System Sensors

LIST OF SENSORS

1. IRIS Data Acquisition System

2. Depth Drawworks Encoder
3. Hook Load
4. Rotary RPM
5. Electrical Rotary Torque
6. Standpipe and Choke Pressure
7. Pump Stroke Switch
8. Mud Density
9. Mud Conductivity
10. Mud Temperature
11. Mud Flow Out
12. Mud Volume Monitor
13. Conventional Gas Trap
14. Quantitative Gas Measurement (QGM)
15. H2S Sensor
16. Portable H2S Detector
17. Calcimeter
18. UV Box (Fluoroscope)
19. Cuttings Gas Detector
20. Geological Microscope and Fiber-Optic Illuminator
21. Portable Resistivity Meter
22. Advanced Total Hydrocarbon Analyzer
23. Fast Chromatograph
24. Mud Duck
25. Unit Layout

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IRIS
(Integrated Rig Information System)

INSITE data acquisition System

Power
Box Supply Unit
cover
Power
Cable
o Safety
Barrier
RS-232
interface
q
Cable to
IRIS server
n Multi-core
Cable from
Networked
sensors
Datascan
Modules p
Typical IRIS Box showing Datascans and PF barriers layout

Description

IRIS hardware comprises at least three Measurement Systems Ltd Datascans

units arranged in a “stack”. Datascans have been in use with Sperry-Sun, a
Halliburton company, for more than a decade and provide a reliable means of
collecting data from a distributed sensor array such as that found on a rig.

Each Datascan module has a series of DIP switches. These are used to
identify each Datascan in the stack (network). The system can accommodate
as many Datascan modules as required for extended array of sensors and
signals.

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IRIS Datascan Modules

7320

Analogue Processor (16

analogue signal channels
plus RS232)

7041

Digital input (16 digital signal

channels)

7050

Analogue output – (for chart

recorders).

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IRIS Configuration and Operation

IRIS channels configuration screen

The 7320 powers the stack and provides the interface to INSITE through a
RS232 serial link to the IRIS server on the network.

Each sensor is connected to a Datascan channel, each Datascan has 16

channels. If a stack of 3 Datascans is built up, the channels are numbered
sequentially from 1 thru 48. Each Datascan in the stack is called a Node. In
the Datascan Node, each channel is assigned two numbers, the sequential
number (e.g. 1-48) and the channel number in the Node (1-16). The
sequential number is then assigned a parameter name. This name is
“mapped” to its equivalent parameter in the INSITE database (the ADI) and
is logged in the relevant record in each run.

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Drawworks Depth Encoder

Description and Theory of Operation

The drawworks depth encoder is mounted on the drawworks shaft for

continuous depth monitoring during all rig activities. In addition to the
up/down pipe movement, the encoder can accurately monitor pipe speeds to
help minimize surge and swab problems.

The sensor consists of four large metal pieces attached together by means of
two sets of screws. The inner cylindrical part of the device has 30 blades

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 System Sensors

protruding from its widest point. These blades act as targets for the two
Pepperl+Fuchs switches that are screwed through the casing and locked in
position. An aluminum cuboid is used to protect the inner parts with an
outside threaded hole for a gland to be fitted. The casing is filled with grease
to lubricate the moving parts.

There are brass bushings on the large circular holes on either side of the
casing to protect the steel from wear as the inner targets rotate. Each end of
the inner "targeted" cylinder is threaded with one side being female and the
other male. The male end screws directly into the axle of the drawworks and
the female end accepts the installation of an air hose from the cooling nipple
(this would normally be connected directly into the drawworks axle).

These two Pepperl+Fuchs switches are spaced

slightly out of phase with each other. The
direction of movement is determined by the
first signal received after both sensors have
been in the off state. In this way one sensor
will always “lead on”, the A in one direction
and the B in the other. The signals are
processed by the Quadrature conversion
module and output to the 7320 Datascan
Module as an UP and a DOWN set of pulses.

Pepperl-Fuchs KFD2-SOT-EX2

Specifications

• Intrinsically safe
• Operating Temp: -20: +60 °C (-4 : +140 ºF)
• 5 VDC supply voltage through P/F KFD2-SOT-EX2
• 2 digital outputs A+B with 90 degrees phase different
• Max Frequency: 5 KHz
• Weight: 1.5 Kg
• Shaft: Stainless steel

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Hook Load

Description and Theory of Operation

The Hook Load sensor uses a full bridge strain gauge sensing element with
high accuracy measurement. The pressure-to-electrical signal electronics
eliminate the day-to-night temperature drifts seen by the usual
implementation.

The wire rope is fixed at the centre of the transducer body between two
deflection blocks. When additional load is applied to the wire rope, it tends to
straighten at the deflection point and creates a strain on the transducer body
which is detected by the strain gauge. The strain gauge bridge and the signal
conditioner combine to produce a 4-20 mA output signal proportional to the
tension in the wire rope.

Specifications

• Intrinsically safe
• Operating Temp: - 40: +180 ºF (-40 : + 80 ºC)
• Power: 4-20 mA loop powered
• Principle: Strain gauge
• Capacity: 100,000 lbs (45,000 kg)
• Wire rope: 0.875-2” (2.2 cm-5.1 cm)
• Accuracy: 0.2% repeatability

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Rotary RPM

Description and Theory of Operation

The RPM proximity switch consists of a reed switch enclosed in two magnets.
The two magnets are set in opposite polarity so that they cancel each other
out and hence turn the reed switch off. The field is only imbalanced, and the
reed switch turned on, by the proximity of the other magnet or magnetic
substance such as steel. The sensor is positioned over the top drive or rotary
motor driving shaft.

Specifications

• Intrinsically safe
• Operating Temp: -10 : +160 ºF (-25 : +70 ºC)
• 5 VDC supply voltage through P/F KFD2-SOT-EX2
• Digital pulse sensor
• Principle: Proximity switch
• Certification: EEx ia IIC T6
• Range 0- 500 RPM
• Sensor Accuracy+/- 1 RPM/ FS

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Electrical Rotary Torque

Description and Theory of Operation

The torque sensor is a 'Split Core Current Transducer'. It takes the form of a
clamp which sits round the main power cable to the Top Drive System. Being
clip-on, it requires no cutting/splicing of electric cables. It works on the
principle of deformation of Hall-effect chips by the magnetic field produced
around the cable due to the current being drawn through it, i.e. the greater
the torque being produced as the pipe rotates, the greater the current drawn
by the Top Drive (greater 'Hall effect').

The Hall-effect chips are made of Indium Arsenide (semi-conducting

material) with a ferrite core that focuses the effect of the magnetic field on to
the semi-conductor. In short, they give a variable resistance effect which is
directly proportional to the strength of the magnetic field they are exposed
to. They give a variable 4-20 mA signal back to the logging unit.

Specifications

• Intrinsically safe
• Operating Temp: -10 : + 160 ºF (-25 : +70 ºC)
• Area Classification EEX d II T6
• Electrical cable size: up to 2”
• Range: up to 1000 Amps
• 4-20 mA output I.S
• Sensor Accuracy 0.1% FS

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Standpipe Pressure
Choke Pressure

Description and Theory of Operation

The sensor design puts the transducer in contact with mud. The sensor
utilizes a bonded-foil strain gauge sensing element and a completely
encapsulated electronic signal amplifier to produce a 4-20 mA output that is
proportional to applied pressure.

The unit is environmentally sealed with the stainless steel cover being
electron-beam welded to the pressure fitting. The parts which come in
contact with the drilling fluid meet the NACE standards for contact with a
sour gas (H2S).

The sensor features a 4-pin Glenair connector for 24 VDC input power. Even
though the transmitter is polarity dependant, it is protected against reversing
polarity.

Specifications

• Area Classification Intrinsically Safe Approved for Class 1 Div 1 Group

A,B,C and D
• Operating Temp: -25: +70 ºC (-10 : +160 ºF)
• Stainless steel construction
• Pressure ranges available: 0-6000, 0-10000, 0-15000 psi
• Accuracy: 0.25% at FS
• Supply Voltage 8 – 30 VDC
• Output Signal 4-20 mA, 2 wire current loop.

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Pump stroke switch

Description and Theory of Operation

This intrinsically safe, whisker-type sensor is simple to operate and maintain

with a high degree of accuracy and reliability.

The sensor gives a signal by the physical making and breaking of a contact
switch attached to a whisker arm. The sensor is connected to PF KFD2-SOT-
Ex2 barrier for Hazard application and signal conditioning. The signal is
connected to the digital Datascan module 7041 for processing.

Specifications
• Intrinsically safe
• Operating Temp: -25: +70 ºC (-10 : + 160 ºF)
• 5 VDC supply voltage through P/F KFD2-SOT-EX2
• Proximity electrical switch
• Certification: EEx ia IIC T6
• Range : 0 – 500 SPM
• Sensor Accuracy +/- 1 SPM at Full Scale

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Mud Density

Description and Theory of Operation

The differential pressure transducer measures the difference in pressure

between the two remote pressure diaphragms at the bottom of the sensor
pole.

The two pressures are applied through isolating diaphragms to each side of
sensing diaphragms. On each side of this sensing diaphragm is a capacitance
plate. These detect relative movement of the sensing plate by changing their
capacitance. The plates are driven by an oscillator whose frequency is altered
by the change in capacitance of the plates. This signal is demodulated to DC
voltage and is then amplified to give 4-20 mA signals at 24 VDC.

Specifications

• Intrinsically safe
• Operating Temp: -25: +70 ºC (-10 : + 160 ºF)
• Supply Voltage: 8 – 30 VDC
• Method of Measurement: Current loop 4 - 20 mA
• Working Principle: Differential pressure cell
• Area Classification: EEX ia IIC T6
• Range: 6-24 ppg
• Accuracy: +/- 5 % at Full Scale

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Mud Conductivity

Description and Theory of Operation

The sensor works on the principle of the toroidal coupling effect. The sensor
contains two coils known as the primary and secondary coils. AC current is
fed to the primary coil by oscillator.

The magnetic effect caused by this current is transmitted to the secondary

coil by the medium surrounding the coils. The phase difference of the second
coil is related to the resistivity of the medium. The phase difference is
detected by a modulation unit and then amplified to a 4-20 mA signal. The
sensor also contains a thermistor for temperature compensation so that the
actual value given is at its 20 °C equivalent.

Specifications

• Intrinsically safe
• Operating Temp: -20: +150 ºC (-4 : + 302 ºF)
• Method of Measurement: Current Loop 4 -20 mA
• Working Principle: Toroidal coupling effect
• Area Classification: EEX ia IIC T6
• Supply voltage: 8 - 30 VDC
• Range: 0 – 100 mmho
• Accuracy: 0.1 % full scale

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Mud Temperature

Description and Theory of Operation

This sensor consists of a thermistor enclosed in a stainless steel probe that in

turn is protected by a stainless steel cage. The probe is submerged in the
mud. The thermistor is a temperature sensitive resistor that has proved its
high accuracy with durability and ease of installation and maintenance.

The temperature sensor probe used on the INSITE IRIS is a thermistor

device. The thermistor is connected to a current loop converter element
supplying 24 VDC isolated power from the PF barrier. The sensing element
gives a variable resistance to current loop converter which is then amplified
to give 4-20 mA signals.

Specifications
• Intrinsically safe
• Operating Temp: -20 : +150 ºC (-4 : + 302 ºF)
• Working Principle: Thermistor
• Area Classification: EEX ia IIC T6
• Range: 0 – 100 º C
• Supply voltage: 8 – 30 VDC
• Output signal: 4–20 mA
• Accuracy : 0.1 ºC full Scale

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Mud Flow out

Description and Theory of Operation

The flow out sensor is a counter weighted flow paddle. This sensor consists of
a paddle directly connected to a counterweight to provide a balanced
response to flow, and a 1 turn 10 KΩ potentiometer. This potentiometer is
powered through a 4-20 mA current converter module. The flowout signal is
wired directly from the PF KFD2-CR-EX1-30-300 safety barrier.

Available with different paddle size, the device accommodates a wide range
of flowlines. Each paddle is designed to minimize mud cake build up.

Specifications

• Intrinsically safe
• Operating Temp: 0 - +60 ºC ( 32 - 140 º F)
• Working Principle: Potentiometers converted to current loop.
• Area Classification: EEX ia IIC T6
• Supply voltage: 8 – 30 VDC
• Output signal: 4 – 20 mA
• Range: 0 – 100 %
• Accuracy: 5 % full scale

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Mud Volume Monitor

Description and Theory of Operation

The pit volume measurement is done using ultra-sonic transit time. The
sensor is mounted over the pit above the maximum mud level. The following
sequence of events takes place several times each second:
1. The transmitter emits a brief ultrasonic pulse.
2. A short time is allowed for the electronics to settle and for spurious
echoes to die away.
3. The transmitter is switched to receiver-mode automatically.
4. The first pulse returning from the mud surface is received.
5. The receiver is locked out to eliminate confusion caused by secondary
echoes.
6. The sequence is repeated
The electronic Controller contains all the circuitry necessary to determine the
round trip time and to transmit it as a 4-20 mA current signal.

Specifications

• Oper. Temp: -25 : +70 ºC (-10 : + 160 ºF)

• Power: 12 – 28 VDC .1 A surge
• Loop Current : 4 – 20 ma Max
• Range: 0.25 – 5 meters
• Memory: non- volatile EEPROM
• No Battery required
• Approval : CSA, FM Intrinsically Safe for Class I & II DIV 1,GR A, B,
C, D, E, F, G hazardous Location

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Conventional Gas Trap

Description and Theory of Operation

The bottom of the gas trap is submerged in the returning mud stream. The
trap agitates and aerates the mud, releasing gas-enriched air bubbles which
are continuously drawn through flexible tubing into the unit for analysis.

Option: The gas trap body is designed to accommodate either explosion-

proof electric motor or air driven motor for optimum safety.

Specifications

• Electrical Trap Motor

• Manufacturer: Dayton
• Hazardous Location Motor for Class I DIV 1, Group A, B, C, and D
• Voltage Supply: 110 / 220 VAC, 50 or 60 Hz
• Motor RPM: 1725
• Motor HP: 1/3 hp

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Quantitative Gas Measurement

QGM

Description

The Quantitative Gas Measurement (QGM) trap enhances the gas recovery
with constant volume of mud sample. The device is not affected by wind or
normal mud level changes.

Using QGM trap can improve gas correlation independent of service provider
and enhance sensitivity optimized for mud systems and general gas level.
The rapid response provided by the QGM trap improves safety and log
resolution.

The trap performance is based on tested theory and tied to actual gas in
mud.

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H2S Sensor

Description and Theory of Operation

The Ultima H2S Gas monitor is designed to sample the environment where
mounted and alert you to potentially dangerous levels of your target H2S gas

An electro chemical cell is used to react with the H2S gas and generate
electric signal that’s processed and is output at 4-20 mA.

Onboard LEDs and relays provide increased indication of alarm and fault
conditions. “Quick-check” LEDs are easily viewable from afar, and field-
programmable alarm levels and normally energized/de-energized and
latching/non-latching relay functions offer three levels of alarm and one fault.

Specifications

• Operating Temp: -25: +70 ºC (-10 : + 160 ºF)

• Power: 12-28 VDC 0.1 A surge
• Principle: Current Loop 4 - 20 mA Max
• Range: 0-50 ppm (0 - 100 ppm Optional)
• Accuracy: ± 1 % of full scale
• Approval: Safe for Class I DIV 1, hazardous location Groups, B, C, D,

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Portable H2S Detector

Description

Audible and visible warnings or alarms are activated when gas concentrations
exceed two pre-set levels. A "Warning" (W) or low alarm is activated when a
low concentration of hydrogen sulfide is detected. A distinctive pulsing alarm
is activated when a higher concentration is detected. This "High Alarm" (A)
can be cleared only when the concentration drops below the alarm set point.
The measuring range is 0-500 ppm H2S

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Calcimeter

Description and Theory of Operation

This portable apparatus is perfect for accurate calcite measurement on the

well site. Carbonate content can easily help define limestone and dolomite
occurrences and percentages.

Specifications

• Lucite cell and gauge

• Stainless steel carrying case
• Mortar and pestle included
• Built-in recorder and graph paper

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UV Box

Description

These high-intensity cabinets assure maximum UV irradiance, fluorescent

contrast and peak efficiency. The design features a soft rubber curtains on
both sides of the box to allow easy entrance to its interior. The side openings
are very convenient for core examination without having to break it into
pieces.

Specifications

• 1 visible light incandescent bulb

• 1 high intensity long wave UV-A bulb
• 1 high intensity short wave UA-C bulb
• Lens x2 with soft rubber goggles

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Cuttings Gas Detector

Description

Petron’s cuttings gas analyzer is an accurate and simple way to obtain

information about the total gas in the cuttings. The cuttings gas extracted
gives a measurement of the value of gas in mud compared to the reading
obtained from the gas trap which is the gas in air.

The use of the cuttings gas detector replaces the need to use the steam still
or an equivalent boiler to break the gas loose from the cuttings.

The Blender is designed to have a hose connection to the gas detection

system for analysis of released gases.

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Geological Microscope
And
Fiber-Optic Illuminator

Description

Sample description microscope has a stereo 50x magnification power.

Combined with the fiber optic illuminator, the set is ideal for field use.

The illuminator features a dual 18” goose neck cold light tubes that are rigid
enough for steady illumination. A 150 w halogen lamp is used with integral
dichromic reflector to focus the maximum light intensity onto the fiber optic
bundle. The built-in fan is ball-bearing type to reduce vibration and noise
plus extending equipment life.

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Portable Resistivity Meter

Description

A manual suction pump is used to draw in a mud sample into the detector. A
built-in thermometer measures the temperature of the mud sample to be
taken into consideration as a factor influencing the resistivity reading.

The device gives a direct instantaneous reading that’s accurate and reliable.

Specifications

• Range: .01 – 10 Ohm/m

• Thermometer range : 0-100 °F

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Total Hydrocarbon Analyzer

Baseline 8800a

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Fast Gas Chromatograph

Baseline 8900

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Mud Duck

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Halliburton Mud-Logging unit layout

DNV Certified

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Mud- Logging
unit
Dimensions
(approx.)

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