Digital Calibration Screen
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Table 4-7. Calibration Defaults: MUDWATCH Digital Sensor Channels
MUDWATCH Defaults
Channel DAQ Digital

Rate Units
Name Connector
PUMP SPM 1 J1D 1 Strokes per minute
STROKES 1A J1D 1 Strokes
STROKES 1B J1D 1 Strokes
4. Highlight CALIBRATION RATE and enter the correct Calibration rate and
press ENTER. (Figure 4-20)
NOTE
CALIBRATION RATE default is 1 (or) the previous number of pulses per
unit, if the channel was previously calibrated.
Figure 4-20. Digital "CALIBRATION RATE" Screen
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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 displayed,
in engineering units.
c. Divide the value displayed by the rate at which the device is running to obtain the
number of pulses per unit for the channel.
For example: If the device is running at a rate of 100 and the
channel value displayed is 200, then the CALIBRATION
RATE is two pulses per unit.
d. Type-in the calculated value from Step c for CALIBRATION RATE and press
ENTER.
5. To set the DEBOUNCE RATE, highlight DEBOUNCE, enter a new value,
and press ENTER. (Figure 4-21)
NOTE
The DEBOUNCE function corrects for inadvertent counts produced by
sensors which are exposed to bouncing signals. For example; a pump
stroke switch when activated may spring back and tend to slightly bounce
after the stroke. This bouncing action could cause a false stroke count.
DEBOUNCE corrects this action.
Figure 4-21. Digital "DEBOUNCE RATE" Screen
6. Repeat Steps 2 and 3 to calibrate each digital sensor channel. Then proceed to
either analog calibration (Paragraph 4-6-2) or exit calibration and save the
configuration/calibration to disk (Paragraph 4-7).
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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
and press ENTER. (Figure 4-22)
Figure 4-22. DISK: [SAVE ALL] Screen
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. (Figure 4-23)
Figure 4-23. Enter New FILENAME Screen
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NOTE
Always assign a new name to the modified data file.
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 software.
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CHAPTER 5
OPERATION
5-1 INTRODUCTION
This chapter describes the MUDWATCH display panel, including:
• Data display
• Keypad operation
• Display panel fields
• Function codes
5-2 MUDWATCH DATA DISPLAY

The data display portion of the MUDWATCH display panel is shown in Figure 5-1. Data is pre-
sented 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
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OPERATION Manual 60-30
51-SET LOW ALARM

52-SET HIGH ALARM O P T I O N 53-PRESET KEYBOARD ENTRY
61-SET
GA I N
54-SET
H IG H
99-SET TIME 97-SET BACKLIGHT
98-SET DATE
55-SET 0
LOW
RETURN FLOW 6-SET KEYBOARD
GA IN/LO S S ZERO
0 62-SET
RETURNS PERCENT LOSS
BARRELS C OD E
COUNT E R A
1-SET ZERO CO UNT E R A 10-PRESET 64-SET ACTIVE TANKS
1 1- P U M P 1 1 2 3 4 5 6
1 2 - P UM P 2
63-SET
1 3- P U M P 3 15-SET COUNTER
STROKES H IG H
LIGHT-SELECTED ALARM 7 8 9 10 11 12
COUNTER B
2-SET ZERO COUNT E R B 20-PRESET TOTAL ACTIVE VOLUME
2 1 - P UM P 1
2 2 - P UM P 2
2 3- P U M P 3 0
STROKES 25-SET COUNTER BARRELS
LIGHT-SELECTED ALARM
66-SET M OD E TRIP VOL TA NK NO

PUMP 1 RATE PUMP 2 RATE DRILL 1
TRIP OUT
2
TRIP IN
BARRELS 67-SET
44-SET HI SPM 45-SET HI SPM
TOTAL RATE 65-SET
H IG H
4 1- P U M P 1 68-SELECT
TOTAL RATE PUMP 3 RATE TA NK TA NK V OL ACTIVE
4 2- P U M P 2
4 3 - P UM P 3
0
LIGHT-SELECTED
SPM 46-SET HI SPM NO BARRELS TRIP
69-SELECT
47-SET LOW FLOW ALARM DISABLE
Figure 5-1. MUDWATCH Data Display
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Manual 60-30 OPERATION
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 of each
field are etched below. For example, BARRELS are the units for the TOTAL ACTIVE
VOLUME field.
5-2-3 Function Codes

Each display panel field has one or more associated function codes. A function code is a
one- or two-digit code entered by the user to perform a specific action affecting a specific
field. 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 Paragraph
5-3 for instructions on entering function codes and to Paragraph 5-4 for descriptions of
each code.
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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. MUDWATCH 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.
ZERO Press this key to zero the Gain/Loss field on the display.
GAIN/LOSS
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5-3-1 Zero 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 GAIN/LOSS:
1. Press the 6 key.
2. Press the ENT key.
5-3-2 Change Field Value

Follow the steps below to change a field value.
• 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 window of the affected field stops flashing
• the new value is displayed
For example: To change the value of COUNTER A:
1. Key in 10.
2. Key in the new value.
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5-3-3 Change/View Alarm Limits

Follow the steps below to change or view a field’s high/low alarm limits.
• 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 KEYBOARD
ENTRY field displays the new value.
• 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, PUMP SPM and TANKS
fields are presented 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 KEYBOARD ENTRY field clears
• the associated field flashes
2. Press the ENT key to toggle the active status. The following
occurs:
• 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.
2.Press the ENT key.
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5-3-4-2 Activate/De-Activate Tanks
1. Key in function code 64. The following occurs:

• the TOTAL ACTIVE VOLUME field flashes
2. Key in the number of the tank to activate/deactivate. The KEY-
BOARD ENTRY field displays the number of the selected tank
and the associated indicator flashes.
3. Press the ENT key to toggle the active status. The following
occurs:
• the selected field is changed from active to inactive, or vice-
versa
For example: To change the active status of TANK 1:
1.key in 64
2.key in 1
3.press the ENT key
5-3-5 Specify Drill, Trip-In or Trip-Out Mode

A dashed line located next to DRILL, TRIP IN or TRIP OUT in the MODE field indicates
the current mode. Follow the steps below to change the mode from drill, trip in or trip out.
1. Key in function code 66. The following occurs:
2. Press ENT. The next-listed mode is selected.
3. Repeat Steps 1 and 2 until the desired mode is selected.
For example: To change from DRILL mode to TRIP OUT mode:
1. Key in 66.
3. Key in 66.
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5-3-6 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:
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.
5-3-7 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.
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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 is displayed.
KEYBOARD ENTRY
61-SET
GAIN

98-SET DATE
6-SET KEYBOARD
ZERO
CODE
Figure 5-4. KEYBOARD Fields
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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 54: Set High
Enter this code to specify the maximum allowed RETURN FLOW. If RETURN
FLOW reaches this value, the RETURN FLOW bar graph and numerical display
flash and the alarm horn sounds. Refer to Paragraph 5-3-3 to set the high limit.
5-4-2-2 Function Code 55: Set Low
Enter this code to specify the minimum allowed RETURN FLOW. If RETURN
FLOW reaches this value, the RETURN FLOW bar graph and numerical display
flash and the alarm horn sounds, unless it is disabled (Paragraph 5-4-7-3). Refer
to Paragraph 5-3-3 to set the low limit.
51-SET LOW ALARM

52-SET HIGH ALARM OPTION 53-PRESET
54-SET
HIGH
55-SET
LOW
RETURN FLOW
0
RETURNS PERCENT
COUNTER A
1-SET ZERO COUNTER A 10-PRESET
11-PUMP1
12-PUMP2
Figure 5-5. RETURN FLOW Fields
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5-4-3 Total Active Volume/Active Tanks

TOTAL ACTIVE VOLUME/ACTIVE TANKS are used during drilling to monitor the
total volume of mud in active tanks. Under normal drilling conditions, the TOTAL
ACTIVE VOLUME should remain fairly constant. TOTAL ACTIVE VOLUME is also
used to calculate GAIN/LOSS.
TOTAL ACTIVE VOLUME is displayed numerically and graphically (Figure 5-6).
Active tanks are designated by a dash in the tank number field of the ACTIVE TANKS
indicator.
Enter this function code to specify the maximum allowed TOTAL ACTIVE
VOLUME. If the TOTAL ACTIVE VOLUME reaches this value, the bar graph
and numerical display flash and the alarm horn sounds. Refer to Paragraph 5-3-
3 to set the high limit.
5-4-3-2 Function Code 64: Set Active Tanks
Enter this function code to change the status of any mud tank from active to
inactive, or vice versa. When a tank is active, a dash is displayed in its numbered
field on the ACTIVE TANKS display and its volume is included in TOTAL
ACTIVE VOLUME. Refer to Paragraph 5-3-4-2 for instructions on changing
the active status of mud tanks.
62-SET
LOSS
64-SET ACTIVE TANKS

1 2 3 4 5 6
63-SET
HIGH
7 8 9 10 11 12
TOTAL ACTIVE VOLUME
0
BARRELS
66-SET MODE TRIP VOL TANK NO
Figure 5-6. ACTIVE VOLUME Fields
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5-4-4 Gain/Loss
GAIN/LOSS is used during drilling to monitor increases or decreases in the total volume
of all active mud pits. Under normal drilling conditions, GAIN/LOSS should be close to
zero. Increases (gains) or decreases (losses) in total mud volume may indicate abnormal
conditions. GAIN/LOSS is displayed numerically and graphically (Figure 5-7).
5-4-4-1 Function Code 6: Set Zero
Enter this code when steady drilling conditions are established. When this code
is entered, the total volume of mud in all active mud pits (TOTAL ACTIVE
VOLUME) is recorded and GAIN/LOSS is zeroed. As drilling continues,
increases in mud volume are displayed as gains and decreases are displayed as
losses. Gains are always positive numbers; losses always negative. Refer to
Paragraph 5-3-1 to zero a field.
5-4-4-2 Function Code 61: Set Gain
Enter this code to specify the maximum allowed increase in total mud volume
(gain). If the total mud volume reaches the gain value, the GAIN/LOSS bar
graph and numerical display field flash and the alarm horn sounds. Refer to
Paragraph 5-3-3 to set the gain.
5-4-4-3 Function Code 62: Set Loss
Enter this code to specify the maximum allowed decrease in total mud volume
(loss). If the total mud volume reaches the loss value, the GAIN/LOSS bar graph
and numerical display field flash and the alarm horn sounds. Refer to Paragraph
5-3-3 to set the loss.
KEYBOARD ENTRY
61-SET
GAIN

98-SET DATE
0
6-SET KEYBOARD
GAIN/LOSS ZERO
62-SET
LOSS
BARRELS CODE
64-SET ACTIVE TANKS

1 2 3 4 5 6
63-SET
HIGH
Figure 5-7. GAIN/LOSS Fields
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5-4-5 Trip Volume/Tank Volume

The fields and function codes displayed in Figure 5-8 are described below.
5-4-5-1 Trip Vol
The TRIP VOL field displays the total volume of all active trip tanks. A dash
next to the tank number (1 or 2) in the TANK NO. field indicates that the tank is
active. TRIP VOL is displayed numerically.
5-4-5-2 Tank Vol
The TANK VOL field displays the volume in any one selected mud tank or trip
tank. A dash in the top half of the ACTIVE/TRIP TANK indicator field (Figure
5-8) indicates that TANK VOL represents a mud tank volume; a dash in the bot-
tom half of the field indicates that TANK VOL represents a trip tank volume.
The number of the tank whose volume is displayed is presented in the field
labeled TANK, to the left of TANK VOL. TANK VOL is displayed numerically
and graphically.
5-4-5-3 Mode
The MODE indicator field identifies the current rig mode (i.e., DRILL, TRIP
OUT or TRIP IN mode). In DRILL mode, the pump stroke counters
(COUNTERS A and B) count continuously. In either of the TRIP modes, the
pump stroke counters count only when the RETURN FLOW is less than 3%;
when 3% is reached, the counters stop counting (Paragraph 5-4-6). A dash next
to the mode name identifies the selected mode.
5-4-5-4 Function Code 66: Set Mode
Enter this function code to change modes from DRILL to TRIP OUT to TRIP
IN to DRILL. Refer to Paragraph 5-3-5 to set modes.
5-4-5-5 Function Code 67: Set Tank No.
Enter this function code to specify which trip tank volume(s) to include in TRIP
VOL. Refer to Paragraph 5-3-4-2 to select trip tanks.
5-4-5-6 Function Code 68: Select Active
Enter this function code to specify which active mud tank volume to display in
the TANK VOL field. When this code is entered, a dash is displayed in the upper
half of the ACTIVE/TRIP indicator field and the tank number is displayed in the
TANK field. Refer to Paragraph 5-3-4-2 to select an active mud tank.
5-4-5-7 Function Code 69: Select Trip
Enter this function code to specify the trip tank volume to display in the TANK
VOL field. When this code is entered, a dash is displayed in the lower half of the
ACTIVE/TRIP indicator field and the tank number is displayed in the TANK
field. Refer to Paragraph 5-3-4-2 to select a trip tank.
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Enter this code to specify the maximum volume allowed in the mud tank or trip
tank displayed in the TANK VOL field. If the total mud volume reaches this
value, the TANK VOL bar graph and numerical display field flash and the alarm
horn sounds. Refer to Paragraph 5-3-3 to set the high limit.
66-SET MODE TRIP VOL TANK NO

DRILL 1
TRIP OUT
2
TRIP IN
BARRELS 67-SET
65-SET
HIGH
68-SELECT
TANK TANK VOL ACTIVE
0
NO BARRELS TRIP
69-SELECT
Figure 5-8. TRIP VOLUME/TANK VOLUME Fields
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5-4-6 Counter A/Counter B

COUNTER A and COUNTER B (Figure 5-8) are 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 indi-
cator field. Likewise, the value displayed for COUNTER B represents the total number of
strokes made by the pump(s) designated as “active” in the COUNTER B 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., RETURNS indicator is on).
5-4-6-1 Function Codes 1 and 2: Set Zero
Enter these codes to zero the number of strokes counted by Counters A and B,
respectively. When either code is entered, the corresponding counter is zeroed
and then starts counting. Refer to Paragraph 5-3-1 to zero a field.
5-4-6-2 Function Codes 10 and 20: Preset
Enter these codes to specify a starting number of strokes for Counters A and B,
respectively; subsequent strokes will be added to this value. Refer to Paragraph
5-3-2 to preset (change) the field value.
5-4-6-3 Function codes 15 and 25: Set Counter Alarm
Enter these codes to specify the maximum number of strokes allowed for the
pump(s) being monitored by Counter A and Counter B, respectively. If the num-
ber of strokes reaches this value, the COUNTER field flashes and the alarm horn
sounds. Refer to Paragraph 5-3-3 to set the alarm value.
5-4-6-4 Function Codes 11, 12, 13, 21, 22, 23: Pump 1, 2, 3
Enter codes 11, 12, or 13 to change the “active” status of pumps 1, 2, or 3 for
COUNTER A. Likewise, enter codes 21, 22, or 23 to change the “active” status
of pumps 1, 2, or 3 for COUNTER B. The strokes of active pumps are included
in the associated COUNTER field. For example, if COUNTER B is currently
counting strokes for pump 2 and function code 22 is entered, COUNTER B will
stop counting strokes for pump 2 and the PUMP 2 indicator field will darken.
Refer to Paragraph 5-3-4-1 to change the “active” status of pumps.
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0
RETURNS PERCENT
COUNTER A
1-SET ZERO COUNTER A 10-PRESET
11-PUMP1
12-PUMP2
13-PUMP3 STROKES 15-SET COUNTER

COUNTER B
2-SET ZERO COUNTER B 20-PRESET
21-PUMP1
22-PUMP2

PUMP 1 RATE PUMP 2 RATE
Figure 5-9. COUNTER Fields
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5-4-7 Pump Rates/Total Pump Rate

The PUMP RATE fields (Figure 5-10) 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.
5-4-7-1 Function Codes 44, 45, 46: Set High
Enter function code 44, 45 or 46 to set the maximum allowed pump rate for
pumps 1, 2 and 3, respectively. If the rate of any pump reaches this value, the
corresponding PUMP RATE field flashes and the alarm horn sounds. Refer to
Paragraph 5-3-3 to set the high limit.
5-4-7-2 Function Codes 41, 42, 43: Pump 1, Pump 2, Pump 3
Enter function code 41, 42, or 43 to change the “active” status of pumps 1, 2 or
3 for the TOTAL RATE field. When a pump is active, its TOTAL RATE indica-
tor light is on and its rate is included in TOTAL RATE. Refer to Paragraph 5-3-
4-1 to change the pump “active” status.
5-4-7-3 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 Paragraph 5-3-3 to set the LOW FLOW ALARM
DISABLE pump rate.

PUMP 1 RATE PUMP 2 RATE
44-SET HI SPM 45-SET HI SPM

TOTAL RATE
41-PUMP1
TOTAL RATE PUMP 3 RATE
42-PUMP2
43-PUMP3
LIGHT-SELECTED 46-SET HI
SPM SPM
47-SET LOW FLOW ALARM DISABLE
Figure 5-10. PUMP RATE Fields
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5-4-8 Option
The OPTION field is used to monitor the output of a customer-supplied sensor. No units
are specified for the OPTION field. The OPTION field is shown in Figure 5-11.
5-4-8-1 Function Code 51: Set Low Alarm
Enter this code to specify the minimum allowed value of the OPTION field
parameter. If the minimum value is reached, the OPTION numerical display
flashes and the alarm horn sounds. Refer to Paragraph 5-3-3 to set the low limit.
5-4-8-2 Function Code 52: Set High Alarm
Enter this code to specify the maximum allowed value of the OPTION field
parameter. If the maximum value is reached, the OPTION numerical display
flashes and the alarm horn sounds. Refer to Paragraph 5-3-3 to set the high limit.
5-4-8-3 Function Code 53: Preset
Enter this code to specify a starting value for the OPTION field; subsequent
increases/decreases will be added to/subtracted from this value. Refer to Para-
graph 5-3-2 to preset (change) the field value.
51-SET LOW ALARM

52-SET HIGH ALARM OPTION 53-PRESET
54-SET
HIGH
55-SET
LOW
RETURN FLOW
Figure 5-11. OPTION Field
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CHAPTER 6
MAINTENANCE
6-1 INTRODUCTION
This chapter contains periodic inspection procedures for MUDWATCH devices and sensors, a
troubleshooting table and list of initialization codes for the MUDWATCH system. For parts lists
and illustrations depicting component locations, refer to Chapter 7 or to the related device manual.
6-2 PERIODIC INSPECTION OF MUDWATCH 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 MUDWATCH 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:
- Flush out the flow pipe to prevent mud build-up, as this can cause sensor
malfunction or result in incorrect readouts.
- 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 cut-
tings or other obstructions.
• For pit level sensors, perform the following:
- Check for caking or build-up of debris that might interfere with move-
ment of the float up and down the sensor tube.
- Every two years, disassemble the unit and inspect the sealing O-rings for
deterioration. For sensor P/N H10924A-series, also inspect the gearbox
assembly, toothed drive belt and housing tube for corrosion and wear.
April 30, 1999 Page 6-1

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MAINTENANCE Manual 60-30
6-4 TROUBLESHOOTING TABLE: MUDWATCH SYSTEM

Table 6-1 lists problems that might be observed in a MUDWATCH system. For each problem, 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: MUDWATCH 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 sup- 3. Check power supply according to

ply procedure in Paragraph 6-4-1.
Display panel blank, dim, 1. Defective DAQ power 1. Check power supply according to
or displays blinking 8’s supply. procedure in Paragraph 6-4-1.
2. Incorrect jumper set- 2. Compare configuration of SIF I/O
ting on SIF board. board jumpers with Table 6-6;
correct if needed.
3. SIF board failure 3. Verify that +16V is present on

JP6-3. Replace board if needed.
4. Incorrect or faulty 4. Verify wiring per Figure 3-9 and

wiring between DAQ correct if needed.
and display panel.
5. Display panel power 5. Check H10992A-768P barrier by
barrier failure disconnecting it from the circuit
and verifying 150-185 ohms
between terminals 1 and 3 and ter-
minals 2 and 4. Replace barrier if
needed.
6. ISMI module failure. 6. Check display panel controller

boards (Figure 6-3) for +6 V
minimum between TB1-1 and
TB1-2. Replace ISMI module, if
needed (Figure 7-3).
7. Display controller 7. Replace display controller board or

board failure display board, as required.
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Manual 60-30 MAINTENANCE
Table 6-1. Troubleshooting Table: MUDWATCH System (Continued)
Display panel displays 1. No communication 1. If red T-POT communications LED

dashes or bars between SIF and D1 on the SIF (Figure 6-2) is not
DAQ flashing, perform checks 2 through
7 below. If LED is flashing, go to
check 8.
2. DAQ not configured 2. Connect laptop PC to DAQ and
for Spectrum Inter- use Manual 60-40 to check SYS-
face TEM DAQ configuration and Spec-
trum Interface configuration;
correct if necessary.
3. Incorrect SIF device 3. Ensure that SIF device I.D. desig
I.D. nated by jumper settings on JP3 of
SIF board (Figure 6-2) are same
as that assigned to spectrum inter-
face in DAQ configuration soft-
ware. Correct jumpers if needed.
(see Table 6-2)
4. Incorrect T-POT net 4. Ensure that T-POT network baud

work baud rate rate designated by jumper JP4 SIF
is same baud rate that DAQ is con-
figured. (see Table 6-3)
5. Faulty DAQ power 5. Check power supply according to

supply paragraph 6-4-1.
6. Incorrect or faulty wir 6. Verify wiring per Figure 3-9 and
ing between DAQ correct if needed.
and display
7. Incorrect jumper set- 7. Verify jumper settings per Table 6-

ting on SIF board 6; correct if needed.
8. SIF processor mal- 8. Press reset push button S1 on SIF.

function Refer to Table 6-7 and verify the
INIT Code displayed in the display
panel KEYBOARD DATA field.
9. Display panel com- 9. Check both H10992A-787S barri-
munication barrier ers by disconnecting them from
failure the circuit, then verifying 300-340
ohms between terminals 1 and 3
and verifying that the diode return
channel between terminals 4
(anode) and 2 (cathode) is func-
tional. Replace barriers if needed.
April 30, 1999 Page 6-3

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Display panel displays 10.Display panel ISMI 10.Move communication connector in

dashes or bars (Con’t) module failure J2 to backup circuit J3. If this cor
rects the problem, replace the
ISMI module (Figure 7-3).
11.Display panel control- 11a.Check controller board SW1
ler board malfunction settings (Figure 6-3); correct if
needed.
11b.If SW1 settings are correct and

problem persists, replace SIF
board. If problem persists, replace
faulty display controller board or
display board.
Display panel values are 1. Incorrect SIF device 1. Check to see if SIF device I.D.
erratic or incorrect, or one I.D. designated by jumper JP3 of
field shows dashes. SIF(Figure 6-2) is same as that
assigned to SIF in DAQ configura-
tion software. Correct jumpers if
needed (see Table 6-2).
2. Incorrect Spectrum 2. Connect laptop PC to DAQ and

configuration. use Manual 60-40 to check SYS-
TEM DAQ configuration and SIF
configuration; correct if needed.
3. DAQ analog proces- 3a.Check DAQ digital board “ana-
sor malfunction log processor” LED (Figure 6-4).
If LED is off or on steady (not
blinking) proceed to Step 3b. If
LED is blinking, proceed to Step 4.
3b.Press analog processor reset

(SW4, Figure 6-4). If problem per-
sists, proceed 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 MUDWATCH configuration
to DAQ.
Page 6-4 April 30, 1999

M/D Totco
Display panel values are 4. DAQ digital proces- 4a.Check DAQ digital board “watch-
erratic or incorrect, or one sor malfunction dog timer” LED. If LED is off or not
field shows dashes (Con- blinking steady, go to Step 4b. If
tinued) 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 proces-
sor resets, SW1 and SW4; then
place SW2 position 8 to ON. If
problem persists, replace DAQ
digital board and reload MUD-
WATCH configuration to DAQ.
5. Faulty channel con- 5. Compare sensor channel raw

figuration or calibra- counts to engineering units. If raw
tion. counts OK and corresponding
engineering units do not mimic raw
counts, check channel configura-
tion and correct if needed. If prob-
lem persists, recalibrate sensor
channel.
6. Voltage/current 6. Verify if rocker switch setting

rocker switch on DAQ agrees with sensor output
field termination (Figure 3-15); correct if needed.
board set incorrectly
7. Faulty sensor con- 7. Ensure all sensor connections are
nec tion secure and correct. Correct if
needed; then reconfigure and
recalibrate sensor channel.
8. Faulty connector on 8. Connect sensor to a different con-

DAQ field termina- nector; then reconfigure and
tion board recalibrate sensor channel.
9. Sensor malfunction 9. Replace sensor.
April 30, 1999 Page 6-5

M/D Totco
No backlighting on display 1. Backlighting turned 1. Enter function code 97 at display

panel off by software keypad. Replace SIF board if
needed.
2. Insufficient voltage 2. Verify +24V is present at TB6-1 of
from SIF PC Board SIF board. If +24 VDC not pre
sent, 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 set- 3. Check configuration of jumpers
ting on SIF board. according to Table 6-6 and correct
if needed.
4. Faulty wiring 4. Check wiring per Figure 3-9 and

between DAQ and correct if needed.
display panel
5. Display panel back- 5. Check both H10992A-779P barri-

lighting barrier failure ers and verify300-340 ohms
between terminals 1 and 3 and ter-
minals 2 and 4. Replace barriers if
needed.
Page 6-6 April 30, 1999

M/D Totco
6-4-1 DAQ Power Supply Checkout Procedure

Follow the steps below to test both DAQ power supply outputs and associated wiring. Figure 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 connectors to
chassis ground as follows:
Connector/Pins Volts DC
From (+) To (-)
P4-6 Gnd -15
P4-1 Gnd +15
P14-1 Gnd +28
P4-2 Gnd +5
3. If required voltages are not present, replace associated power supply. If required volt-
ages are present, measure voltages as follows:
From (+) To (-)
P8-1 Gnd +5
P8-2 Gnd +15
P11-1 Gnd +28
P11-5 Gnd +15
P11-8 Gnd -15
4. If DAQ contains an EDMS board, measure voltages as follows:
From (+) To (-)
P8-1 Gnd +5
P11-8 Gnd -15
5. If required voltages are not present, repair or replace wiring between power supply
and associated connector
April 30, 1999 Page 6-7

M/D Totco
6-4-2 Spectrum "SUPER" I/F Board

The Spectrum I/F (Super SIF) board, P/N 210034-002, is shown in Figure 6-2. Jumper
settings from MUDWATCH are listed in Table 6-2.
Figure 6-1. DAQ DC Power Distribution Wiring
Page 6-8 April 30, 1999

M/D Totco
JP1
JP2
JP3
JP4
JP5
JP6
Figure 6-2. Spectrum I/F (Super SIF) Board
Table 6-2. Spectrum I/F Board Jumpers
MUDWATCH
Jumper Default Jumper General Description
Setting
JP1 Not Applicable Not currently used.
JP2 Installed between Used to select the T-Pot network baud rate
pins 15 and 16 for (default = 42.8K).
42.8K baud
JP3 Not installed Used to select the SIF device ID.
JP4 Installed between Used to select the SIF processor baud rate
pins 1 and 2 for (default = 42.8K).
42.8k baud
JP5 Installed between Used to select relay power: 24V for IS sys-
pins 1 and 2 for 24V tems and 12V for non-IS systems
relay power.
JP6 Installed between Used to select display power: 16V for IS sys-
pins 2 and 3 for 16V tems and 10V for non-IS systems.
display power.
April 30, 1999 Page 6-9

M/D Totco
Table 6-3. JP3 - SIF Board Jumper Settings
SIF 3-4 5-6 7-8
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
Page 6-10 April 30, 1999

M/D Totco
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.
C LO S E D
OPEN
O P EN
O P EN
OPEN
O PE N
OPEN
OPEN
1 2 3 4
1 2 3 4
SW1
CONTROLLER SW1
BOARD 1
CONTROLLER
BOARD 2
FTB1
DISPLAY
BOARD 2
DISPLAY
BOARD 1
Figure 6-3. Display Panel Controller Boards
April 30, 1999 Page 6-11

M/D Totco
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 1 and 2 of SW2 are used to specify the DAQ device
I.D. For most MUDWATCH systems, which contain only one DAQ, positions 1 and 2
should both be set to ON. All other SW2 positions should be set to ON during normal
operation. SW3 is currently not used.
Figure 6-4. DAQ Digital Board
Page 6-12 April 30, 1999

M/D Totco
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 Workstation device I.D. to be set and/or
changed using the Configuration/Calibration soft-
ware (Chapter 4).
- position 7 is OFF (open) and position 8 is ON
(closed). This sets the baud rate to the default net-
work baud rate of 42.8K.
NOTE
Baud rate must be the same for all network devices.
• 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.
April 30, 1999 Page 6-13

M/D Totco
Figure 6-5. DCM Communications Board
Page 6-14 April 30, 1999

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6-5 INIT CODES

During MUDWATCH 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 SIF
board by pressing push button switch S1.
NOTE
Always check for faulty wiring and power before replacing the SIF board.
Table 6-7. MUDWATCH 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 None
reset button (Figure 6-2)
When displayed for longer than ten seconds and Press SIF reset button (Figure 6-2). If
accompanied by flashing T-POT communications problem persists, replace SIF.
LED, the SIF is faulty.
When displayed for longer than ten seconds and Perform the checks required when
accompanied by non-flashing T-POT communica- INIT 2 is displayed.
tions LED, there is no communication between
SIF and T-POT network.
INIT 2 There is no communication between SIF and T- Check: 1) T-POT modem connections
POT network. Accompanied by non-flashing with SIF PCB, 2) designated baud
T-POT communications LED. rate and SIF device I.D. (Table 6-2
and Table 6-3). If problem persists,
see Manual 60-11.
INIT 3 SIF is re-initializing due to incorrect record None
received from T-POT network during initialization.
INIT 4 There is a SIF software problem. Contact M/D Totco.
INIT 5 SIF is re-initializing due to incorrect record None
received from T-POT network during normal SIF
operation.
INIT 6 SIF is re-initializing due to partial device or screen None
config received from T-POT network.
April 30, 1999 Page 6-15

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Page 6-16 April 30, 1999

M/D Totco
CHAPTER 7
7-1 INTRODUCTION
This chapter contains an Illustrated Parts Breakdown (IPB) and recommended spare parts inven-
tory for MUDWATCH. 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 Figure & Index 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. If an assembly may be disas-
sembled in the field, its component part descriptions are indented to the right one period
( .) from its description.
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 MUDWATCH 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 Use On Code
of “B”. Thereafter, all MUDWATCH components that are used only in systems containing
a DAQ with internal barriers (for example, the junction box) are assigned a Use On Code
of “A”; components used only in systems containing a barrierless DAQ (for example, the
sensor barrier box) are assigned a Use On Code of “B”; and components used in both sys-
tems are assigned a Use On Code of "A, B".
April 30, 1999 Page 7-1

M/D Totco
ILLUSTRATED PARTS BREAKDOWN Manual 60-30
7-4 ABBREVIATIONS
Table 7-1 contains standard abbreviations used in parts lists.
TABLE 2
FIGURE 2
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
Page 7-2 April 30, 1999

M/D Totco
Manual 60-30 ILLUSTRATED PARTS BREAKDOWN
6
4
21
11
15
14
16,17
5
8
12
13
20
12
2
1
9
11
18,19
10
Figure 7-1. MUDWATCH System Components
April 30, 1999 Page 7-3

M/D Totco
FIGURE UNITS USE

& PART PER ON
INDEX NO. NUMBER DESCRIPTION ASSY CODE
7-1 TMW-series MUDWATCH w/ DAQ with internal barriers . . . . . . . . N/A A

7-1 TMW-series MUDWATCH w/ Barrierless DAQ . . . . . . . . . . . . . . . . N/A B
1 220425-100 DAQ, Permanent Location, SIF, with Barriers . . . . . . . . . 1 A
1 220492-008 DAQ, Permanent Location, SIF, Barrierless. . . . . . . . . . . 1 B
2 220082 CABLE ASSY, 9-pin, CAL/CONFIG. . . . . . . . . . . . . . . . . 1 A,B
4 220448-001 DISPLAY PANEL, MUDWATCH, barrels ( Figure 7-2) . . . 1 A,B
3
4 220448-002 DISPLAY PANEL, MUDWATCH, m . . . . . . . . . . . . . . . . 1 A,B
5 220450-001 DISPLAY BARRIER BOX, MUDWATCH ( Figure 7-4) . . . 1 A,B
6 220451-001 ALARM HORN, MUDWATCH . . . . . . . . . . . . . . . . . . . . . 1 A,B
8 220450-002 SENSOR BARRIER BOX, MUDWATCH (Figure 7-5) . . . 1 B
9 220364-002 JUNCTION BOX, w/ Connectors (Figure 7-6) . . . . . . . . AR N/A
10 220372-450 CABLE ASSY, 12 PR/18, 250 ft, 37 socket plug. . . . . . . AR N/A
* 949921-043 PLUG, 37-Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 N/A
* 946941-116 CABLE, 18 AWG/12 pair, shld, EXANE . . . . . . . . . . . . . 250’ N/A
11 946938-001 CABLE, 3C/18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AR N/A
12 272504-102 CABLE ASSY, 8 AWG, 5 ft, ground w/ clamp . . . . . . . . . . 2 N/A
13 H10910A-12 CABLE, 12C/18 shld. . . . . . . . . . . . . . . . . . . . . . . . . . . . AR N/A
14 220371-450 CABLE ASSY, 12C/18, 250 ft, 16 socket plug . . . . . . . . . 1 N/A
* 949921-033 PLUG, 16-Socket, std . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 N/A
* H10910A-12 CABLE, 18 AWG/12C, shld, EXANE . . . . . . . . . . . . . . . 250’ N/A
15 220371-801 CABLE ASSY, 12C/18, 5 ft, 16 pin receptacle . . . . . . . . . 1 N/A
* 949921-035 RECEPTACLE, 16-Pin, 16 shl . . . . . . . . . . . . . . . . . . . . . 1 N/A
* H10910A-12 CABLE, 18 AWG/12C, shld, EXANE . . . . . . . . . . . . . . . 250’ N/A
16 949921-033 PLUG, In-line, 16 socket. . . . . . . . . . . . . . . . . . . . . . . . . AR N/A
17 949921-035 RECEPTACLE, In-line, 16 pin. . . . . . . . . . . . . . . . . . . . . AR N/A
18 949921-043 PLUG, In-line, 37 socket. . . . . . . . . . . . . . . . . . . . . . . . . AR N/A
19 949921-045 RECEPTACLE, In-line, 37 pin. . . . . . . . . . . . . . . . . . . . . AR N/A
20 219354-002 LAPTOP PC, CAL/CONFIG . . . . . . . . . . . . . . . . . . . . . . . 1 A,B
21 220454-series VIP WORKSTATION (Figure 7-9) . . . . . . . . . . . . . . . . . . AR A,B
* 272819-series PIT LEVEL PROBE (Figure 7-7) . . . . . . . . . . . . . . . . . . AR A
* H10924A-series PIT LEVEL PROBE (Manual TW1022). . . . . . . . . . . . . . AR B
* MFTX4A-5 MUD FLOW SENSOR (Manual TW658) . . . . . . . . . . . . AR A,B
* 270700-116 MUD FLOW SENSOR (Manual 27-44). . . . . . . . . . . . . . AR A
* 232389 PUMP STROKE SENSOR ( Figure 7-8) . . . . . . . . . . . . AR A,B
* 999263-002 GROUNDING ROD, 8’ x 1/2-inch, Copper-Clad . . . . . . . AR A,B
* 999264-001 GROUNDING CLAMP, 1/2-inch . . . . . . . . . . . . . . . . . . . AR A,B
Page 7-4 April 30, 1999

M/D Totco
22
6
7
5
26
22
8
13
27
9
19
1
20
4
17, 18
10
16
3
15
2
12
11
14
21, 23, 24, 25
Figure 7-2. MUDWATCH Display Panel
April 30, 1999 Page 7-5

M/D Totco
FIGURE UNITS USE

& PART PER ON
7-2- 220448-001 MUDWATCH Display Panel, barrels . . . . . . . . . . . . .N/A A

7-2- 220448-002 MUDWATCH Display Panel, cubic meters . . . . . . . .N/A B
1 A11313A-09 COVER/ENCLOSURE ASSY . . . . . . . . . . . . . . . . . . . .1 A,B
2 220042 BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
3 A11212A-33B LENS ASSY, Barrels. . . . . . . . . . . . . . . . . . . . . . . . . . . .1 A
3 A11212A-33C LENS ASSY, Cubic Meters . . . . . . . . . . . . . . . . . . . . . . .1 B
4 H11062A KEYBOARD ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
5 220046-02 PLATE, Gland with Holes . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
6 220046-01 PLATE, Gland without Holes . . . . . . . . . . . . . . . . . . . . .3 A,B
7 220064 GASKET, Gland Plate. . . . . . . . . . . . . . . . . . . . . . . . . . .4 A,B
8 J10481A-02 CONDUIT HUB, .75 NPT . . . . . . . . . . . . . . . . . . . . . . . .4 A,B
9 J826-6HB PLUG, .75 NPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 A,B
10 220065 GASKET, Lens/Bezel . . . . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
11 220066 GASKET, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
12 220034 FRAME, Display Mounting . . . . . . . . . . . . . . . . . . . . . . .1 A,B
13 N/A TERMINAL BLOCK (Figure 7-3) . . . . . . . . . . . . . . . . . .1 A,B
14 J812-6NS SCREW, Pnhd, 10-32 X .75, cres. . . . . . . . . . . . . . . . . 24 A,B
15 B10449A GASKET, PCB Isolator . . . . . . . . . . . . . . . . . . . . . . . . . .4 A,B
16 PCB287A-01 PCB ASSY, Display with Backlight . . . . . . . . . . . . . . . . .2 A,B
17 J814-3NS SCREW, Pnhd, 6-32 x .38, cres . . . . . . . . . . . . . . . . . . .8 A,B
18 G241-1 WASHER, Flat, #6 fiber . . . . . . . . . . . . . . . . . . . . . . . . .8 A,B
19 J841-4RN SCREW, Rdhd, 4-40 x .25, nylon . . . . . . . . . . . . . . . . . .6 A,B
20 PCB295A PCB, Display Controller . . . . . . . . . . . . . . . . . . . . . . . . .2 A,B
21 J814-3FS SCREW, Flhd, 6-32 x .38, cres. . . . . . . . . . . . . . . . . . . .8 A,B
22 J812-4NS SCREW, Pnhd, 10-32 x .5, cres . . . . . . . . . . . . . . . . . . 48 A,B
23 M10072A-080006 STANDOFF, 6-32 x .50 m/f, .38 cres, hx. . . . . . . . . . . . .8 A,B
24 G180A-01943 WASHER, #6 Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 A,B
25 J827-1CS NUT, 6-32, hx cres . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 A,B
26 955706-007 CONN, Cord, .75 NPT, .38-.50 . . . . . . . . . . . . . . . . . . . .2 A,B
27 955706-009 CONN, Cord, .75 NPT, .50-.62 . . . . . . . . . . . . . . . . . . . .2 A,B
* B10448A-01 NAMEPLATE, Keypad . . . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
* B10447A NAMEPLATE, Instruction . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
* 220301 NAMEPLATE, MUDWATCH . . . . . . . . . . . . . . . . . . . . . .1 A,B
* M10368A STANDOFF, .38 Hx, m/f, 6-32 x 1.25 . . . . . . . . . . . . . . .6 A,B
* J814-4NS SCREW, 6-32 X .50, pnhd, cres . . . . . . . . . . . . . . . . . . .6 A,B
* H12007A-02 CONNECTOR, Screw Term, 2-socket, .2" . . . . . . . . . . .2 A,B
* Not shown
Page 7-6 April 30, 1999

M/D Totco
Figure 7-3. Terminal Block Detail: Display Panel
FIGURE UNITS USE

& PART PER ON
7-3- N/A TERMINAL BLOCK DETAIL, Display Panel . . . . . . .N/A N/A

1 220035 BAR, Terminal Block, ISMI master mounting . . . . . . . . .2
2 H12010A ISMI MASTER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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 J841-4NS SCREW, 4-40 x .25, pnhd, cres . . . . . . . . . . . . . . . . . . .2
8 G180A-01042 WASHER, Flat, #4, cres . . . . . . . . . . . . . . . . . . . . . . . . .4
9 J841-8NS SCREW, 4-40 x .50, pnhd, cres . . . . . . . . . . . . . . . . . . .6
10 H12031A-02 CONNECTOR, Screw Term, 2-socket, .3" . . . . . . . . . . .1
April 30, 1999 Page 7-7

M/D Totco
Figure 7-4. Display Barrier Box

FIGURE UNITS USE
& PART PER ON
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
Page 7-8 April 30, 1999

M/D Totco
6, 8
Figure 7-5. Sensor Barrier Box

FIGURE UNITS USE
& PART PER ON
7-5- 220450-002 SENSOR BARRIER BOX . . . . . . . . . . . . . . . . . . . . . .N/A N/A

1 H12292A-16 BARRIER BOX, 16 + 3 Position . . . . . . . . . . . . . . . . . . .1
2 H10992A-765A BARRIER, I.S., 15V/15V . . . . . . . . . . . . . . . . . . . . . . . 16
3 951540-007 BARRIER, I.S., prox, amplifier, NPN . . . . . . . . . . . . . . .3
4 955706-009 CONN, Cord, nyl, .75 NPT, .50-.63. . . . . . . . . . . . . . . . 14
5 955706-008 CONN, Cord, nyl, 1.0 NPT, 1.00-1.13. . . . . . . . . . . . . . .4
6 J10481A-02 HUB, Conduit, .75 NPT . . . . . . . . . . . . . . . . . . . . . . . . 14
7 J10481A-03 HUB, Conduit, 1.0 NPT . . . . . . . . . . . . . . . . . . . . . . . . .4
8 J10009A-000400 REDUCER, .75 NPT to .5 NPT . . . . . . . . . . . . . . . . . . 14
April 30, 1999 Page 7-9

M/D Totco
14, 15
14, 18, 19
9, 10
2
4
16, 17
11, 12, 13
Figure 7-6. Junction Box
Page 7-10 April 30, 1999

M/D Totco
FIGURE UNITS USE

& PART PER ON
7-6 220364-002 JUNCTION BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A N/A

1 220365 JUNCTION BOX, Modified, 12 x 10 x 6, sst . . . . . . . . . .1
2 220225 BASE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3 219991-005 TERMINAL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
4 220367 CONNECTOR ASSY, 37-Pin . . . . . . . . . . . . . . . . . . . . .1
5 948510-003 END COVER, Terminal. . . . . . . . . . . . . . . . . . . . . . . . . .2
6 948500-003 TERMINAL END BRACKET, with Label . . . . . . . . . . . . .2
7 948513-002 TERMINAL, 300V, 20A . . . . . . . . . . . . . . . . . . . . . . . . . 36
8 948500-002 TERMINAL, End Brkt . . . . . . . . . . . . . . . . . . . . . . . . . . .2
9 J812-4TS SCREW, 10-32 x .50, truss hd . . . . . . . . . . . . . . . . . . . .4
10 999279-024 NUT, 10-32 Hx, slflkg . . . . . . . . . . . . . . . . . . . . . . . . . . .4
11 J811-8KS SCREW, 1/4-20 x 1.00, allen hd . . . . . . . . . . . . . . . . . . .8
12 J806-4CS NUT, 1/4-20, elastic stop . . . . . . . . . . . . . . . . . . . . . . . .8
13 999310-013 WASHER, Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
14 969161-001 HUB, Conduit, 1/2-inch NPT. . . . . . . . . . . . . . . . . . . . . 15
15 J1292-4 PLUG, .50, NPT plastic . . . . . . . . . . . . . . . . . . . . . . . . .7
16 220362-103 PLATE, Cover, blank. . . . . . . . . . . . . . . . . . . . . . . . . . . .1
17 220362-203 GASKET, Cover Plate, blank . . . . . . . . . . . . . . . . . . . . .1
18 950859-001 CAP, Rcpt, MS14S, with chain and ring . . . . . . . . . . . . .8
19 218384-005 WIRE HARNESS, Conn Assy, 4-pin . . . . . . . . . . . . . . . .8
* 220366 LABEL, Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . .1
* 220226 LABEL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* 948509-004 LABEL, Terminal, 1-10 . . . . . . . . . . . . . . . . . . . . . . . . . .2
* 948509-005 LABEL, Terminal, 11-20 . . . . . . . . . . . . . . . . . . . . . . . . .2
* 948509-006 LABEL, Terminal 21-30. . . . . . . . . . . . . . . . . . . . . . . . . .2
* 948509-007 LABEL, Terminal, 31-40 . . . . . . . . . . . . . . . . . . . . . . . . .2
* 947619-001 TIE, Wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
* H10711A-03 WIRE FERRULES, #18 . . . . . . . . . . . . . . . . . . . . . . . .100
* 999393-226 SCREW, 1/4-20 x 1.00 Hx, sst . . . . . . . . . . . . . . . . . . . .4
* J827-4CS NUT, 1/4-20, hx, sst . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
* 999268-011 WASHER LOCK, .25 . . . . . . . . . . . . . . . . . . . . . . . . . . .4
* Not shown
April 30, 1999 Page 7-11

M/D Totco
5 13 14
15
6, 7, 8
10
12
18, 19, 20
6, 7, 8 11
16
9
21 2
1
17
3, 4
Figure 7-7. Pit Level Sensor
FIGURE UNITS USE

& PART PER ON
7-7 272819-series PIT LEVEL SENSOR ASSY . . . . . . . . . . . . . . . . . . . .N/A N/A

-- 272819-224 PROBE & CLAMP ASSY, 6’, with 250’ EXANE . . . . . .N/A
-- 272819-220 PROBE & CLAMP ASSY, 8’, with 250’ EXANE . . . . . .N/A
-- 272819-221 PROBE & CLAMP ASSY, 10’, with 250’ EXANE . . . . .N/A
-- 272819-229 PROBE & CLAMP ASSY, 6’, no cable . . . . . . . . . . . . .N/A
-- 272819-225 PROBE & CLAMP ASSY, 8’, no cable . . . . . . . . . . . . .N/A
-- 272819-226 PROBE & CLAMP ASSY, 10’, no cable . . . . . . . . . . . .N/A
-- 262622-205 PROBE ONLY, 6’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
-- 262622-202 PROBE ONLY, 8’. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
-- 262622-201 PROBE ONLY, 10’. . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
-- 262622-203 PROBE ONLY, 15’. . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
-- 262622-204 PROBE ONLY, 20’. . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
Page 7-12 April 30, 1999

M/D Totco
FIGURE UNITS USE

& PART PER ON
7-7 (Con’t) 272819-series PIT LEVEL SENSOR ASSY . . . . . . . . . . . . . . . . . . . .N/A N/A

* 272825 CLAMP ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N/A
* 230352-009 CABLE ASSY, 250’ EXANE . . . . . . . . . . . . . . . . . . . . .N/A
1 262645 FLOAT ASSY, 8-Inch Plastic. . . . . . . . . . . . . . . . . . . . . .1
* 220383-001 INSERT ASSY, 6’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* 220383-002 INSERT ASSY, 8’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* 220383-003 INSERT ASSY, 10’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* 220383-004 INSERT ASSY, 15’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* 220383-005 INSERT ASSY, 20’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
3 262626 COLLAR, Retaining, sst . . . . . . . . . . . . . . . . . . . . . . . . .1
4 999333-015 SETSCREW, Socket Hx, cup pt, 3/8-16 X .37, sst . . . . .2
5 272829 BRACKET, Extension . . . . . . . . . . . . . . . . . . . . . . . . . . .1
6 999397-049 NUT, Hx, 5/16-18, sst . . . . . . . . . . . . . . . . . . . . . . . . . . .4
7 999268-012 LOCKWASHER, 5-16, sst . . . . . . . . . . . . . . . . . . . . . . .4
8 999393-251 SCREW, Hx, 5/16-18 x 1.50, sst . . . . . . . . . . . . . . . . . .4
9 270410-101 CLAMP ASSY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
10 978915-001 GASKET, Conduit Outlet . . . . . . . . . . . . . . . . . . . . . . . .1
11 955220-022 CONDUIT, Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
12 951508-004 TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
13 950814-004 CRIMP, Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
14 955701-009 CONNECTOR, Cord. . . . . . . . . . . . . . . . . . . . . . . . . . . .1
15 946941-002 CABLE, #18/3 Shld, EXANE . . . . . . . . . . . . . . . . . . . . AR
16 947619-055 STRAP, Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
17 949807-389 CONNECTOR, 4-Pin . . . . . . . . . . . . . . . . . . . . . . . . . . .1
18 979439-009 O-RING, Viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
19 999333-001 SETSCREW, 1/4-20 x .31, sst . . . . . . . . . . . . . . . . . . . .2
20 262627 ADAPTOR, Mud Probe Stem . . . . . . . . . . . . . . . . . . . . .1
21 270401 BRACKET ASSY, with Clamp, mounting . . . . . . . . . . . .1
* 262643 SPACER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* 218911-002 SPACER, TB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
* 218910 CUSHION, Neoprene . . . . . . . . . . . . . . . . . . . . . . . . . . .2
* Not shown
April 30, 1999 Page 7-13

M/D Totco
Figure 7-8. Pump Stroke Sensor

FIGURE UNITS USE
& PART PER ON
7-8- 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
Page 7-14 April 30, 1999

M/D Totco
Figure 7-9. VIP Workstation

FIGURE UNITS USE
& PART PER ON
7-9 220454-001 VIP WORKSTATION, without PC, printer, paper . . . . .N/A A

220454-002 VIP WORKSTATION, with PC, printer, paper . . . . . . . .N/A B
1 219205 MODEM, Internal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
2 219497 PCB ASSY, DCM Communications Board, TOTAL. . . . .1 A,B
3 219916-001 T-POT MODEM, DCM, TOTAL . . . . . . . . . . . . . . . . . . . .1 A,B
4 220453-250 CABLE ASSY, RG59/U Coax, with connectors . . . . . 250’ A,B
5 949895-001 TEE, BNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 A,B
6 219607 COMPUTER, with Monitor . . . . . . . . . . . . . . . . . . . . . . .1 B
7 218778-018 LABEL, ID, workstation. . . . . . . . . . . . . . . . . . . . . . . . . .1 B
8 219282 PRINTER, Color Graphics . . . . . . . . . . . . . . . . . . . . . . .1 B
9 946955-001 CABLE, Printer, PC parallel . . . . . . . . . . . . . . . . . . . . . 10’ B
10 999384-004 PAPER, 1-Ply, 11 x 14.87 . . . . . . . . . . . . . . . . . . . . . . . .1 B
April 30, 1999 Page 7-15

M/D Totco
Table 7-2. Recommended Spare Parts Inventory
MANUAL/
PART
FIGURE &
NUMBER DESCRIPTION QUANTITY
INDEX NO
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
Page 7-16 April 30, 1999

M/D Totco
APPENDIX A
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 next to
electrical power cables. This prevents induced noise from causing erratic sensor channel values.
A-4 SHIELDED CABLE SPLICING

Sensor cables must typically be spliced in the field. Figure A-1 shows the recommended method of
using butt splices to join two pieces of shielded cable or a length of shielded cable and a shielded
cable pigtail assembly.
WARNING
Plan each rig-up so that splices are not located in hazardous areas.
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.
April 30, 1999 Page A-1

M/D Totco
Appendix A MUDWATCH - System 4
SHIELDED CABLE GUIDELINES Manual 60-30
A-5 CONNECTING TWO DEVICES WITH SHIELDED CABLE

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.
CAUTION
If the shield is connected to ground at both ends of the cable, the shield will
attract electrical interference, rather than shield against it.
• 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.
Page A-2 April 30, 1999

M/D Totco
MUDWATCH - System 4 Appendix A
Manual 60-30 SHIELDED CABLE GUIDELINES
Figure A-1. Recommended Method of Splicing Shielded Cable
April 30, 1999 Page A-3

M/D Totco
Appendix A MUDWATCH - System 4
SHIELDED CABLE GUIDELINES Manual 60-30
Page A-4 April 30, 1999

M/D Totco
APPENDIX B
CONVERSION 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 degrees
Fahrenheit, then multiply by 0.556, as shown below:
oC = [ oF - M32 ] x 0.556
To convert from degrees Centigrade (oC) to degrees Fahrenheit (oF), multiply the degrees Centi-
grade by 1.7985, then add 32, as shown below:
o
F = [ oC x 1.8 ] + 32
B-3 CONVERSION FACTORS

Conversion factors for commonly used units are presented in Table B-1.
April 30, 1999 Page B-1

M/D Totco
Appendix B MUDWATCH - System 4
CONVERSION DATA Manual 60-30
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 (m 3/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)
3
cubic feet (ft ) 7.4805 gallons, U.S. liquid
3
cubic feet (ft ) 28.32 liters
3)
cubic feet (ft 0.178 barrels (bbl) of petroleum
3
cubic meters (m ) 6.289 barrels (bbl) of petroleum
3
cubic meters (m ) 264.2 gallons, U.S. liquid
3/cm)
cubic meters per centimeter (m 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
3)
grams per cubic centimeter (g/cm 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
3)
kilograms per cubic meter (kg/m 0.00835 pounds per U.S. liquid gallon (lb/gal)
kilograms per meter (kg/m) 0.672 pounds per foot
3
kilograms per square centimeter (kg/cm ) 14.2227 pounds per square inch (psi)
kilometers (km) 0.6215 miles
(Continued)
Page B-2 April 30, 1999

M/D Totco
MUDWATCH - System 4 Appendix B
Manual 60-30 CONVERSION DATA
MULTIPLY BY TO OBTAIN
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/m 3)
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)
2) square inch (in2)
square centimeters (cm 0.155
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)
April 30, 1999 Page B-3

M/D Totco
Appendix B MUDWATCH - System 4
CONVERSION DATA Manual 60-30
Page B-4 April 30, 1999

M/D Totco
APPENDIX C
WORKSHEET DRAWINGS
C-1 INTRODUCTION
This appendix contains instrument block diagram drawings for the five most common
MUDWATCH configurations. Use these drawings to document a MUDWATCH system.
C-2 HOW TO DOCUMENT A SYSTEM

To document a system, combine the first three general information and schedule sheets with the
appropriate block and interconnect drawing sheets. Then edit the drawings as needed to correctly
represent the system (i.e., mark out inapplicable equipment, etc.). Finally, copy the drawings and
place them in the “DRAWINGS” section of the supplied binder.
C-3 CONTENTS OF THIS APPENDIX

The drawings in this appendix are listed below:
• Sheets 1 through 18 - Worksheet Drawings
April 30, 1999 Page C-1

M/D Totco
Appendix C MUDWATCH - System 4
WORKSHEET DRAWINGS Manual 60-30
Page C-2 April 30, 1999

M/D Totco

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Part Number 60-30

INSTALLATION, OPERATION, MAINTENANCE

Manufacturers of Precision Instruments

Printed in U.S.A. April 30, 1999

Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . April 1999

Information in this manual is subject to change without notice.

April 30, 1999 iii

The warranty periods for various products are:

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

iv April 30, 1999

April 30, 1999 Page TOC -1

Page TOC-2 April 30, 1999

5-4 DISPLAY PANEL FIELDS ..............................................................................................................5-9

April 30, 1999 Page TOC-3

Page TOC-4 April 30, 1999

April 30, 1999 Page LOF -1

Page LOF-2 April 30, 1999

April 30, 1999 Page LOF-3

Page LOF-4 April 30, 1999

Table 2-1. MUD WATCH Specifications .......................................................................................2-14

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

Table 4-1. Channel Descriptions: Standard MUDWATCH Configuration .......................................4-2

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

Table 6-1. Troubleshooting Table: MUDWATCH System ...............................................................6-2

April 30, 1999 Page LOT-1

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

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

Page LOT-2 April 30, 1999

1-2 SCOPE OF MANUAL

q Chapter 1 - Introduction to manual

q Chapter 2 - Description of the MUDWATCH system, its main components,

q Chapter 3 - Installation of main components, optional components and sensors

q Chapter 4 - Configuration and calibration of sensor channels

q Chapter 5 - Operation of display panel keypad, description of display panel

q Chapter 6 - Maintenance and troubleshooting

q Chapter 7 - Illustrated parts breakdown and recommended spare parts inventory

q Appendix A - Guidelines for working with shielded cable

q Appendix B - Conversion data

q Appendix C - General information/schedule sheets, block diagrams and intercon-

1-3 INTENDED AUDIENCE

1-4 PERSONNEL QUALIFICATIONS

April 30, 1999 Page 1-1

1-5 NOTES, CAUTIONS AND WARNINGS

Provides information to prevent equipment malfunction or damage that

1-6 RELATED DOCUMENTS

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2-3 MAIN COMPONENTS

Only UL-approved and CENELEC-approved MUDWATCH components

April 30, 1999 Page 2-1

Figure 2-1. Typical MUDWATCH System

Figure 2-2. DAQ (Data Acquisition Unit)

April 30, 1999 Page 2-3

2-3-2 MUDWATCH Display Panel

RE TURN FLOW G AI N / LO S S KE Y BOA RD

CO UNT ER A RETU RNS P ERCENT BA RRE LS CODE

LIG H T-S E LE C TE D PUMP 1 RAT E P U MP 2 R A T E MOD E T RIP VO L

Figure 2-3. MUDWATCH Display Panel

Page 2-4 April 30, 1999