Auto Trak

Baker Hughes INTEQ

AutoTrak Operations Manual 750-500-085 Rev. A

May 1998

Confidental

Baker Hughes INTEQ Technical Communications P.O. Box 670968 Houston, TX 77267-0968 USA 713-625-4694

This manual is provided without any warranty of any kind, either expressed or implied. The information in this document is believed to be accurate; however, Baker Hughes INTEQ will not be liable for any damages, whether direct or indirect, which results from the use of any information contained herein.

© 1998 Baker Hughes Incorporated. All rights reserved.

Preface

Preface This manual is the first part of a series of manuals that exist or will exist. Note pages are located in the back of each Chapter. If you should find a discrepancy or if additional information is needed, please write this on the “Notes” pages and either copy them to Technical Services - Drilling Systems in Celle Germany or e:mail me a full description of where and what needs to be changed. These notes will then be transported to the new edition.

Baker Hughes INTEQ Technical Services - Drilling Systems Celle, Germany FAX +49-5141-203362 Baker Hughes INTEQ Technical Publications attn. Gary Foster 2001 Rankin Road Houston, Texas 77073 TEL (713) 625-4694 FAX (713) 625-5694

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Table of Contents Preface

Table of Contents Chapter 1 Introduction History of Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Rotary Steering Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chapter 2 6 ¾” AutoTrak Pilot Series

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 General Tool Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Sensor Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Component Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Steering Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ATI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Nearbit Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Pulser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Alternator/Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Hydrostatic Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Downlink Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Pulser Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Memory Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Vibration Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Reservoir Navigation Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Master Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Directional Attitude Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Reference Guide 750-500-085 Rev. A / May 1998

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Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hold Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribs Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18 2-18 2-19 2-20

Chapter 3 Surface Systems Bypass Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustable Nozzle/Sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustable Nozzle Unit Functional Description . . . . . . . . . . . . Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle Sub Functional Description . . . . . . . . . . . . . . . . . . . . . Handling - To Change out a nozzle . . . . . . . . . . . . . . . . . .

3-1 3-2 3-4 3-5 3-5 3-6 3-6 3-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Bypass System Rig Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Operational Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Basket Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 DrillByte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 System Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Veritas Plotter Configuration . . . . . . . . . . . . . . . . . . . 3-11 BPC Port Configuration . . . . . . . . . . . . . . . . . . . . . . . 3-12 SvyMonitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 LF Conversion Factor . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Database Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Telemetry Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 MWDParams Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Copying to/from UNIX/DOS . . . . . . . . . . . . . . . . . . . . . . 3-15 Backup/Restore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Tool Communication Rig-up . . . . . . . . . . . . . . . . . . . . . . . . 3-18 RIBox Tool Comms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 PowerComms To be included in a later release. . . . . . . . . . . . . . . . 3-19

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Chapter 4 Pilot Series Tool Programming “Tool Set-up” Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “Steering Set-up” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . “Module Communications” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telemetry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telemetry Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FE Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telemetry Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Making a .TEL File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modules ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT_103 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1 4-1 4-1 4-2 4-2 4-3 4-3 4-3 4-6 4-7 4-7 4-8

Chapter 5 Operating the AutoTrak Tool Tool Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Deck Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 D-Series Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Drill String Components . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Rig Floor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Memory Dumping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Post Run Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Preparing a Log of Memory Data . . . . . . . . . . . . . . . . . . . . . . 5-9 Veritas Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Chapter 6 Downlinking Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wakeup Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Header Byte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checksum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Series Downlinks Available . . . . . . . . . . . . . . . . . . . . . . . . . . Set Steer Mode (Command 0) . . . . . . . . . . . . . . . . . . . . . . . . . Set Hold Mode (Command 1) . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering Direction (Command 2) . . . . . . . . . . . . . . . . . . . . . . . Steering Force (Command 3) . . . . . . . . . . . . . . . . . . . . . . . . . Target Inclination (Command 4) . . . . . . . . . . . . . . . . . . . . . . . Walk Force (Command 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . Build Force (Command 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . Use Programmable Survey (Command 8) . . . . . . . . . . . . . . . . Set Gamma Select (Command 9) . . . . . . . . . . . . . . . . . . . . . . Set Phase Select (Command 10) . . . . . . . . . . . . . . . . . . . . . . . Set Attenuation Select (Command 11) . . . . . . . . . . . . . . . . . . . Control Method (Command 12) . . . . . . . . . . . . . . . . . . . . . . . Set ATI Command Ext. (Command 13) . . . . . . . . . . . . . . . . . . Module ON/OFF (Command 14) . . . . . . . . . . . . . . . . . . . . . . Pulse Rate (Command 15) . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing and Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4 6-4 6-5 6-5 6-5 6-5 6-6 6-6 6-6 6-7 6-7 6-7 6-8 6-9

Chapter 7 Directional Drilling With The AutoTrak Tool Pre Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Well Planning Considerations . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Bottom Hole Assembly Configurations . . . . . . . . . . . . . . . . . . 7-2 Drill Bit Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Directional Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Steer Mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Hold Mode: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Ribs Off: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Relationship Between Modes and Forces . . . . . . . . . . . . . . . . . 7-6 Dog Leg Gradient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Rib Force Relationship to Dog Leg Severity . . . . . . . . . . . 7-8 Dog Leg Gradient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Directional Drilling Thought Process . . . . . . . . . . . . . . . . . . . 7-9 Tool Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Running In Hole Without Downhole Motor . . . . . . . . . . . . . . 7-10 Running In Hole With Downhole Motor . . . . . . . . . . . . . . . . 7-11

Surface Testing Of The Motor . . . . . . . . . . . . . . . . . . 7-11 Backreaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Drilling Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Kicking Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 iv Confidential

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Open Hole Side-tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Specific Drilling Considerations . . . . . . . . . . . . . . . . . Tool Idiosyncrasies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Effects on Dog Leg Gradient . . . . . . . . . . . . . . . . . . . . . . . . . Effects of Overgauge Hole . . . . . . . . . . . . . . . . . . . . . . . . . .

7-15 7-16 7-17 7-17 7-17

Chapter 8 AutoTrak Reporting MWD FSE Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downlink Analysis and Tracking . . . . . . . . . . . . . . . . . . . . . . MWD Run Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AutoTrak Diary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard MWD FE Report . . . . . . . . . . . . . . . . . . . . . . . . . . . Directional Driller Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . Drilling Parameter Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily Drilling Report and BHA Report . . . . . . . . . . . . . . . . . . Directional Drilling Recap or Section Summary . . . . . . . . . . . . AutoTrak Diary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . End Of Well Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Chapter

1

Introduction

Chapter 1 describes the history and theory of the AutoTrak tool.

History of Development The AutoTrak tool was developed from the existing successful technologies of SDD (Straight Hole Drilling Device), RNT (Reservoir Navigation Tool), Calimero, Probe MWD and DrillByte Surface Logging System. Development was assisted by AGIP SpA, who had a requirement for a high temperature rotary steering device. Over the course of prototype development, the high temperature requirement was dropped and a low temperature version was pursued (as a consequence of this, you may see some references to the LTM or Low Temp. Master). Field testing of the first prototypes began in the summer of 1995 and continued until spring 1997 when the launch of the Pilot series tools began.

Rotary Steering Tools The benefits of a tool, capable of steering while rotating, are immense, and with increasingly challenging well plans, a well may (in some cases) only be possible with a rotary system. The AutoTrak system offers the potential to drill longer horizontal sections, faster and more safely. Sliding rates of penetration are generally 50% less than while rotary drilling, thus a rotary steering system can deliver substantially higher overall ROP. This combined, Operations Manual 750-500-085 Rev. A / May 1998

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with the fact that no time is wasted orienting the toolface prior to drilling, will increase overall ROP in comparison with conventional steerable systems, especially in extended reach and horizontal applications where orienting is particularly difficult. By eliminating the necessity to steer by orienting and sliding, drag on the drillstring can be significantly reduced allowing a constant application of WOB, reducing axial shock and vibration, and improving drilling dynamics. Studies have shown that drillstring rotation helps keep cuttings suspended, positively affecting hole cleaning and minimizing drillpipe-to-borehole friction. This results in fewer wiper trips and circulating operations, fewer stuck pipe incidents, fewer washout conditions and a lower, more constant ECD. In conventional directional drilling, bit selection is often dictated by the need to slide, resulting in a choice of a less aggressive PDC bit, or in the worst case, a Roller Cone bit, reducing ROP and in the latter case, increasing the number of bit trips required. Using a rotary steerable system allows drill bits to be selected on the basis of Penetration Rate rather than steerability.

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Chapter

2

6 ¾” AutoTrak Pilot Series

This chapter describes the overview, description and specifications of the AutoTrak tool.

Overview The AutoTrak tool is a rotary steering system which uses three independent ribs mounted on an uncoupled sleeve behind the bit to apply steering forces in the desired direction to achieve a steering action. As can be seen from the diagram, the sleeve, ribs and drive shaft distribute the hydraulic pressure correctly (a force which may be applied in any direction with a magnitude of up to 18.6 kN. The magnitude of the Dogleg Severity should be proportional to the magnitude of the resultant force exerted by the three ribs. Electronics in the uncoupled sleeve are able to sense the orientation of the sleeve and thus the orientation of the ribs. With this information, the sleeve electronics can distribute hydraulic pressure Operations Manual 750-500-085 Rev. A / May 1998

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generated by a pump in the collar, to the three ribs by means of three proportional valves. As the sleeve rotates (slowly by comparison to the drillstring rotation, 1-12 revolutions per hour would be an acceptable range), the electronics in the sleeve will calculate the new orientation and redistribute the pressures accordingly. In order to adjust the steering settings (among other things) we have the ability to communicate with the tool by means of flow rate modulation at surface. This process is referred to as downlinking. Flow rate modulation is achieved by mounting an automatic valve on the standpipe manifold which, when opened, diverts a proportion of the flow back to the return system. The operator can send commands from his surface system (DrillByte or MSS2/3), via an interface box, to the valve while drilling or off bottom.

General Description The diagram of the AutoTrak tool, shows the layout of the major components of the tool from the bit box (on the left) to the top of the flex sub (on the right). A brief description of the components and their function follows. Externally, the tool consists of three main sections: The steering section comprises the upper and lower drive shafts which run through the uncoupled sleeve, the pulser/ alternator sub and the upper stabilizer. The RNT section, directly above the upper stabilizer, is a standard Reservoir Navigation sub which provides dual frequency phase and attenuation resistivity measurements and Natural Gamma measurement by two scintillation counters. The RNT sub is connected at the top to the flex joint, using an RNT crossover.

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The third section is the non magnetic flex joint, which uncouples the tool from any bending moments in the drillstring above.

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General Tool Specifications General Tool Specifications Borehole Size:

Sensor Specifications

8-1/2” standard

Propagation Resistivity

8-3/8” - 9-7/8” on order

Distance From Bit

Build Rate:

0 - 6.5 °/100ft (30 m)

2 MHz Resistivity

Tool OD:

6-3/4” Steerable Stabiliser 7-3/4”

Phase Difference

Range: 0.1 - 3000 ohm-m Accuracy: ± 1% (0.1 - 50 ohm-m), ± 0.5 mmho/m (>50 ohm-m)

Attenuation

Range: 0.1 - 500 ohm-m Accuracy: ± 2% (0.1 - 25 ohm-m), ± 1.0 mmho/m (>25 ohm-m)

Vertical Resolution

8" (20cm) for 90% response in conductive beds

Length:

38.7 ft (11.8 m)

Weight:

3,400 lb (1550 Kg)

Connections:

NC50 Box Up 4-1/2” API Reg Box Down

Operating Specifications and Limits Flow Rate:

370 - 630 GPM 1,400 - 2,380 l/min

Flow Rate For Downlink Operation

490 - 630 GPM 1,850 - 2,380 l/min

Maximum WOB:

55,000 lbs 250 kN

Maximum Tool Rotation:

18.0 ft (5.5 m)

400 kHz Resistivity Phase Difference

Range: 0.1 - 1000 ohm-m Accuracy: ± 1% (0.1 - 25 ohm-m), ± 1.0 mmho/m (>25 ohm-m)

250 rpm

Attenuation

Maximum Drilling Torque: (at the Bit)

14,500 ft.lbs 20 kNm

Range: 0.1 - 200 ohm-m Accuracy: ± 5% (0.1 - 10 ohm-m), ± 5.0 mmho/m (>10 ohm-m)

Vertical Resolution

Maximum Torque To Failure:

22,000 ft.lbs 30 kNm

12" (30 cm) for 90% response in conductive beds

Maximum Overpull (Continued Operation):

109,000 lbs 487 kN

Gamma Ray

Maximum Overpull To Failure:

578,000 lbs 2,620 kN

Sensor Type

Scintillation (x2)

Max. Temperature: Operating Survival*

300 °F (150 °C) 311 °F (155 °C)

Measurement

API GR

Maximum Hydrostatic Pressure:

20,000 psi 1,380 bar

Maximum Bit Pressure Drop:

2,000 psi 138 bar

Maximum DLS For Tool Passage:

With Rotation: 9 °/100ft Without Rotation: 11 °/100ft

Distance From Bit

16.7 ft (5.1 m)

Range

0 - 250 API

Accuracy

± 3% of full scale

Statistical Repeatability

± 3 API @ 100 API and ROP = 60 ft/hr (18.3 m/hr)

Vertical Resolution

6” (15.3 cm)

Near Bit Inclination

Surface Unit - Bypass Actuator Unit

Distance From Bit

3.0 ft (0.9 m)

Weight:

900 lbs 400 Kg

Sensor Type

Tri-axial Accelerometer

Dimensions:

1.6 m x 0.6 m x 0.9 m

Directional

Maximum Standpipe Pressure:

7,100 psi 500 bar

Distance From Bit

32.8 ft (10.0 m)

Sensor Type

Tri-axial Accelerometer

Required Air Supply:

90 - 130 psi @ 630 l/min.

Hammer Union Connections at Unit:

HP Mud Line In: 2” Fig.1502 Box LP Mud Line Out: 2” Fig.1502 Pin

Tri-axial Flux Gate Vibration Distance From Bit

21.7 ft (6.6 m)

Sensor Type

Tri-axial Accelerometer

*Tool must not be exposed to either static or circulating temperatures which exceed 160 °C due to limits on lithium battery component in the system.

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Sensor Offsets

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Component Overview Steering Sleeve The heart of the AutoTrak tool is the uncoupled sleeve or non rotating sleeve. The sleeve is electrically connected to the collar by a pair of rotating brush connections and hydraulically by a system of high pressure seals. Mud is prevented from contaminating the oil in the space between the drive shaft and the sleeve by two sets of mud/oil seals, at either end of the sleeve. Two electronic modules, the ATI (AutoTrak Inclination) and NBA (Near Bit Actuator), are mounted in slots between the steering ribs. These modules calculate the pressure to be applied to the ribs and control the valves which physically distribute the pressures to the ribs.

The picture above shows a schematic of the sleeve. The upper and lower drive shafts are inserted at either end and meet at a thread connection in the middle of the sleeve. This connection is torqued to 20 kNm (15 kft-lbs) in the workshop. It is possible that this connection could be backed off if tongs are placed on the upper drive shaft when breaking of the bit. Care should be taken to ensure that this connection is not backed off or over torqued. To this end, it is not 2-6

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considered advisable to have the tool made up to the topdrive when making up the bit, rather having it hanging in the elevators, free to rotate.

The sleeve has three ribs mounted 120° apart. Behind each rib is a hatch containing a hydraulic valve which distributes the pressure produced by the hydraulic pump to its rib. Behind the proportional valve hatch for ribs 2 & 3, there is a hatch for access to the rotating brush connection. None of these hatches should be removed in the field. The only hatch to be removed in the field is the Readout Port behind the proportional valve of rib 1. The readout port is held in its slot by two bolts (It is the ONLY hatch on the sleeve with 2 bolts). When replacing the hatch, ensure that the O-ring is in good condition and lightly lubricated with silicone grease. Ensure that the O-ring is correctly in position before torquing the bolts, otherwise it will be damaged and will not seal properly. This could lead to contamination of the oil system and subsequent tool failure. After cleaning the bolts with Loctite cleaner spray (acetone) and allowing this to dry, Loctite 243 should be applied and the bolts torqued to 23 Nm (17 ft-lbs).

ATI The ATI module is mounted in one of the three slots in the uncoupled sleeve. It contains three orthogonally mounted accelerometers. Its function being to provide sleeve Operations Manual 750-500-085 Rev. A / May 1998

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orientation, near bit inclination and temperature data. Temperature data is required for correction of the accelerometers and the hydraulic valves. The sensor inclination is derived from all three accelerometers, unlike the Navigator which has the facility to transmit a Gz value only. Thus, when the sleeve is rotating out of control, erroneous nearbit inclination values will be transmitted. The ATI inclination value is also slightly affected by vibration, which will produce a sinusoidal variation with sleeve orientation. Bearing these points in mind, the ATI inclination measurement should be interpreted over a range of values and not on the basis of a single measurement. Ideally, a reading should be derived from observation over a complete rotation of the sleeve, or by comparing AT inclinations from similar sleeve orientations. It is important, when looking at AT inclinations, to have a well presented graphical record in the form of a time based plot and a depth based plot. Data from the ATI module is acquired by the master every 5 seconds (this is definable in the AutoTrak communications software, but is set to 5 seconds as a default). The value sent to the master is an average taken over a period defined by the ATI Command Extension, which will be set to 2 seconds as a default, but may be changed by downlink. Historically, the ATI command extension was an important parameter which could seriously affect the tool’s performance during periods of fast sleeve rotation, due to the time over which it acquired sleeve orientation data. With data now acquired using the above method, reducing the ATI command extension by one second will make little difference, however the facility does exist to change this parameter. The slot for the ATI module has an angular offset to RIB 1, which is used as the highside reference. Furthermore, the module is mounted in the slot with a rotation relative to the surface of the sleeve. The combination of these offsets, means that the direction which the module considers to be “up” is actually 115° to 130° to the left of RIB 1. The 2-8

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correct offset will be measured during calibration in the workshop and inserted as the ATI GTF Offset. In the downhole tool software, a default value of 125° has been set, thus if the calibration in the tool is lost, the tool will still function normally. This should, however, be checked in the tool programming software prior to running in hole.

Nearbit Actuator Having acquired data from the ATI module, the master then sends the data back to the Nearbit Actuator (NBA) module. The NBA can then apply this data to the current steering commands in order to calculate the required rib pressures. The NBA module holds the current steering commands in its memory. These commands are: Mode

Steer (mode 0) / Hold (mode 1) / Ribs Off (mode 3)

Steer Force The force applied in steer mode, adjustable from 0 - 18.6 kN in 0.6 kN steps. Steer Direction The direction relative to highside reference in which to apply the steer force. Adjustable through 360° in 1.5° increments. Build Force Force applied vertically up or down in hold mode adjustable from 0 - 18.6 kN in 0.6 kN steps. Walk Force Force applied to the left or right in hold mode, adjustable from -18.6 (Left) - +18.6 kN (Right) in 0.6 kN steps. Target Inclination Programmable inclination to which the tool will build or drop by applying the current build force. Inclination is adjusted from 0 to 128° in 0.125° increments. Operations Manual 750-500-085 Rev. A / May 1998

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All five parameters and the mode are stored in the NBA memory, regardless of the mode the tool is in. The current mode will only define the parameters that are used by the NBA. Knowing the force and steering direction or build force, walk force and target inclination required by the operator, and knowing the orientation of the sleeve and the ATI inclination, the NBA can calculate the pressure required on each rib to produce that force. Having recalculated the pressures required, the NBA can then directly adjust the hydraulic valves that control the individual rib pressures.

Hydraulic Valves Behind each of the three ribs on the sleeve, there is a hatch housing and a hydraulic valve. These three valves distribute the hydraulic pressure generated by the hydraulic pump to their respective ribs. These valves are calibrated in the workshop flow-loop prior to shipping the tools.

Turbine The turbine in the tool consists of a rotor with a single stage of blades. The mud is channelled by a fixed spiral guide wheel (or stator) to strike the rotor blades at the correct angle. The rotor drives the alternator and the oil pump, providing the tool with electrical and hydraulic power. A typical turbine RPM for 2000 L/min (528 gal/min) would be 55 rev/sec (3300 rpm).

Alternator The alternator of AutoTrak serves as the power supply for the complete downhole electronics including all added Triple Combo and Modular Dynamics and Pressure Subs. The alternator is driven by a mud turbine via a magneto coupling, sometimes referred to as a magnetic clutch, which seals the drilling mud from the oil reservoir inside the alternator. The alternator drive shaft is also connected to the oil pump of the hydraulic system. The operating 2-10

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range of the turbine / alternator unit is 1400 L/min (369.8 gal/min) to 2400 L/min (634 gal/min) resulting in a voltage range of the alternator of 40 VDC to 83 VDC. The voltage will be transformed to 33 VDC continuous by the Alternator Voltage Regulator. The alternator will have to supply 105 Watts peak power when AutoTrak is run with the Triple Combo Addition. With a maximum power output of 200 Watts, the alternator will be capable of achieving this.

Pulser The pulser, in the AutoTrak tool, uses differential pressure caused by mud flowing through a restriction to produce a pressure pulse. The diagram shows the pulser assembly mounted in the pulser housing. As mud flows through the tool, there will be a pressure drop over the restriction. Thus, the pressure at “A” will be higher than the pressure at “B”. A small portion of the flow will go through the pulser mesh, and follow the dark arrows, since there is a pressure differential between the two ends of the flow path. If we now activate the solenoid and push the Control Valve upwards to close off this flow path, we will increase the pressure in area “C” until it is the same as in area “A”. The high pressure area “C” is surrounded by the relatively low pressure area “B”, and will attempt to expand. In order for Operations Manual 750-500-085 Rev. A / May 1998

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area “C” to expand its volume, the valve body must now move upwards. This will reduce the clearance between the Valve Body and the Restriction, increasing standpipe pressure, and thus creating a pulse. The position of the Control Valve is determined by the Pulser Driver Board which in turn is controlled directly by the master CPU.

Oil Pump The hydraulic pump, mounted below the alternator, uses a cylindrical housing containing five spring mounted pistons, rotated below a fixed eccentric cam plate. As the pistons are pressed inward by the cam plate, they pass over a fixed, grooved base plate that acts as an inlet/outlet valve. With the cylinder rotating between 2000 and 3500 rpm, the pump output needs to be regulated to a constant pressure. This is achieved by sending the output through a relief valve which regulates the pump output pressure to nominally 140 bars (2030 psi).

Alternator/Voltage Regulator The three phase AC alternator output is converted to a 33 VDC supply by the AVR (Alternator/Voltage Regulator). It also provides a digital value of alternator RPM (and hence the turbine RPM) by analyzing the frequency of one of the phases of the alternator output. This value is then passed on to the Downlink Controller (DLC). The AVR is housed in the first probe above the pulser along with the Pulser Driver Board and the Downlink Controller Board.

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Hydrostatic Compensation

If the hydraulic system was completely isolated, producing 140 bars (2030 psi) at atmospheric pressure, as we increase hydrostatic pressure, the relative pressure difference between the hydraulic system and its surrounding environment will decrease, and thus the force applied by the steering ribs will decrease. To counter this effect, the hydraulic system is hydrostatically compensated. A rubber bellows inside the alternator/pulser housing acts as a flexible barrier between the oil reservoir and the mud system in the annulus. Mud from the annulus can enter via the compensation ports, and compensate the hydraulic oil in the reservoir between the support and the bellows. Thus, the oil on the low pressure side of the system is already at hydrostatic pressure before it goes through the hydraulic pump, and oil in the high pressure system will be at hydrostatic pressure plus 140 bars (2030 psi) relative to atmospheric pressure.

Downlink Controller The DLC constantly monitors the digital turbine RPM value from the AVR, and decides when a downlink is being sent. It will inform the master that a downlink is in progress and after the downlink, will inform the master of the content and status of the downlink.

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Pulser Driver Board The master module produces a 0 - 5 V digital signal to control the pulser. This is transmitted down the Pulse Control Line to the Pulser Driver Board (PDB). The PDB will amplify the signal and provide the current control required to operate the pulser solenoid. When a pulse is initiated, a relatively high current is required to accelerate the pulser control valve, however the current can be reduced slightly when the control valve has closed off the port in the valve body. Thus, when looking at the current draw during deck testing of the tools, a short lived current peak followed by a short drop will be seen. The regulation of this current is performed by the PDB.

Memory Module The tools memory is a 2 Mbyte probe mounted M30 memory. With the tool set in the default configuration, the memory will last about 100 hours. After this time, the memory will not wrap.

Vibration Module The vibration module (VMM) is mounted in the probe adjacent to the RNT M30 crossover, providing it with a more rigid mount than would be achieved using rubber probe centralizers. The module contains three orthogonal accelerometers. Three transmitted values are provided by the tool. EGYZX

Axial energy level, transmitted as a value between 0 and 7. The maximum value corresponding to an acceleration greater than 13g.

EGYXYX Lateral energy level, transmitted as a value between 0 and 7. The maximum value corresponding to an acceleration greater than 13g.

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HFSNAP High frequency axial acceleration transmitted as a value between 0 and 31. Data from the VMM gives no stick slip information, and its interpretation is not well understood. As a guideline, if EGYZX and/or EGYXYX reach 3, the drilling parameters should be modified to reduce vibration. With the introduction of the modified master module, it is hoped to replace the VMM with a VSS (Vibration Stick Slip) type sensor.

Reservoir Navigation Sub A standard Reservoir Navigation Sub (RNT) is mounted above the upper stabilizer, and is connected to the M30 line via a branch passed through a crossover at the top of the sub. Although there is an inclination sensor as a standard in the NBIG module of the RNT, its output is only stored in memory. The transmitted Nearbit Inclination is acquired from the ATI module in the Sleeve.

Battery The battery is required to provide power ONLY after the tool is powered down for the duration of the static delay (or flow off time). It provides power ONLY for the master and directional packages. It will not power the M-30 line, having a direct connection to the Master/DAS. The battery is a high temperature NaviTrak battery, with a maximum temperature of 160°C (320°F). It should be noted that there is a danger of explosion if this temperature is exceeded. The tool as a complete system is rated to a maximum operating temperature of 150°C (302°F).

Master Module In the early stages of AutoTrak development, the tool was specified as a high temperature tool, however the need for a high temperature version has diminished and a low Operations Manual 750-500-085 Rev. A / May 1998

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temperature version capable of operating at 150°C (302°F) was produced. You may therefore hear the Master being referred to as the Low Temperature Master (LTM). The master module has overall control of the tool. All communications between modules are carried out on the M30 line via the master. For example, data from the ATI module that is required by its close neighbor, the NBA does not go directly from one module to the other. First the master requests the individual items of data, the sleeve orientation for example, from the ATI. The ATI sends the master the sleeve orientation, and then the master sends the same information to the NBA. The only method of module to module communication throughout the tool is M30, with the exception of the connection between the battery and the Master/Directional modules. There is no ADAM bus in the tool (ADAM is a fast communication method used in collar based tools for communication within the directional collar). The master will poll the various modules for data at intervals defined by the user in the tool programming software, however the default setting is as follows: 5 sec 5 sec 10 sec 30 sec

Acquire DLC Acquire ATI Acquire Gamma / Res. Acquire Vibration

It is possible to increase these acquisition rates, however excessive increases could lead to bus contention, so if you deviate from the defaults, thoroughly test the tool on deck prior to picking up the tool.

Directional Attitude Sensor The tools directional sensor (DAS) is, in essence, a standard NaviTrak DAS module with three orthogonal accelerometers and three orthogonal magnetometers. However, the NaviTrak DAS contains its own master which is completely different to the AutoTrak Low Temperature Master.

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Electrical Schematic

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Steering Control In order to control the tool, we must establish a method of communicating our desired steering options to the tool. We do this with a combination of MODES and associated PARAMETERS. For drilling, there are two main modes, steer mode and hold mode. While tripping and drilling out ratholes, a third mode, Ribs Off, may be used. Five parameters are used in conjunction with the modes. These parameters and modes are held in the NBA memory, to be used in its calculation of the necessary rib pressures. These modes and parameters can be pre-programmed at surface using the tool communications software or may be changed downhole using downlinks.

Steer Mode Using an analogy with conventional steerable systems, steer mode uses a toolface and a predicted dogleg. In AutoTrak nomenclature, however, we give the tool a Direction and a Steer Force. The tool will apply that force in the given direction relative to its highside reference. Steer mode is of use to us when a three dimensional profile such as a combined build and turn is required with a constant dogleg but with regular changes in toolface. It does not have a target inclination and will continue to apply the steer force in the specified direction until changed by downlink. 2-18

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Steer Mode is referred to as Mode 0 and uses the parameters Direction and Steer Force. The use of modes and parameters is discussed further in ’Relationship Between Modes and Forces’ on page 7-6.

Hold Mode Hold mode allows us to apply forces up/ down and left/ right in order to achieve our objective. The parameter Build Force is applied up or down and the parameter Walk Force is applied to the left (-ve) or right (+ve). The most useful aspect of hold mode is that the tool will build or drop using the Build Force to a preprogrammed Target Inclination. Thus, if the ATI Inclination is below the target inclination, the tool will build using the Build Force to the target inclination and then hold angle. Conversely, if the ATI Inclination is above the target inclination, the tool will attempt to drop. A constant force to the left or right may be applied to either counter a walking tendency or to induce a planned turn. In hold mode, the NBA calculates the effective direction and force to achieve the Build and Walk programmed (i.e. the tool THINKS in steer mode). In the situation where the vector sum of the Build and Walk Forces exceeds the tools maximum force of 18.6kN, the NBA will apply the maximum force in the correct direction, thus both Build and Walk will be less than expected. Operations Manual 750-500-085 Rev. A / May 1998

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Hold Mode is referred to as Mode 1 and uses the parameters Build Force, Walk Force and Target Inclination. The use of modes and parameters is discussed further in ’Relationship Between Modes and Forces’ on page 7-6.

Ribs Off Mode In steer and hold modes, when the tool is powered by the turbine, there will always be pressure applied to the pistons behind the ribs. If the tool is set to steer mode with a steer force of 0 kN, there will still be 70 Bars (1015 psi) on each rib. Even after circulation has stopped, there will be oil in the pistons, and a considerable force is required to bleed the oil back from the pistons to the low pressure system. If the oil is forced back by the rib being forced into the closed position, the seals on the piston may be damaged, rendering the rib useless. Thus, care must be taken when passing through changes in hole diameter. When drilling out a casing shoe with steer force of 0 kN, when the ribs come out of the 12 ¼” casing shoe into a possibly washed out rat hole, the ribs will expand to their maximum extent of 9-3/16”. As the bit drills a new 8 ½” the ribs may hang up on the ledge between the old hole and the new hole. A possible solution is to set the tool to a mode which applies no pressure to the pistons, and therefore allows the ribs to collapse to the closed position. This is the function of Ribs Off Mode. If Ribs Off Mode is used, care must be taken while rotating. If there is no rib contact with the bore hole wall, the sleeve will rotate with the drillstring. If for any reason the ribs do grip the bore hole, the sleeve rotation will drop from the tool RPM to zero almost instantaneously, possibly damaging the sleeve. As such it is recommended that tool rotation be kept below 60 rpm in Ribs Off Mode. Further discussion of Ribs Off Mode can be found in the Directional Drilling Section. The use of modes and parameters is discussed further in ’Relationship Between Modes and Forces’ on page 7-6. and the use of 2-20

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Ribs Off Mode is discussed in detail in ’Tool Operation’ on page 7-10. There are no parameters associated with Ribs Off Mode.

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•Notes•

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Chapter

3

Surface Systems

Chapter 3 describes the Surface System components.

Bypass Actuator The downlinking process relies on our ability to modulate flow rate at the surface in order to provide a variation in flow rate downhole which is decodeable by the DLC. To this end, we must install a bypass actuator (BPA) valve on the standpipe manifold to divert flow back to the return mud system. The BPA, shown below, consists of a solenoid controlled air motor capable of rotating a diamond disc through 90°. This disc has two holes in it, as does a second disc mounted hard up against the first. In the closed position the holes lie at 90° from each other, however, when the first disc is rotated 90°, the holes line up and allow flow to pass from the standpipe to the outlet. Current certification requires that the BPA be maintained onshore after no more than 3 hours of bypass flow or 1000 valve actuations, whichever is reached first. The outlet side of the PBA should be inspected regularly, for signs of washing. The operation of the BPA is controlled by an electrical signal from the Bypass Controller box (BPC).

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Bypass Controller The BPC can be instructed, either by DrillByte or by a 4x4 keypad on its front panel, to send a command with an associated set of parameters to the AutoTrak tool. It is the BPC’s job to convert this command into a sequence of valve openings and closings, i.e. it will encode the command and electrically send the encoded command to the BPA solenoid valve.

The BPC operation panel consists of a power switch, power supply (three LEDs), solenoid driver (one LED red/ green) and LC display (This may have a reset button. The reset button is not available on all BPC’s. If a BPC appears to react strangely simply cycle power using the power switch). In addition, the power supply board may contain three trim pots to readjust the output voltages. Do not readjust any of these. If in doubt, request a new power supply for replacement. After turning power on, all three LEDs on the power supply will light up. If one LED does not work, replace the power supply. If the BPC is powered up properly, you will see the following or similar start up message.

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Bypass Controller Version 3.29 or Bypass Controller Version 3.40 The LED on the solenoid driver should not light up until a transmission has been initiated. It will show a green light when the output driver is activated. If it shows a red light, there is most likely a problem with the connection to the Bypass Actuator solenoid valve. Check the cabling and connections and try again. The BPC should not need any servicing under normal conditions. If there is a malfunction observed, replace the whole unit. If the solenoid driver card does not work, dismount it and check the fuse before sending the unit back. See below on how to dismount and re-mount the solenoid driver card. Double check the rating when replacing any blown fuses. Do not replace the fuse with other ratings than 315 mA (fast response). The power supply and solenoid driver card can be replaced by following these steps: 1.

Turn the BPC off and disconnect it from the main power.

2.

Unscrew the visible screws which hold the solenoid driver (two screws) or power supply (four screws) in place using an appropriate screwdriver.

3.

After all screws have been unscrewed, pull the unit gently out of the frame. Be especially careful with the solenoid driver, as it has no extra case.

4.

Insert the new unit.

5.

Tighten the screws.

6.

Reconnect main power, turn the BPC on and observe the start-up message.

Should you need to send a downlink using the keypad, press the Menu key (M). The LCD displays: Enter Pulse Length

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Use the left/right arrow keys to set the pulse length to 8, 12 or 16 seconds and press Enter. To select the desired command, use the left/right arrow keys. Once the desired command is selected, press Enter. You will now be prompted to enter the parameters associated with that command. Different types of parameters must be entered differently. Directions and Inclinations should be entered numerically, all other parameters can be adjusted using the left/right arrow keys. Once you have entered the correct parameter, press enter (if there are two parameters associated with the command, repeat the parameter entry process and press Enter). The LCD should now read: Transmit

Yes/No

When you are ready to send the downlink, highlight “yes” and press Enter. You may abort the downlink by pressing the cancel key (C). The LCD should now read: Abort Transmission

Yes/No

Highlight “yes” and press Enter. Detailed instructions on downlinking using the keypad can be found in the BYPASS CONTROLLER MANUAL, however it is recommended that the Survey Monitor is used to downlink from DrillByte.

Adjustable Nozzle/Sub In order to control the amount of flow bypassed, a nozzle is installed on the outlet side of the BPA. This may be in the form of an adjustable nozzle assembly or a short sub with two fixed nozzle carriers. The nozzle or nozzle equivalent opening must be adjusted for the particular hydraulic conditions of the well, however as a general rule a 12/32” nozzle will be satisfactory. In a well with a particularly high standpipe pressure, a smaller nozzle may be required to limit the bypass flow, and conversely, a larger nozzle may be required with lower standpipe pressures. 3-4

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Adjustable Nozzle Unit Functional Description The adjustment of the Nozzle Unit will define the ratio of borehole flow and the by pass flow back to the pit. Turning the handwheel of the unit will adjust the position of the internal valve disc and, with it, the total opening of the unit. Turning the handwheel clockwise will enlarge the opening and with it the by pass flow, which will reduce the standpipe pressure while the BPA Valve is open. Turning the handwheel counterclockwise will reduce the opening and with it the by pass flow which will increase the standpipe pressure while the BPA Valve is open. Table 3-1: Shaft Position

Equivalent nozzle /32”

1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9

10.2 10.8 11.5 12.0 12.6 13.2 13.7 14.2 14.7 15.1 15.6 16.0 16.5 16.9 17.3 17.5 17.7

Handling For 6-3/4” tools set the ANU shaft position to 2.5, equivalent to 12/32”, prior to operation. The position can Operations Manual 750-500-085 Rev. A / May 1998

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be corrected during operations until the required by pass flow has been reached. A comparison between Shaft Position and the equivalent Nozzle Size is given on the table.

Inspection The Adjustable Nozzle Unit will not be inspected or maintained at the rig side, however if serious damage is detected, the BPA basket should be shipped back to the shop. Current certification requires that the ANU be maintained onshore after no more than 3 hours of bypass flow or 1000 valve actuations, whichever is reached first.

Nozzle Sub Functional Description The nozzle size of the one or two nozzles inside the Nozzle Sub will define the ratio of borehole flow and the by pass flow back to the pit. The Nozzle Sub will be shipped to the rig site assembled with one 12/32” nozzle. By using the software program (NozzleCalc.XLS), or by analyzing the results of previous downlinks, the nozzles can be changed on the rig site.

Handling - To Change out a nozzle 1.

Close the Plug Valve connecting the Standpipe with the BPA.

2.

Remove the Nozzle Sub out of the basket by breaking the hammer union connectors on both ends of the sub and unscrew the bolts of the shells supporting the Sub in the basket.

3.

Remove the Nozzle Holder by using the T-Handle.

4.

Replace the nozzle.

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5.

Be sure that the O-Rings are not damaged. If they are, replace them.

6.

Screw Nozzle Holder into the Nozzle Sub (handtight).

7.

Replace the Nozzle Sub and make up the hammer union connectors.

8.

Fix the Sub with the shells inside the basket.

9. Open the Plug Valve. Note: If only one nozzle is used, place this nozzle at the flow in side of the Nozzle Sub.

Inspection The Nozzle Sub will not be inspected or maintained at the rig side, however if damage to the nozzle sub is detected, the BPA basket should be returned to the workshop.

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Bypass System Rig Up The BPA acts as a valve controlling a high pressure line. As such, your primary concern during the rig up of this equipment should be safety. When rigging on the standpipe, always ensure that the person responsible for that area, normally the driller, is aware of your intentions and deems the work you are about to do to be safe. Check for yourself that there is no pressure on the standpipe. By forcing mud at high pressure through a small nozzle, we create an extremely high velocity jet of mud. This is capable of cutting through steel very quickly in extreme cases. In the early field tests, this lead to chicksan and flexible hoses washing out. The suggested solution to the problem was to direct the jet at a sacrificial blind plug, the thinking being that the plug would take longer to wash out and could be replaced easily. What seems to happen is that when the mud enters the dead end created by the blind plug, an area of high pressure mud is created that dissipates the energy of the jet. Experience has shown that over the course of 50 downlinks, less than 1mm of wear was seen on the plug. After rigging up the bypass system, get the rig personnel responsible for the area to inspect and check your installation. They will have more experience of chicksan than you do!

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Operational Limits The wear on the Adjustable Nozzle Sub and the BPA should be monitored carefully during the duration of the job. A record of bypass actuator and adjustable nozzle use should include the amount of time in the open position with mud being bypassed through the system, and also a running total of the number of valve actuations (openings or closings) produced by the actuator. An extra column should be inserted into the downlink record sheet for this purpose, if a modified sheet is not available. These figures form a part of the certification for these components. It is specified in the certification of the Bypass Actuator that it shall not exceed 3 hours of bypass flow or 1000 valve actuations, without a complete service. The Adjustable Nozzle Unit (ANU) is also certified for 3 hours bypass flow or 1000 actuations. Having reached their certified endurance limits, these components should be returned to the shop for maintenance.

Basket Unit The by-pass unit will normally arrive at the rigsite, readily assembled in the basket. The components mounted in the basket are shown below:

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Rated operating Working Pressure: Temperature: Service:

500 bar (7252 psi) -29° to 82 °C (18° to 180°F) Standard (for H2S only on request)

Documentation For traceability, the following data have to be recorded on the Downlink Analysis and Tracking sheet: •

equivalent nozzle size of the Adjustable Nozzle Unit or used nozzle size inside the Nozzle Sub

•

standpipe pressure (BPA closed)

•

standpipe pressure (BPA open)

•

flow rate of the mud pumps (BPA closed)

•

flow time through the BPA

•

number of BPA activations

Inspection The Blind Plug inside the T-Connector behind the Adjustable Nozzle Unit or behind the Nozzle Sub has to be checked for wash outs after 1.5 hours flow time through the BPA. A wear up to 20% of the thickness is permitted. All other components will not be inspected or maintained at the rig site. Only if serious damage is detected should the BPA basket be shipped back to the shop.

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DrillByte DrillByte is currently the only surface software platform on which AutoTrak is to be run. This will in due course be replaced by MSS2/3. It is not within the scope of this manual to give a detailed discussion of DrillByte/MSS2, however some points pertinent to AutoTrak operations are included below. Since several extra plots may be running constantly while drilling with AutoTrak, it is recommended that the Virtual Windows Manager is run. If this is not already configured, go to the file .xinitrc in the home directory, which will most probably be /usr2/mwdfse. To enable the Virtual Window Manager, change the line: olwm -3 & to: olvwm -3 & To register this change, you must exit and log in again.

System Set-up Several changes may have to be made in the System Setup program in order to run the AutoTrak service. These may already be in place on your system but they should, nonetheless, be checked.

Veritas Plotter Configuration Since the Veritas plotter is the only plotter used on the job, it should be capable of operating with both DrillByte and the off-line D-Series machine/MPLOT. To this end, it must be fitted with a dip switch card and have firmware version 1.1f. In future, Veritas Plotters will be available to automatically detect the incoming signal. The settings required for each input source are given in ’Tool Verification’ on page 5-13. Operations Manual 750-500-085 Rev. A / May 1998

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The Veritas Plotter should be set up in “System Set-up”, “Devices”, as follows: Device Name Port Type XGS Driver Port/File Size Res.

Veritas Parallel Versatec /dev/bpp0 x=0.0, y=0.0 x=0.0, y=0.0

When making plots in DrillByte, remember that there is usually a filter in the .Xdefaults file in the home directory (/usr2/mwdfse) which only shows the plot formats beginning with “MWD_” in the Plot program. Most AutoTrak plot formats have the prefix “RCLS_”. Either delete the line: plot.filter: MWD_ which will give you ALL the available plot formats (a lot of plot formats), or modify the line to read: plot.filter: RCLS_ which will only show the plot formats specific to AutoTrak.

BPC Port Configuration If it does not already exist, a device must be created in “System Set-up”, “Devices”, for the BPC as follows: Device Name Port Type Port/File Baud Rate Parity

RCLSPORT Serial /dev/ttya 9600 8 Bits No Parity

SvyMonitor In order to operate the Bypass Controller from DrillByte, the program SvyMonitor has to be run with a switch, which

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will open the program with an “RCLS” button in the main screen. The switch is set up as follows. In System Set-up, log in as Administrator and press the Programs button. Find the Survey Monitor in the lower window of the pop-up screen and click on it. Below this, the Execute Command should read SvyMonitor. In order to run survey monitor with the BPC enhancement, modify this command to: SvyMonitor -mode RCLS Now, when Survey Monitor is started in Launcher, the survey monitor screen should appear with an additional “RCLS” button which brings up the BPC control panel. If the BPC is switched on and connected to the active Sparc, SvyMonitor will interrogate the BPC to ascertain which version of firmware it contains. If no BPC is connected or it is not switched on, an error will occur and the button in the lower right hand of the RCLS screen will give you the option to “Check BPC”. After connecting or switching on the BPC, by pressing the “Check BPC” button, SvyMonitor will interrogate the BPC again for its firmware version. No error should be given this time and the “Check BPC” button should be replaced by the “Transmit” button. The parameter options that now appear with each command type should be compatible with the BPC.

LF Conversion Factor Since all of our AutoTrak forces are quoted in kN, we must ensure that the DrillByte system is using the same units for Load or Force (LF). This is changed in the “System Setup” initial screen. While in Administrator role, scroll down to: LF

Load or Force

and change the units to kN. Ensure that you save and “Make Active” before exiting.

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Database Classes Two additional database classes exist to store AutoTrak specific data. X_RAW_NB Contains: act_innx1, the near bit inclination transmitted. act_htfx, Sleeve Orientation transmitted X_RAW_EL Contains: egyzx, Axial energy level transmitted. egyxyx, Lateral energy level transmitted. hfsnap, High frequency bit signature vibration transmitted.

Telemetry Files Having made a telemetry file in the pre-run deck test (See ’Making a .TEL File’ on page 4-7), it must be copied to the /dbyte/ctl/mwd/uft/ directory. Also in this directory, you must ensure that the file “master.uft” includes the name of this telemetry format and also refers to the language definition file “77249ud.ud5”. This language definition file does not contain words required for other service types and is therefore only to be used with AutoTrak. Remember to change the master.uft file back to the latest 77249 file if AutoTrak should be replaced by another service.

MWDParams Set-up The MWDParams version in DrillByte 2.3.1 TD does not contain an AutoTrak option. To set up the tool and sensor offsets, the tool may be considered similar to a modular RNT or NaviGator tool. The tool may be divided into a NaviGator, 6.0 m (19.7 ft) in length with sensor offsets as follows: ATI 0.9 m (2.9 ft), Gamma 5.1 m (16.7 ft), resistivity 5.5 m (18.0 ft), and a directional collar 5.3 m (17.4 ft) in length, with directional sensor offset 4.0 m (13.1 ft) from the bottom of the sub (giving a total directional sensor offset from the bit box of 10.0 m (32.8 3-14

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ft). DrillByte version 2.3.1 TF contains an AutoTrak option.

Copying to/from UNIX/DOS Having plugged into the tool and programmed it using the current tool communications software, you will have a DOS format disk with the telemetry format to be used on it. This needs to be copied into DrillByte (and PC-Raw). Put the disk in the Sparc and from a command tool, do the following: mwdfse > dosmount -m mwdfse > cd /pcfs mwdfse > l (lists the files on the disk) Go to the UFT directory, i.e.: mwdfse > cd /dbyte/ctl/mwd/uft mwdfse > dos2unix /pcfs/at_103.tel AT_103.TEL Now unmount and eject the floppy: mwdfse > dosmount -ue Check in File Manager that the file is there. Now you must update the master.uft file by adding the name of the new format to the file, and ensuring that the correct 77249 file is present. To copy a UFT file to disk: mwdfse > dosmount -m mwdfse > cd /dbyte/ctl/mwd/uft mwdfse > unix2dos AT_103.TEL /pcfs/ AT_103.TEL

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Backup/Restore A regular schedule of backups is essential, should it be necessary to restore the database for any reason. During the job, DrillByte backups should be created on a regular basis as follows. 1.

In a command tool, log in as versant.

2.

Type DbArchive and press Enter on the command line. Use the set-up button if necessary to connect to the database to be backed up.

3.

Press the backup button and enter the device to be backed up to, this will normally be the tape drive, /dev/rst0

4.

Press the Backup Database button, a screen will appear giving details of the backup and the progress of the backup.

To Restore the Database from a DrillByte backup, the procedure is as follows: 1.

In a command tool, log in as versant.

2.

Ensure the tape is not write protected and insert it in the tape drive.

3.

Set the database to single user. Type dbinfo -1 drillbyte

4.

Stop the database. Type stopdb drillbyte. If the database is in use, an error (E7045: UT_ER_DB_INUSE:) will appear. Type stopdb -f drillbyte.

5.

To perform the restore. Type vbackup -device /dev/rst0 -position 0 -restore drillbyte

A display of the restoration progress should be displayed. When complete, you may be asked if you wish to do 3-16

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another level of restoration. Answer NO. You may also be asked if you wish to “apply records from log file”, again say NO. If instead of the progress report, you were given the error: ERROR 7103 UT_ER_WRONG_DB wrong dbid, perform the following steps: a.

Type dbinfo -m drillbyte

b.

Type removedb drillbyte

c.

Type dbinfo -1 drillbyte

Now go back to step 4 and try again. 4.

Reset database to multiple user. Type dbinfo -m drillbyte

5.

Restart database. Type startdb drillbyte

This should complete the restore procedure At the end of each job, a DrillByte backup should be performed and in addition, an ASCII backup is required. This will allow the importation of data to different DrillByte versions.

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Tool Communication Rig-up Two systems are currently in use to electrically communicate with the AutoTrak tool. The current RIBox method is considered to be unreliable over long cable runs (over 8m (26 ft)), and is to be replaced by the PowerComms system.

RIBox Tool Comms The RIBox tool communication system is an M30 system designed specifically for AutoTrak. The tool is connected via an armoured coaxial cable to a RIBox, a box containing a modem, and this in turn is connected to a PC.

This system provides a facility to connect the RIBox to the TR700 decoding unit. The current draw fluctuation caused by the activation of the pulser is converted to digital 0 - 5V level and output from the BNC connector on the lower left hand corner of the RIBox. By connecting to the “Standpipe In” BNC connector on the TR700, the tool telemetry may be checked at the surface. Before powering up the RIBox, ensure that the switchable fuse is set to the correct voltage.

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PowerComms To be included in a later release.

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•Notes•

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Chapter

4

Pilot Series Tool Programming

This chapter describes the programming for the AutoTrak tool.

“Tool Set-up” Guidelines The most important section of the AT_103 program is the “Tool Set-up” section. For instructions in the use of the program, refer to the “AutoTrak 150°C System Reference Manual”. The following guidelines should be born in mind before changing the tool set-up. Remember, after any change is made in a set-up or configuration screen, the F2 button must be pressed to send the change to the tool.

“Steering Set-up” Prior to running in hole, the steering set-up of the tool may be pre-programmed, using steering set-up in AT_103. Remember to move the cursor or press Enter after making a change and prior to sending the new set-up to the tool, otherwise the new value will not be sent to the tool.

“Module Communications” This area of the communications program allows you to select, which if any, of the modules (Memory, RNT or Vibration) to switch off, and to define the rate at which the master acquires data from the various modules. The default data acquisition and storage rate has been tested to ensure Operations Manual 750-500-085 Rev. A / May 1998

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reliable communication on the M30 bus. Any dramatic increase in the acquisition rate of any module may detrimentally affect bus communication and hence tool operation. If a change is made to increase acquisition rates, rigorously test the tool after the change to ensure bus communication has not been affected.

Telemetry The telemetry configuration of the tool is performed in “Tool Setup” / “MPT Setup” in AT_103. This should be checked if not changed prior to each run.

Parameters Certain transmitted parameters are specific to the AutoTrak tool. DLCERRX DLERRX ATIM30ERRX ACTM30ERRX VMIM30ERRX NBACNTLX NBAVECTX NBAFRCEX NBAWALKX NBABULDX NBATARGX ACTINNX ACTHTFX

Downlink controller error status bit. Downlink error status bit. ATI communications status bit. NBA communications status bit. Vibration module communications status bit. Actuator control method. Mode, 0=Steer, 1=Hold, 3=Ribs off. Actuator vector or Steering Direction. Actuator Force or Steer Force. Actuator Walk Force. Actuator Build Force. Actuator Target Inclination ATI Inclination. Sleeve Orientation or the orientation of rib 1 relative to highside reference.

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Telemetry Setup Some basic variables need to be set up before running in hole to aid decoding. 1.

The data rate must be set to a suitable rate for the conditions. Its default value is x4.

2.

The time delay used between pumps on and pulsing, the initial delay, can be adjusted from 40 seconds to 4 minutes. The default value is 60 seconds.

3.

The time required to take a survey, the Static Time or Flow Off Time, can be adjusted from 40 seconds to 2 minutes. The default value is 60 seconds.

FE Setup The default FE transmission provides real-time gamma scintillation sensor #1, 2Mhz compensated phase and 400khz compensated low resolution attenuation data. Should any variation from this be required, they may be changed in MPT Set-up. Remember, any change in the tool will require a corresponding change in the telemetry format of the surface system. See ’Telemetry Formats’ on page 4-6 for details.

Programmable Survey Under some circumstances, a client may request a data transmission sequence, which is not available as standard. We can accommodate his request using the programmable survey sequence. This allows us to produce a survey sequence (FID 7, BNR). These data items may be used in any combination, repeated as often as required. Instructions on making the Programmable survey can be found in the “AutoTrak 150°C System Manual”. When making the format, Operations Manual 750-500-085 Rev. A / May 1998

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remember that to run the tool, you will require a reasonable number of sleeve orientation words, Nearbit Inclination words and a set of error flags. Also, beware of making the format too long, otherwise you may spend a long time waiting for the tool to re-sync in poor decoding conditions. Programmable Survey Data Elements Available are: Raw Survey Data

• • • • • •

GXBX1 GYBX1 GZBX HXBX HYBX HZBX1

DAS Temperature Data

•

TCDX

VMM Vibration Data

• • •

EGYZX EGYXYX HFSNAP

RNT Gamma

• • • •

GRBX1 GRBX2 GR1BX GR2BX

(GR*BX for scintillator)

Downlink Response Data

• • • •

TRPMHIX TRPMLOX DLCCMDX DLCDATAX

ATI Data

• •

ACTHTFX ACTINNX

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RNT DDS Data

•

GZBX

Status Bits

• •

SYSERRX ERRORFLAGS will select 8 Errorflags as there are:

• • • • • • • •

SWWPERRX DLCERRX DLERRX MEMERRX MPRERRX NBIM30ERX NBAM30ER X VMMM30ER X

Actuator Settings

• • • • • •

NBACNTLX NBAVECTX NBAFRCEX NBAWALKX NBABULDX NBATARGX

RNT Phase and Attenuation Data

• • • • • •

PDBCHX PDBCLX ATBCHX ATBCLX ATBCHX0 ATBCLX0

(0 denotes high resolution)

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Telemetry Formats The AutoTrak tool currently has the capability to transmit 7 different survey sequences. 1.

RAW Survey (RAW FID 15)- Only sent after the tool has powered up, providing the raw accelerometer and magnetometer values currently stored in the master memory, current NBA Parameter/Mode steering set-up, temperature and a set of 8 error flags.

Note:

This is the only temperature value transmitted in a standard sequence.

2.

DEFAULT Survey (AR FID 10) - Sent as a continuous loop regardless of whether the tool is or is not rotating. It contains Near Bit Inclination, Sleeve Orientation, FE and Vibration data, as well as the 8 standard error flags. This sequence will be sent continuously until the tool power is cycled or a downlink is sent.

3.

DOWNLINK RESPONSE Survey (ANR FID 6) Sent after a downlink, to confirm the downlinked data was decoded correctly, repeat the current Actuator Settings, and to give a minimum and maximum Turbine RMP value seen by the DLC during the downlink. (Maximum is measured after the downlink has finished but before the tool starts pulsing again).

If the facility to turn off a module is invoked (see ’Modules ON/OFF’ on page 4-7), it will be wasteful to transmit null values for that module, thus the tool will automatically change to a survey sequence which does not contain irrelevant data.

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4.

DEFAULT WITHOUT VIBRATION (BR FID 11)

5.

DEFAULT WITHOUT RNT (CR FID 12)

6.

DEFAULT WITHOUT VIBRATION AND RNT (DR FID 13)

7.

PROGRAMMABLE Survey (BNR FID 7) - In the tool communications software, it is possible to create a user defined survey sequence to suit the requirements of specific situations or clients. Details of the Programmable Survey may be found in the “AutoTrak 150°C System Manual” and in ’FE Setup’ on page 4-3 of this manual.

Making a .TEL File A telemetry file is a file containing some of the information your surface system will need to convert the stream of 1’s and 0’s coming from the decoding unit, into values for specific parameters. There is considerable flexibility in the data transmission set up of the AutoTrak tool, so much so that it was considered impractical to have a collection of Telemetry (*.TEL) files to cope with every possible permutation. To solve this problem, the tool communications software has a very simple procedure for making a .TEL file to match what is in the tool. If the sequence of actions given in ’Deck Test’ on page 5-1, under step 18 is followed, you can be sure that the telemetry set ups in your surface system and the tool are identical.

Modules ON/OFF We have the facility to turn off three modules in the tool by either programming at the surface or by downlinking. These modules are the RNT sub, the Vibration module and the Memory module. This may be done to conserve memory, as no data will be written to the memory by a node, while it is switched off, and no data will be written Operations Manual 750-500-085 Rev. A / May 1998

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to the memory at all if the memory module is switched off. Another reason for switching off the RNT of Vibration modules would be to increase the transmission bandwidth devoted to other data types, as discussed in ’Telemetry Formats’ on page 4-6.

AT_103 Manual The “AutoTrak 150°C System Manual” provides information on the tool communication program AT_103, downlink definitions, telemetry formats and memory file configurations. You should read it before you use AT_103.

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•Notes•

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•Notes•

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Chapter

5

Operating the AutoTrak Tool

Chapter 5 describes the operations and testing of the tool.

Tool Testing Deck Test The following should be carried out at the earliest opportunity on arrival at the rig site. Prior to the electrical test, the PC used to program the tool should be synchronized with the DrillByte computer. 1.

Remove inspection port cover next to the name plate on the non-rotating sleeve. It is the only cover that is secured by two bolts. Accidental removal of any other cover will render the tool inoperable.

2.

Connect the tool to the RIBox using the shortest cable length possible.

3.

Connect the RIBox to the D-Series PC serial port and to the TR700 “standpipe in” BNC connection.

4.

Ensure that the M30 power supply is off (Use the On/ Off labels on the switch rather than the confusing labels on the box).

5.

Switch On the RIBox power supply.

6.

Switch On the M30 power supply from the RIBox. The current draw should be ±0.7A, increasing over a few seconds to ±0.9 A. After 1 minute, the tool should start pulsing and the current draw should

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fluctuate to a peak of ±1.5A. A continuous draw of > 2.0A is indicative of a fault on the M30 Bus. 7.

On the D-Series computer, run the Atrak software AT_103.

Note:

When starting AT_103 with a shortcut from the Windows 95 desktop, be sure it is NOT in training mode. This will lead to problems during Master assertion.

8.

Select “M30 Monitor”. This option does a Master assertion and then reboots the Master, so the tool should stop pulsing for 1 minute. Check that all the values on the display are reasonable. Press F1 and bus communication statistics should be displayed. These should be in a range from 95 - 105%. Press to return to the main menu.

9.

Select “Steering Control”. Here, the tool can be configured with job specific steering commands. The control method selected with parameters entered will be used on power up of the tool with pumps on. All the control parameters will be held in memory. Press F2 to send to the tool. Press to return to the main menu.

10. Select “Memory Utilities”. This will bring up the Memory sub menu. 11. Select “File Directory” and check file size to ensure that some data has been stored to memory during testing. Press to return to Memory sub menu. 12. Select “Clear Memory Module” and answer Yes to clear memory. Press to return to the Memory sub menu. 13. Select “Get Current Time” and press to synchronize the tool time to the D-Series PC which should have already been synchronized with the DrillByte computer. Press F2 to send to the tool.

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Press to confirm. Press twice to return to the main menu. 14. Use viewer to look at the .RPT file. First confirm that the ID time is right for the Tool ID that is required. Check that the configurations set up are correct and that there are values in the calibration data. Press to return to the main menu. 15. Select “Tool Setup” to bring up the tool set up sub menu. 16. Select “Module Communications”. Default values are as follows: Connect RNT ? Connect VMM ? Connect MEM ?

YES YES YES

Acquire DLC Acquire ATI Store ATI Acquire Gamma / Res. Store Gamma / Res. Acquire Vibration Store Vibration

5 sec 5 sec 60 sec 10 sec 10 sec 30 sec 90 sec

Memory Fill Time

99.9 h

Normal operation is to answer Yes to all modules connected. Set the memory store times to give a reasonable memory fill time of ±100 hrs. To send the default or changed configuration to the tool, press F2. Press to return to the tool set up sub menu. 17. Select “MPT Setup”. This is the menu where tool, RNT and Telemetry format is set up. The software also offers the operator the option to create their own telemetry format using Make Survey (F4). Default set up is as follows (By pressing F3 the defaults will be entered):

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Pulse Rate Flow Time Static Time Use Prog. Survey

4x 60 sec 60 sec NO

Gamma Select

Gamma 1 Scint

Phase Select Trans. Phase Select Freq.

Transmitter 1+2 Freq. 2.0 MHz

Atten Select Trans. Atten Select Freq. Transmitted Res.

Transmitter 1+2 Freq. 400 kHz Low

The above is a standard set-up that can be used in most situations. The only things that one would be likely to change are pulse rate and Transmitted Resolution. Press F2 to send the default or personal configuration to the tool. The telemetry format will now be sent to the AT_103 directory on the hard drive and to a floppy disc in A: drive. Press F4 to Make Survey. A personal programmable survey can be created or the default programmable survey used. This telemetry format is only transmitted if it is selected as Use Prog. Survey on the previous menu or if a downlink is sent to transmit the programmable survey. The programmable survey will replace the AR repeated telemetry, if selected. Press F2 to send to tool. At this stage, the telemetry format from the previous (F2) will be pulled from the hard drive, the programmable format added and the completed file sent back to the hard drive and to the A: drive as a:\AT_103.tel overwrites the previous file sent. Press three times to return to the main menu. By using dos2unix and copying this file to the DrillByte system as /dbyte/ctl/mwd/uft/AT_103.tel, you can be certain that DrillByte will be set up for the same telemetry format as the tool. Do not overwrite the old .tel file on DrillByte, but rename it prior to loading the new format as AT_103.old. 5-4

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18. Select “Tool ID” on the main menu. This will store all the configuration and calibration data to a .report file stored as c:\AT_103\ xxxx_406\xxxx__yy.rpt where xxxx is the master serial # and yy is the report number starting with 00 for the first report. Example: 5005__01.rpt is the second report for the tool with master # 5005. 19. Start up Surface Receiver and confirm telemetry from the tool to the RIBox is being decoded by DrillByte. 20. To enable the tool to be picked up and run straight in hole without any electrical testing on the rig floor, the RNT can be verified at this stage by picking the tool clear of any conductive material with the crane and a verification run. 21. To run the verification, press “Exit Program” to exit the AT_103 software and run verification using DSeries, having entered the calibration and BHA data.

D-Series Setup D-Series is currently the preferred method for dumping memory from the tool and for running pre and post run verifications. From the HPUTIL main menu, select DSeries RWD System. Since there is no option for AutoTrak, the separate components should be added.

Drill String Components Directional/MEM Subs - serial number (e.g. AT-11), size (6-3/4”), directional type (MTC), memory name (MEM). Add also RNT DDS. Gamma sub. data: serial number, GRAPICF, size, type (RNTGAMMA). Resistivity sub. data: Serial number, size, type (RNT Res.). F1 allows you to enter the RNT Resistivity Factors.

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Bottom Hole Assemblies: put in the assembly (tool setup) for each run, including sensor offsets (no scribeline correction is required), e.g. Drill String Component Dir.: Sub# AT-11 Res.: Sub# 1000 Gam: Sub# 1000 Dir.: Sub# AT-11

Sensor Offset

6 ¾” MTC (MEM) 32.81 ft 6 ¾” RNT Res. 18.04 ft 6 ¾” RNTGAMMA 16.73 ft 6 ¾” RNT DDS 3.08 ft

Remember to put in all the required Correction Factors; e.g. Mud Resistivity and Total Grid Correction. Once the above details have been entered, you can test the tool as follows: Utilities - Poll: this checks that you have communication with the tool. The message Hardware is Being Initialized appears. A screen showing if there is a response from the relevant nodes then appears. F1 gives a display of the data. Once you confirm that you have full communication with each node, go to “Tool Verification” and select “Pre-Run Verification”; you now get the screen “Select Pre-Run Bottom Hole Assembly”. Type the relevant run (e.g. BHA) number. Once the verification is complete, the data will be saved in D:\HPUTIL>VERIFY. It may be necessary at the start of the job to check that there is indeed a VERIFY directory in HPUTIL. If not, you’ll need to make this directory prior to doing a verification. Using “Dump Memories”, the verification data should be dumped to Run99. 22. The power can now be switched Off on the RIBox, the cable disconnected from the tool and the port cover replaced. 23. When replacing the port cover prior to running in hole, a new O-ring should be coated with O-lube and fitted with new lock down bolts cleaned with Loctite 5-6

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cleaner 7063 and coated with Loctite 243. The make up torque for the port cover bolts should be 23 Nm (17 ft-lbs). Note:

The O-ring has the tendency to jump out of the groove.

24. If the verification has been carried out, the tool is now ready to run in hole. In the course of the deck test procedure, you will have created a number of files and directories. They are added to the root directory (normally c:\AT_103) in the following structure. Those files or directories that have been created are underlined. AT_103 Directory Structure

The new directory [xxxx_403] is unique to the master ID of the tool. In this case, the master ID is 5003, and the directory name will always end “_406”. The memory dump sub.-directory, prefixed with “m”, will take its name from the date (DDMMYY) and will alphabetically Operations Manual 750-500-085 Rev. A / May 1998

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increment the last letter according to the number of memory dumps written to the sub.-directory that day. Likewise for the ASCII directory (if created), but with the prefix “a”.

Rig Floor Test A drill floor test is only required if there has been no opportunity to run the RNT verification on the crane. Prior to a drill floor test, a deck test should have been carried out where the tool will have been configured and the telemetry format dumped and checked. The drill floor test should be carried out in a similar way to the deck test. Go through steps 1 to 8, followed by steps 21 to 24, using the D-Series verification notes as an aid.

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Memory Dumping Procedure Post Run Test The post run test is run to dump the memory data, check tool functionality and dump a Tool ID. This should be carried out on deck, if possible, to save rig time. Again, the general procedure for plugging into the tool is the same as the pre run deck test. Go through steps 1 to 8, then using D-Series, dump the memory for processing using conventional MWD techniques (see “Preparing a log of the Memory Data” below). Next follow steps 18 to 20 and 22.

Preparing a Log of Memory Data Having reached the end of an AutoTrak run, you should do the following: 1.

Transfer all the real-time data using the script file/ export file procedure.

2.

Make an ASCII file of your ROP/WOB data for the whole run (for Time Since Drilled calculation). This is only needed if you intend to keep the real-time and memory data in separate binary files.

3.

Create a spool file from the MWD_TIME file.

4.

Copy the real-time binary file to a suitably named file, e.g. MWD03.*, then copy your memory data from the previous runs to the binary file.

5.

Dump the data using D-Series, then process the data, appending it to the binary file.

6.

Use imp2mplt to add ROP/WOB to the new binary file.

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7.

Add time since drilled. A) Transferring real-time data from DrillByte On the database machine, start Launcher from the workspace. Select Group: Database and run the program Database Archive. [Select Import/Export] and choose text. Go to [Scripts] and select Load Scripts. A window will appear with a series of script files. Highlight the file MWD_ALL.txtscr or MWD_ALL.fpstxtscr and press load. Check that the hole id is correct by going into DbEdit, selecting Drilldepth and noting Hole_id. In order to change the depth range (which is always in meters) click on the right button and select Enable Range Change. Type in the depth you want to begin the transfer (again in meters) and with the right button, select Apply Range Change. The depth range you have selected has only been applied to Drilldepth. In order to apply the depth range to all other items, go to [Scripts] and select Propagate Range. Once this is done, from the [Scripts] menu select: Run Scripts - Export. The message, “Warning: data file(s) included in this script already exist” appears. Press Continue. If DrillByte and the off-line PC are networked, from Launcher run “Processing db2mplt” which generates the files 1,2,3,4, etc. along with a .bat file in /dbyte/ backup/mwd/xfer. FTP these to HPUTIL, run the .bat file and use imp2mplt to import the files into MPLOT. If DrillByte and the off-line machine are not networked, from the workspace, select [MWD

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Tools] and run run exp_mwd_all script with the console open and a disk in the machine. Once the disk has been ejected, take it to the HPUTIL machine and check the transfer disk files. D:\HPUTIL>see a:\1 (and 3,4,5 etc.) Once you confirm the data, import the files into MPLOT using the following command: D:\HPUTIL>imp2mplt You’re then asked for the filename e.g. a:\1. Press Enter then F1 to import the file and then repeat for a:\2, a:\3, a:\4 etc. B) Creating an ASCII File for the Whole Run From the real-time binary file, an ASCII file of ROP/ WOB can be made using the “Make Definition File” and “LIS ASCII” programs in HPUTIL. Alternatively, once the real-time data has been saved and the current memory files loaded into binary.*, you can re-import Drilldepth for the entire run from DrillByte and imp2mplt ROP and WOB. C) MWD_TIME File: Creating Spool.fil If DrillByte and the off-line PC are networked, from Launcher run “Processing spool.fil”. This removes the header and any -ve depths, and saves the data in / dbyte/backup/mwd/xfer as spool.dat, along with a .bat file. FTP these to HPUTIL and run the .bat file to create the spool.fil. If DrillByte and the off-line PC are not networked, the MWD_TIME.txtscr file can be created in a similar way to the MWD_ALL.fpstxtscr file described above. Once the correct time range has been loaded for the bit run, the MWD_TIME.txtscr can be exported by clicking on [Scripts] and running Run Script - Export. Operations Manual 750-500-085 Rev. A / May 1998

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From File Manager, open up MWD_TIME.txtdat and check that all the depths are sequential. If there are any bad depth points, these will need to edited in the database editor and the file loaded again. From the workspace menu select [MWD Tools] and run the program Run exp_MWD_TIME scripts... with a disk in the machine and the console open. Once the disk has been ejected, put it in the HPUTIL machine and type the following: D:\HPUTIL>surface feet a:\mwd_time.txt (or meters, according to your ASCII file) The file spool.fil has now been created. D) Backing Up Real-Time Data in HPUTIL Once all the real-time data has been transferred to HPUTIL, save the binary files to a suitably named set of files e.g. D:\HPUTIL>copy binary.* mwd03.* Now, copy the memory files from the previous run to the binary file e.g. D:\HPUTIL>copy rwd02.* binary.* This is only necessary if you are keeping the realtime data and memory data in separate binary files. E) Dumping Memory Data Using D-Series Having plugged into the tool and carried out the appropriate electrical tests using the AT_103 software, go to D-Series and check that the details of the tool and the run have been input correctly in options 1 to 4. Now go through the following menus. Utilities - POLL Check that you have communication with the tool. F1 will give you a display of the data; Here, you can check the tool clock. 5-12

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Dump Memories Inteq Run Number: ComPort 1: Baud Rate: Handshake: Method: Echo Node:

3 COM1 19200 ON SPEW DISABLED

Once data has been dumped, escape out and look at the memories in MemView. Backup/Restore Data - The data should be backed up to the hard drive. Process Data - Select the run and the following screen will appear. Ensure that the following options are selected. Handle Error Data : DISCARD Handle Backplotted data : KEEP Borehole Corrected Res. : YES Conductivity Rec. : NO Calc. Toolface for all Comps : NO Gamma Ray Dark Current Corr. : BIAS ON Average Data : NO Calc Near/Far Resistivity : NO CRIM Corrected Resistivity : YES (dielectric) Nuclear Processing : P-Series 2.13 Bottom Hole Assemblies - Add a BHA for the next run. If running the same tool and assembly, simply copy the previous run. Tool Verification - Details of the verification procedure can be found in ’Deck Test’ on page 5-1, step 15, but instead of selecting Pre Run Verification, select “Post-Run Verification” and plot this to the Gulton or Veritas. The verification is saved in D:\HPUTIL\VERIFY> as post3. Dump Memories - the verification data should be dumped to Run99. Operations Manual 750-500-085 Rev. A / May 1998

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F) Add ROP/WOB Data The surface data will not need to be re-imported into HPUTIL if both the real-time and memory data are being stored in the same binary file. If the data are being stored in separate binary files, the ROP/WOB ASCII file should be imported into MPLOT using the imp2mplt command: D:\HPUTIL>imp2mplt Enter the file name e.g. a:\1, press Enter, then F1 to import the file. G) Adding Time Since Drilled This can be done from the main HPUTIL menu or from the DOS prompt. e.g. D:\HPUTIL>addtsd select the RNT option, select Y for the RPCM option and N for the two other options.

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Veritas Settings At the time of writing, several versions of the Veritas plotter exist. If your plotter has a Dip Switch Board mounted on the left hand end, you may need to change its configuration when changing from DrillByte plotting to HPUTIL/MPLOT plotting. The required settings are listed below. DrillByte Setup: Dip Switch #1: Contrast: Scanwidth: Vert. Res.:

OFF Normal (0%) 264 BYTE (no arrow) 200 DPI

MPLOT Setup: Dip Switch #1: Contrast: Scanwidth: Vert. Res.:

ON 30% 264->BYTE 200 BPI

On newer Veritas models, the capacity to automatically detect the data source is being implemented.

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•Notes•

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Chapter

6

Downlinking

This chapter describes the communication of the AutoTrak tool.

In order to communicate with the AutoTrak tool, a flow rate modulation communication system (referred to as downlinking) has been devised. The modulation is achieved by diverting a portion of the mud flow, 10% 20%, from the standpipe back to the most convenient place in the return system. The rig-up of the bypass valve or Bypass Actuator (BPA) is discussed in ’Surface Systems’ on page 3-1.

Structure Similarly to the collar based tool telemetry systems preamble and marker bit, when sending a downlink we need to first tell the decoding unit, in this case the Downlink Controller (DLC) in the tool, that we are sending data and synchronize the sending and receiving units. This is done by sending a Wakeup Sequence. Continuing the analogy, the FID, giving information about the type and duration of data to be sent, is replaced by the Header Byte. After the header byte, the actual data is sent, followed by a 4 bit checksum completing the downlink. About 30 seconds after the downlink has finished, the tool will restart pulsing with a downlink confirmation sequence (FID 6, ANR). This will confirm the success or otherwise of the downlink and provide turbine RPM information.

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Wakeup Sequence The wakeup sequence gives a specific set of valve open and closed periods, which the DLC should recognize as a signal to stop pulsing and listen to the remainder of the downlink. It will also give the DLC information about the downlink data rate to be used for the remainder of the downlink. The DLC will look for a sequence similar to that below. The length of the two open and closed periods at the start will define the data rate, in this case 8 seconds. The options are 8, 12 and 16 seconds. Having seen the required wakeup sequence, the AutoTrak tool will stop pulsing towards the end of the 30 second valve open section. If the tool has not stopped pulsing before the end of the last closed period of the wakeup sequence, the downlink has not been recognized.

8 8

30

8

C losed

T his Sequen ce w ill tell the tool to decode th e d ow n lin k at 8 secon d d ata rate

O pen W akeup

H ead er

Sequence

B yte

Header Byte The type of data which will follow the header byte is defined by the first four bits of the byte. This is referred to as the command number. This will be a number between 0 and 15, which has been assigned to a specific command. The functions of the different commands is discussed in ’Pilot Series Downlinks Available’ on page 6-4. The next three bits of the header, the Parameter size, define the length of the data string to follow. To transmit a direction 6-2

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between 0° and 360° divided into increments of 1.5°, a total of 240 different options would normally require 8 bits. However if we tell the DLC that the data is a direction word (command number 2), and is only 2 bits long, it will know that the direction (with a value between 0° and 6°) we are about to send only requires two bits and will thus allow us to shorten the downlink. The Parameter Size of a particular length of data (Bit Count) is defined as follows: Parameter Size = (Bit Count/2)-1, The final bit of the eight bit header byte is an odd parity bit.

Data The data transmitted in the downlink gives the value of the parameter or parameters associated with the command number. It will vary between 2 and 16 bits long. This, along with the bit length, will define the duration of the downlink.

Checksum As a form of error detection, a four bit checksum is included at the end of the downlink. It’s value is dependent on the total number of 1’s in the header byte and data sections of the downlink. If either the checksum or the parity bit in the header byte is incorrect, the downlink will be rejected and the DLERRX status bit in the subsequent downlink response survey will be set to 1.

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Pilot Series Downlinks Available The command number described above relates to a particular command and a set of parameters which will be transmitted in the data section of the downlink. An explanation of the function of each possible command follows.

Set Steer Mode (Command 0) The Near Bit Actuator (NBA) will be set to Steer Mode (Control Method 0). Two parameters will be sent in the data section, a steer direction (up to 8 bits from 0° to 360° in 1.5° increments) and a steer force (up to 4 bits from 0kN to +18.6kN in 0.6kN increments).

Set Hold Mode (Command 1) The Near Bit Actuator (NBA) will be set to Hold Mode (Control Method 1). Two parameters will be sent in the data section, a Target Inclination (up to 10 bits from 0° to 128° in 0.125° increments) and a Walk Force (up to 6 bits from -18.6kN to +18.6kN in 0.6kN increments.)

Steering Direction (Command 2) Sends a Steering Direction (up to 8 bits from 0° to 360° in 1.5° increments). This parameter is stored in the NBA memory and is only used in steer mode.

Steering Force (Command 3) Sends a steering Force (up to 4 bits from 0kN to +18.6kN in 0.6kN increments). This parameter is stored in the NBA memory and is only used in steer mode.

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Target Inclination (Command 4) Sends a Target Inclination (up to 10 bits from 0° to 128° in 0.125° increments). This parameter is stored in the NBA memory and is only used in hold mode.

Walk Force (Command 5) Sends a Walk Force (up to 6 bits from -18.6kN to +18.6kN in 0.6kN increments). This parameter is stored in the NBA memory and is only used in hold mode.

Build Force (Command 7) Sends a Build Force (up to 4 bits from 0kN to +18.6kN in 0.6kN increments). This parameter is stored in the NBA memory and is only used in hold mode.

Use Programmable Survey (Command 8) As discussed in the AutoTrak Tool Communication Software section, we have the option to create a user definable survey sequence, or Programmable Survey, as required by ourselves or at the request of a particular client. As a default, the standard survey sequence (FID10 AR) will be transmitted as a continuous loop, however this may be replaced by a continuous loop of the programmable survey sequence by sending the command: “Use Programmable Survey - YES”. We may revert back to the Default Survey by sending the command: “Use Programmable Survey - NO” The data section of this downlink is either YES or NO but is sent as two bits, the minimum length possible.

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Set Gamma Select (Command 9) The standard RNT sub in the AutoTrak tool has two gamma sensors. These will in most circumstances be of the scintillator type. It may be possible, though unlikely, that the sensors are of the Geiger Mueller type. This command allows the transmitted gamma value to be acquired from either sensor #1 or sensor #2, scintillator or GM. This would be of use if the default sensor (normally sensor #1) failed. There are four possible values encoded as two bits of data in the downlink.

Set Phase Select (Command 10) The transmitted Phase Resistivity value can be configured downhole to switch the frequency of the measurement between 2MHz to 400KHz. We can also select the transmitter combination used, either transmitter #1, transmitter #2 or if the compensated measurement is required, transmitter #1 and #2. The default setting is 2MHz transmitter #1 and #2. The six available options are encoded as four bits of data. (The number of data bits must be even.)

Set Attenuation Select (Command 11) The transmitted attenuation value may be configured in a similar fashion to the phase measurement, however in addition we may configure the resolution of the transmitted parameter from a 10 bit word (low resolution) to a 14 bit word (high resolution). The default configuration is 400KHz transmitter #1 and #2, low resolution. The twelve available options are encoded as four bits of data. Note:

Any change in command numbers 9, 10 or 11 will require a change in the Telemetry format (*.TEL) file in the surface system.

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Control Method (Command 12) The control method or Mode used by the NBA can be changed to one of three options: 0 - Steer Mode 1 - Hold Mode 3 - Ribs Off Mode Note that option 2 - Build Mode still exists in some surface software but should not be used.

Set ATI Command Ext. (Command 13) The rate that data is acquired from the AutoTrak Inclination Module (ATI), will have a bearing on the speed at which the force on the steering sleeve is updated. Historically, the ATI command extension referred to the number of acquisitions the ATI data (Sleeve orientation, Near Bit Inclination and Temperature) was averaged over. Thus, a high value for the ATI command extension could give rise to a substantial time delay in adjusting the rib pressures. In a situation where the sleeve was rotating quickly, this could lead to a serious discrepancy between the desired and actual steering directions. The method of averaging has since been changed, the ATI command extension now refers to the number of seconds prior to acquisition by the master over which the ATI data is averaged. The default value is set to two seconds. Thus, any reduction in the ATI command extension will have a very limited effect on the speed at which the rib forces are updated, the minimum value being 0.

Module ON/OFF (Command 14) The Vibration, RNT and Memory modules in the tool can be switched OFF or ON by downlink. This may be required to save on memory space, or to enhance the data transmission of other parameters. If the Vibration module Operations Manual 750-500-085 Rev. A / May 1998

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Downlinking

is shut down, the tool will automatically change the default survey sequence to a sequence without vibration data, thus increasing the amount of RNT and ATI data transmitted. By switching off a module, no data for that module will be stored in memory.

Pulse Rate (Command 15) The “uplink” data rate may be varied between x2 and x5 splitphase. After the downlink has been sent, the tool will continue to transmit at the old data rate. Only after the pumps have been cycled will the new data rate come into effect.

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Timing and Procedure Certain periods should be avoided when trying to send a downlink: 1.

Valve off’s between surveys generate pressure drops and then rises as pulsing starts again. In a slightly compressible medium, these may be seen as flow rate variations by the DLC causing interference with an intentional downlink. Thus, the period 30 seconds after and 60 seconds before a valve off should be avoided.

2.

If the driller shuts down the pumps or alters the flow rate, the downlink will be corrupted. Thus, during periods close to stand down, the driller must be told to maintain circulation until the downlink is complete.

3.

Experience has shown that when drilling with a motor, better results can be seen while on bottom.

The Sequence for a successful downlink should be as follows: 1.

Inform the Driller. He will see a large drop in his standpipe pressure and hear a fairly loud noise when the BPA opens. Make sure the driller knows what you are doing and the consequences.

2.

Open the Downlink control screen of the Survey Monitor, select the downlink data rate, command and set the parameter(s).

3.

Start the Downlink Pressure Scanner. This is a real-time standpipe pressure trace on the Veritas, used for downlink analysis both at the rigsite and in the office. The trace is normally called Downlink_Gulton_Modified.

4.

Wait for the right moment, i.e.30 seconds after the valve off etc. and press the Transmit button.

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Downlinking

The downlink should complete itself automatically. If the tool continues to pulse after the end of the wakeup sequence, the downlink has not been recognized and can be aborted by pressing the “Abort Transmission” button or by pressing “C” on the BPC and selecting: Abort Transmission

Yes/No.

Assuming the downlink was recognized, the downlink response survey should follow. Ensure that the DLERRX status bit is 0, and that the parameters to be changed have actually changed. This would then be considered as a successfully decoded downlink.

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•Notes•

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Downlinking

•Notes•

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Chapter

7

Directional Drilling With The AutoTrak Tool

Chapter 7 describes assembly planning for AutoTrak.

Pre Planning Well Planning Considerations AutoTrak is capable of producing ± 6.5°/30m (100 ft) dogleg severity, with a maximum force of 18.6 kN, in medium strength formation. As with conventional directional technology, it would be bad practice to plan a well to the tools maximum capability. Thus, planned doglegs of greater than 5°/30m (100 ft) should be avoided. The capability has been seen to be influenced by formation strength, dropping to as low as ± 4°/30m (100 ft) in very soft formation. Formation strength and offset tool run information should be considered prior to planning an AutoTrak profile. Unlike conventional techniques, where frequent tool face changes are of no real significance, this is not the case with AutoTrak. Which ever mode of operation the tool is in, it will have a fixed effective toolface for any command. Changing the effective toolface requires a downlink message during which the real-time log is interrupted and real-time data lost. The number of tool face changes should be minimized on an AutoTrak profile.

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Directional Drilling With The AutoTrak Tool

The primary use of the tool is to drill a horizontal section through the reservoir. In the past, long continuous curves, with doglegs of less than 0.5°/30m (100 ft) have been used to achieve TVD changes. With AutoTrak, the most effective way to make a TVD change is to use a higher dogleg and tangent in the hold mode. Well plans should not pass through zero inclination. Sleeve orientation is calculated from the attitude of the accelerometers in the ATI (AutoTrak Inclination) module with reference to gravity highside. The rib forces are then distributed with respect to the sleeve orientation to result in the programmed steer vector. Due to loss of highside resolution below ± 3°, a minimum inclination of less than 5° should not be planned.

Bottom Hole Assembly Configurations The standard assemblies used in horizontal applications are as follows: Motor

Rotary 8-1/2” PDC Bit AutoTrak Tool 3 x 10m x 5” NMCSDP 3 x 5” HWDP 6-1/2” Jars 3 x 5” HWDP 5” Drillpipe……

8-1/2” PDC Bit AutoTrak Tool 2 x 10m x 5” NMCSDP 4-1/2”IFPin to4-1/2” REG Pin X/O 6-3/4” Navidrill (Stabilized) 8-3/8” String Stabilizer 3 x 5” HWDP 6-1/2” Jars 3 x 5” HWDP 5” Drillpipe……

Note: i. As with all directional drilling assemblies, a torque and drag analysis should be carried out at the planning stage to avoid critical buckling and establish theoretical torque and drag trends for rotary drilling. 7-2

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ii. For low inclination applications, the NMCSDP and HWDP should be replaced by non mag. and standard 6 ½” drill collars. iii. Magnetic isolation requirement will be dependent on latitude of the well being drilled. PC Raw must be applied at all times due to the proximity of the steel components of the tool to the DAS. vi. To avoid bending moments on the 4 ½” Reg. connection on the bit box of the Navidrill, the motor must be either fully stabilized, both top and bottom, or run slick. v. Consideration should be given to running a float in the string to prevent solids ingress to the tool, which could result in an internal blockage. If a steel float sub is used, it must not be run directly above the AutoTrak tool due to the proximity of the directional sensor to the top of the tool.

Drill Bit Selection Drill bit selection for AutoTrak is based on performance and not steerability, as with motor drilling applications. Care must be made to avoid induced slip stick by over aggressive bit choice for a specific formation type. Use of a Navidrill to drive the system, will reduce the effects of slip stick by delivering torque directly to the system, thus acting as a torsional shock dampener. Although little data derived from experience is available on bit selection, it is currently believed that a bit with a short gauge and some gauge cutting structure would improve the steering performance of the tool.

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Directional Drilling With The AutoTrak Tool

Directional Drilling Modes of Operation The fundamental difference between conventional steerable motor technology and AutoTrak is the way that the hole curvature is produced. The steerable motor uses a fixed bend to create bit offset and side forces. The AutoTrak uses hydraulic force on the ribs to create a bending force on the string. There are four modes of operation that define the directional control of the AutoTrak system. These modes are the “Steer”, “Hold”, “Build” and “Ribs Off”. The Steer and Hold modes are shown below. Build mode is never used because the same result can be achieved by using Hold mode and changing the target inclination to achieve a build or drop. Ribs off shuts down the pressure to the ribs and is used for open hole side-tracking, reaming in hole and drilling from an over gauge rathole.

Steer Mode:

This mode uses the steer force on a vector direction relative to gravity highside. This can be compared to steering with a motor on a toolface relative to highside.

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Hold Mode: This mode uses build force to either build or drop to the Target inclination. Once the target inclination has been reached, the build force will alternate from + ve to - ve to maintain this inclination. Walk force can be applied to induce or counter walk tendencies.

Ribs Off: The Ribs Off command shuts down the hydraulic pressure to the ribs. This command is used for open hole side-tracking and other situations where zero rib pressure is required. The choice of mode is dependent on the desired profile of the well. Steer Mode is primarily used to drill three dimensional profiles such as a build and turn. As well as drilling a tangent section, the Hold Mode can be used to build or drop a two dimensional profile to a desired inclination at a rate determined by the build force.

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Directional Drilling With The AutoTrak Tool

Relationship Between Modes and Forces The vector addition of the build and walk forces can be expressed as an equivalent steer force. Build Force Resultant Steer Force if Below Target Inclination

Walk Force

Resultant Steer Force if Above Target Inclination Build Force

The tool, in fact, calculates a steer force from the build and walk components. This steer force is then applied by the hydraulic ribs. The maximum steer force that can be applied is 18.6 kN. This does not cause any confusion in the Steer Mode where one force is being applied. In Hold Mode, however, the vector sum of the build and walk forces cannot exceed the 18.6 kN. If the vector sum of build and walk forces exceeds this maximum of 18.6 kN, the effective resultant Steer direction will be used, but the force will be truncated to 18.6 kN. To aid selection of build and walk forces, an Excel Force Calculator program has been written. This can be used, not only to select forces, but can be used to calculate the theoretical resultant build and turn from any command. An example of the display can be seen below and the

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explanation of the new expression ’Dog Leg Gradient’ on page 7-8. Table 7-1 Dogleg Gradient

°/30 m/kN

0.35

deg

90

expected Dogleg

°/30 m

6.5

= steer force *dogleg gradient

expected Build rate

°/30 m

6.5

= steer force *dogleg gradient *cos (steering direction)

expected Walkrate

°/30 m

0.7

= steer force *dogleg gradient *sin (steering direction)/sin (inclination)

Actual Hole Inclination Steer Mode

Steerforce

kN

18.6

Steering Direction

deg

6

Hold/Build Mode Buildforce

kN

18.6

Resultant Steer force

kN

18.6 = squareroot (build force2+walk force2) but maximum 18.6 kN

Walkforce

kN

0

Resultant Direction

deg

0.0

= arctan (Walkforce/ Buildforce) if negative Buildforce -> +180 deg

expected Dogleg

°/30 m

6.5

= resultant steer force *dogleg gradient

expected Build rate

°/30 m

6.5

=resultant steer force *dogleg gradient *cos (resultant direction)

expected Walkrate

°/30 m

0.0

= resultant steer force *dogleg gradient *sin (resultant direction)/sin (inclination)

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Directional Drilling With The AutoTrak Tool

Dog Leg Gradient Rib Force Relationship to Dog Leg Severity One useful relationship is that between the force magnitude applied and the resulting Dog Leg Severity. With the force magnitude applied (whether it be build, walk or steer) will determine the resulting Dog Leg Severity produced. One way of expressing this Dog Leg capability is to calculate a Dog Leg Gradient.

Dog Leg Gradient Dog Leg Gradient is defined thus: Dog Leg Severity Dog Leg Gradient = -----------------------------------------ForceApplied

The Dog Leg Gradient (DLG) will represent the expected Dog Leg Severity produced by the tool, using an overall force of 1 kN. If we now look at the case of a normal 6-3/4” AutoTrak tool with an expected maximum Dog Leg Gradient of 6.5 deg/30m, by using the full available tool capability of 18.6 kN, the theoretical DLG will be: 6.5° ⁄ 30 m Theoretical Dog Leg Gradient = -------------------------18.6 kN = 0.35°

Of course, the theoretical DLG will not be valid for all formations and drilling parameters. For any formation / bit combination, the tool will have a specific Dog Leg capability that has to be established in the field. The theoretical gradient of 0.35 should be used to start drilling until the actual gradient for this combination can be established. e.g.

Required Dog Leg Severity is 5.0°/30m

Force Programmed should be = 5.0 / 0.35 = ±14.3 kN

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Directional Drilling With The AutoTrak Tool

The DLG should be constantly monitored and re evaluated as drilling progresses as a measure of the tools performance and functionality.

Directional Drilling Thought Process One mistake that can be made with AutoTrak is to consider the tool a fully automatic steerable system. Experience in the field, to date, has proven that directional decisions have to be made very quickly with logical thought process for the following reasons. 1.

The average ROP is faster than conventional systems.

2.

Profiles tend to be more complex.

3.

The tool is used in critical sections of the well with tight target tolerances.

The following should be considered/carried out to ensure full directional control. 1.

EC* Trak must be used to carry out real-time revised planning and forward projection.

2.

Near Bit Inclination should be monitored closely to determine tool performance and to allow for immediate reaction.

3.

A downlink command can take up to 8.5 minutes to transmit, during which the tool will continue with the current command in memory.

4.

Drilling parameters must be controlled and supervised to ensure optimum tool performance.

5.

Dog Leg Gradient should be calculated and recorded to evaluate tool capability and functionality.

Operations Manual 750-500-085 Rev. A / May 1998

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Directional Drilling With The AutoTrak Tool

Tool Operation Subjects, such as surface test, are covered in detail elsewhere in the manual due to the MWD specific content. This section covers operational aspects of the tool below rotary, that the directional driller should be aware of, and be responsible for.

Running In Hole Without Downhole Motor As with all systems, the mud displacement during the trip should be monitored to ensure open end displacement. This will be a more likely occurrence when the tool is run with a Navidrill motor. To avoid ingress of solids to the tool, it is recommended that circulation be broken at regular intervals while tripping in hole. This will avoid internal blockage of the tool components. Care should be taken when passing through any internal diameter changes in the hole, as the rib hydraulic system can be damaged by the ribs hanging up on any restriction or by the ribs being forced inwards rapidly. This consideration is more critical when washing or reaming into the hole with the hydraulic system activated, as the ribs will expand to 9-3/16” if not restrained by casing or open hole diameter. The tool should be programmed to Ribs Off for washing or reaming in the hole, for the above reason and to eliminate any unnecessary bending forces and the chance of side-tracking. With the ribs shut down, the sleeve will rotate. The rotation speed should be restricted to minimize shocks on the sleeve. Examples of such changes in internal diameter are: •

BOP and wear bushing

•

Changes in casing diameter

•

Liner tops

•

Casing shoe and rathole

•

Stringers and washouts in open hole

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Directional Drilling With The AutoTrak Tool

To reduce the chance of system damage, washing or reaming in hole should be avoided where at all possible.

Running In Hole With Downhole Motor The following is mandatory: •

Only Ultra Series XL NaviDrill Motors should be run with AutoTrak.

•

Only the specifically designed Baker Hughes INTEQ high strength crossover should be used for this operation. This should be provided by the District ex Celle.

•

The motor should either be run slick with no stabilization above or, if stabilized at the upper bearing housing, it must be run with either a clamp on stabilizer on the stator OR with a stabilizer immediately above the motor.

Surface Testing Of The Motor •

Pick up the motor and check AKO torque, as per normal procedure. Ensure that the AKO is set to zero degrees tilt.

•

Rotate drive sub to the right by hand, using a chain tong to feel for smooth running of bearing and tightness of stator/rotor fit.

•

Check bearing play, as per normal procedure.

•

Make up top stabilizer (if motor stabilized at the upper bearing housing as explained above) and two joints of HWDP or as per BHA.

•

Flow test the motor to ensure rotation of the drive sub.

•

Rack back the motor and two HWDP or as per BHA.

•

Pick-up AutoTrak and ensure that the ribs are collapsed using the “Pushy Tool”. If the ribs are in

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Directional Drilling With The AutoTrak Tool

the expanded position, problems may be encountered running through the BOP´s. AutoTrak MUST be set for zero force to centralize bit and tool in casing during testing. •

Make up the bit, ensuring correct positioning of tong wholly on the bit sub. It is recommended to mark with chalk above and below the steering sleeve from the aluminum shells to the rotating drive sub and pulser housing prior to making up the bit. This will indicate any torquing of the drive shaft mid connection (under the steering sleeve), should any of the bit make up torque be transferred to the tool. Torquing of this connection will render the tool inoperable. It is also likely that the bit breaker will have to be used upside down as the handles tend to interfere with correct positioning of the tong. If the tool is tied back, using a tugger line when making up the bit, ensure that the sling used to tie the tool allows for rotation of the tool in the event that torque is transferred while making up the bit.

•

Make up required NMCSDP above the AutoTrak.

•

Make up the pin / pin crossover for connection to the motor.

Note:

ONLY the specifically designed Baker Hughes INTEQ high strength crossover should be used for this operation. This should be provided by the District ex Celle.

•

Make up the motor.

•

Run in hole to below the BOP´s and into the top of the 9-5/8” casing. NOTE that on many ERD wells the 9-5/8” casing may have been run as a liner. It is not recommended to test the AutoTrak / Motor BHA until inside the 9-5/8” string, as this will cause rotation of the sleeve, non centralization of the tool

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Directional Drilling With The AutoTrak Tool

in hole and possible impact damage to the hydraulic system. •

CAUTIOUSLY bring up the pumps to operating flow rate and observe vibration at surface as the motor begins to turn. The ribs will be expanded and prevent unwanted sleeve rotation while also preventing the bit from contacting the casing.

•

Observe pulsing of the AutoTrak tool, check telemetry and downlink operation.

•

CAUTIOUSLY bring the pumps down to zero. NOTE that although the ribs shall prevent contact of the bit with the casing, it is recommended to slowly reciprocate the pipe throughout this operation to prevent contact of the bit with the same section of casing in the event of a tool malfunction.

CAUTION: Caution must always be exercised when bringing the pumps up and down when running the AutoTrak assembly on a motor, to prevent damage to the motor. This must be explained and stressed to the driller on shift. Failure to do so may cause backing off of or over torquing of internal motor connections or damage to the stator due to the high inertia of the assembly below. It must also be stated that use of motors under similar load conditions (e.g. motor coring) is a regular operation.

Operations Manual 750-500-085 Rev. A / May 1998

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Directional Drilling With The AutoTrak Tool

Backreaming Most operators like to backream out of hole, especially out of a horizontal section. As with washing and reaming into the hole, this can cause system damage if the hole ID varies due to washed out sections and stringers. One other consideration is that ribs may loose wall contact if the wash out is larger than the maximum rib extension. The sleeve would then rotate with the string, causing shocks to the sleeve electronics and hydraulic control system. For this reason, pumping out of hole is preferable to backreaming. If backreaming is required, then the rotary speed should be minimized. If hole wash outs or stringers have been identified in a section, then particular care should be taken. The tool should be pulled into the shoe without pumps, due to the change of ID from the rathole to the casing. The tool should be programmed to zero force when backreaming to eliminate unnecessary bending forces.

Drilling Cement When drilling cement, plugs and casing shoe, the tool should be programmed to zero force to avoid bending forces on the tool. Zero force will distribute equal forces to the ribs and consequently minimize the wear on Bit and Casing. As with normal shoetrack drilling, the parameters should be reduced to minimize wear on the casing and shock loading on the drilling assembly. The zero force command should be used until the bit is through the shoe. The Rib pressure should then be shut down to clean out the rathole and drill the first 2 m (6.5 ft) of formation, at which point the ribs will be in the drilled hole diameter. Shut down rib pressure can be achieved by downlinking to Ribs Off or more simply by reducing the flow to below the minimum flow for power up of the tool. If reaming of the shoe track is necessary: 1.

Cut flowrate back to < 1100 L/min (290 gal/min)

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Directional Drilling With The AutoTrak Tool

2.

Pull slowly into csg. Shoe

3.

Increase flowrate to normal and ream down

Kicking Off As explained under Well Planning Considerations, the tool is not capable of kicking off from vertical in a specific direction. An inclination of ± 3° is required for the tool to establish high side resolution. In case of clearance problems where the profile has to execute at inclinations below ± 5°, a conventional motor and gyro has to be available on site. Having said this, if a blind side-track is acceptable, then the tool has shown the capability of kicking off with theoretical dog legs from vertical.

Open Hole Side-tracking With the Ribs Off command, this following procedure is recommended when attempting an open hole side-track. 1.

The side-track must be carried out on the lowside of the well, if possible in a section of the well where there is a build up dog leg.

2.

With the tool set to Steer / 18.6 kN / 180 deg, a section of 20m (65 ft) prior to the kick off point should be reamed slowly several times to create a ledge.

3.

At this stage, the rib pressure should be shut down by either downlinking Ribs Off or by reducing flow to below power up flow.

4.

With slow rotary, to prevent shocks to the sleeve, the same section above the KOP should be reamed several times slowly.

5.

The side-track should then be time drilled from the KOP at an ROP dependent on the formation strength with rotary speed as above and reduced flow.

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Directional Drilling With The AutoTrak Tool

6.

To evaluate the progress of the side-track, the rotary should be shut down at regular intervals to obtain an accurate ATI measurement.

7.

The sleeve must be well into new hole, with the bit on bottom, before the ribs are re-activated to prevent the hydraulic pressure from pushing the tool back into the original hole.

8.

Any further pass through the side-track point should be carried out with the pumps below 1000 L/min (264 gal/min) or the rib pressure off.

Motor Specific Drilling Considerations The tool has been used extensively with Navidrill mud motors. There has been no evidence to date of any detrimental effect on the two way communication with the tool. Compared with conventional motor drilling, where the motor drives a bit only, the motor has to drive a bit, the AutoTrak tool and two 10m (32 ft) NMCSDP. This is a mass of ± 3 tons and care should be taken when starting and stopping the pumps, due to the increased momentum below the drive sub, which in worst case could result in a back off. Guidelines for running the AutoTrak on a Navidrill: 1.

Fill the pipe while running in hole.

2.

Bring up the pumps to drilling flowrate before starting string rotation and going on bottom.

3.

Start and stop pumps smoothly (because of the mass below the bit motor drive sub.)

4.

Minimize string rotation speed. The total tool RPM is the sum of motor RPM and surface RPM.

5.

If motor stalls: Stop rotation, reduce pump rate, pick up off bottom.

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Directional Drilling With The AutoTrak Tool

Tool Idiosyncrasies Effects on Dog Leg Gradient During the field tests, the following AutoTrak specific behavior has been observed: •

Dog Leg capability can be influenced by rate of penetration. The higher the ROP, the less the capability

•

Dog Leg capability can be influenced by formation strength. The softer the formation, the less the capability

•

Dog Leg capability can be influenced by Steer Vector. Higher DLG has been observed in turn than in build

The above are observations and may not be true in all areas and formation types. As with conventional motor techniques, the tool performance should be monitored closely and trends noted.

Effects of Overgauge Hole Overgauge hole can result in sleeve slippage and loss of directional control. This should be identified from the DrillByte real-time log of sleeve orientation. Reduced flow rate and constant bit weight should be used to attempt to eliminate the problem. Overgauge hole has not, however, been seen to be a problem.

Operations Manual 750-500-085 Rev. A / May 1998

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Directional Drilling With The AutoTrak Tool

•Notes•

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Chapter

8

AutoTrak Reporting

Chapter 8 describes the reporting sequence of field personnel.

It is essential that job reporting is accurate, complete and standardized. This will result in professional customer reports, effective fault finding/troubleshooting and accurate performance evaluation. At a minimum, a copy of the Daily Drilling Report should be faxed to Technical Services - Drilling Systems in Celle, Germany every morning on number + 49-5141-203362 and to the local co-ordinator. If it is not possible to send an international fax from the rig site, then the report should be sent to the local co-ordinator for forwarding. On a run-by-run basis, further data such as drill parameters and downlink information will need to be faxed. If an e-mail facility is available at the rig-site, daily reports, downlink tracking sheets and drill parameter record should be sent to the following list daily: Hartmut Gruenhagen Detlef Ragnitz Frank Wiese Ray Newton Region AT Co-Ordinator Region DD Co-Ordinator Region MWD Co-Ordinator

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AutoTrak

AutoTrak Reporting

MWD FSE Responsibility The MWD FSE is responsible for the following paperwork, as well as the standard DrillByte logs and data: Downlink Analysis and Tracking MWD Run Sheet AutoTrak Diary Standard MWD FE Report

Downlink Analysis and Tracking The Downlink Analysis and Tracking Form is an Excel spreadsheet, used for recording downlink data and calculating the amount of flow diverted at the Bypass Actuator from the pressure drops observed at surface. A Veritas plot of stand pipe pressure is used to log the surface pressure. Once the downlink is complete, the Maximum and Minimum pressures for both long and short pulses should be entered in the spread sheet, as well as the other information requested. The sheet will then calculate the percentage of diverted flow. 13 to 15% of flow, for the short pulse, is desirable for successful downlinking. The data can be entered in any units e.g. psi as the calculation for percentage diverted flow uses a ratio. The percentage bypass flow, as measured by the Max/Min turbine RPM’s, will also be recorded and calculated here. This sheet should also be used to track BPA and Adjustable Nozzle use. A new sheet should be used for each run.

MWD Run Sheet The MWD run sheet is the standard run sheet used in a particular region.

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AutoTrak Reporting

AutoTrak Diary An AutoTrak Diary has been in use for all field tests and has proven to be a valuable tool for post job analysis. Data that should be recorded in the diary is: •

Arrival, rig up, details and timings.

•

Surface test details and timings.

•

Trip in hole tests etc.

•

All down link details including depth and time.

•

Date and time of all connections and survey stations.

•

As much information as possible regarding suspected faults or failure.

•

Any unusual occurrences or rig problems.

No one will accuse you of writing too much in the diary!!!

Standard MWD FE Report MWD FE Report as per local requirement. This will complement the Directional Driller’s run summary to form the basis of the AutoTrak End of Well Report.

Operations Manual 750-500-085 Rev. A / May 1998

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AutoTrak

AutoTrak Reporting

Directional Driller Responsibility The directional drilling paperwork has been found to vary from region to region. To standardize the reporting parameter, daily reports and BHA reports have been created on Excel spreadsheets. The sheets accept text and do not do any calculations. The Directional Driller is responsible for the following paperwork: •

Drilling Parameter Sheet.

•

AutoTrak Daily Drilling Report.

•

AutoTrak BHA Report.

•

EC*Trak survey listing.

•

Standard Directional Drilling Recap.

•

Entry of any specific Directional Drilling data into the diary.

•

Run summary sheet.

Drilling Parameter Sheet A blank sheet should be used on the drillfloor as a Directional Driller work sheet. The data will then have to be entered into the Excel sheet.

Daily Drilling Report and BHA Report Even if there is a local requirement to use DDS Lite, this paperwork must be completed, in addition, as there are specific AutoTrak details that should be recorded.

Directional Drilling Recap or Section Summary This is a section review of Directional Driller’s performance in words. This section will be used in

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AutoTrak Reporting

conjunction with the MWD FE Report to produce the AutoTrak End of Well Report.

AutoTrak Diary Log any useful additional information into the AutoTrak diary.

End Of Well Requirements For Each Run, the following Data is required On Disc Run Summary Sheet Downlink Record Sheets BHA Reports Drilling Parameters Record Tool ID Report In/Out Deck/Surface test Protocol (*.PCL) Files Hard Copy Time based Parameter Log Downlink Pressure Scans MWD Run Sheets For the Complete Job, the following data is Required On Disc Resistivity Correction Sheet Gamma Correction Sheet End of Well Report Binary files *.CFG files Daily Drilling Reports Hard Copy EC*Trak Survey Listing AutoTrak Diary Memory Log Operations Manual 750-500-085 Rev. A / May 1998

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AutoTrak Reporting

Streamer Tape DrillByte Backup DrillByte ASCII Backup

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AutoTrak Reporting

•Notes•

Operations Manual 750-500-085 Rev. A / May 1998

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AutoTrak Reporting

•Notes•

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