Generation 2.

5
Operations Manual
 Baker Hughes INTEQ

AutoTrak Generation 2.5

Operations Manual

Confidential

Technical Communications
P.O. Box 670968
Houston, TX 77267-0968
USA
713-625-4694
 CONFIDENTIAL
This manual contains sensitive information
pertaining to INTEQ services. It should be
regarded as
COMPLETELY CONFIDENTIAL

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.

© 2001 Baker Hughes Incorporated. All rights

reserved.

November 29, 2001

Preface
This manual is made for supporting the field engineer in
running the Generation 2.5 AutoTrak tools.
This manual covers all differences to the existing
AutoTrak Generation 1.5 tools, but does not cover all
sections of the 1.5 manual which are the same or very
similar for this tool, like Surface system, downlinking, etc.
A complete manual for the modular Generation AutoTrak
3.0 will be released with the introduction of AutoTrak 3.0
in Q1 2002.

If you should find any discrepancy or if additional

information is needed, please send a request to
Technical Services - Drilling Systems in Celle Germany
or e-mail a description of improvements. This information
will then be implemented in to the next edition.

Baker Hughes INTEQ

Technical Services - Drilling Systems
Celle, Germany
TEL +49-5141-203-0
FAX +49-5141-203362

Baker Hughes INTEQ

Technical Publications
2001 Rankin Road
Houston, Texas 77073
TEL (713) 625-4694
FAX (713) 625-6510

Reference Guide
Confidential!
Table of Contents

Preface 4
Brief overview of AutoTrak 2.5 6
Tool Diagram. 6
BCPM, Bi-Directional Communication and Power Module. (HBC-917600000) 6
ATK2 Steering Head (ASS-10061649) 7
Flex Sub (FLX-10061322) 8
Sensor Sub (SHE-919103304) 8
T2 Modular Connections 8
Preparation of Mounting Wrench (p/n 917-600-078). 9
Installation of Teflon Stop Ring (p/n 917-600-075). 9
If you have to remove the Teflon Stop Ring, the following procedure is applicable. 10
Removal of Teflon Stop Ring (p/n 917-600-075). 10
Readout Sub 12
Tool Communications 13
RiBox III 14
TCS (Tool Control System) 15
Testing Procedure 16
RiBox III Procedure. 16
TCS Procedure. 17
T2 Comm Caps and Cabling 17
Tool Communications Software 19
ToolCom NT 19
BCPM 23
ATM25 26
Setting Azimuthal Gamma Correction 27
AT2 28
Vibration 30
DRILLING PROCEDURES 31
Running in Hole. 31
Reaming / Logging into Hole 31
Reaming / Logging out of Hole 31
Drilling out Cement/Shoetrack/Shoe 32
RE-RUN Qualification / Trouble Shooting 33
Flush Rib Hydraulics 33
Rib Hydraulics showing no pressure after post deck test 33
No communication to the Steering Unit 34
Transmitted 0’s and 1’s. 34
APPENDICES 35
Appendix A: Connection Makeup Torques 35
Appendix B : Technical Data Sheet 36
Appendix C : Fishing Diagrams 6.3/4” AutoTrak 2.5 38
Appendix D : New Terminology. 40
Appendix E : Tool Specific Telemetry Words 41
Appendix F : Hercules TCS System 42

AutoTrak Generation 2.5 Operation Manual 5

 Brief overview
of AutoTrak 2.5
Directional Collar

D ir e c ti o n a l S e n s o r

Tool Diagram.

Autotrak 2.5 has several major

benefits over previous AutoTrak
tool generations. Its modular
7 .1 m design allows maintenance of key
(2 3 . 3 f t )
1 3.6m
components to be performed in
( 4 4.6ft) local INTEQ workshops and
Reser voir Navigation S ub

easier transportation of
components. This means that
R e s i s ti v i ty
more remote operating areas can
G a m m a R ay
get access to AutoTrak Rotary
Closed Loop technology together
with an increase in tool utilization.
V ib r a ti o n In addition to this, there are a
number of technological
improvements incorporated in the
system to increase tool reliability.
Power & Communication Module

There are several new key

components, affecting both the
operation of the tool and the way
9 .4 m it is set up. These include:
(3 0 . 7 f t )
BCPM, Bi-Directional
9 .0 m
(2 9 . 5 f t )
Communication and Power
Module. (HBC-917600000)
8 .5m
7 .5 m (2 8 . 0 f t )
(2 4 . 7 f t)
This new module is responsible
for the pulsing sequence of the
tool, power generation and pulser
control. The BCPM module has
It’s own software and needs it’s
own Telemetry file (*.BCP File,
see BCPM Software notes)
AutoTrak Steeri ng He ad

I n c lin a ti o n

1 .0m
( 3 .1 f t)

AutoTrak Generation 2.5 Operation Manual 6

ATK2 Steering Head (ASS-10061649)

Each of the 3 ribs has its

own Motor, Hydraulics and
Rib Pressure Sensor. The
picture left shows the rib and
its hydraulic unit. Target
versus Actual Rib pressure
can be monitored. This will
provide a measurement to
determine if a Rib has failed.
In Ribs Off mode, the ribs
can truly be switched off and
will not expand while
circulating due to a titanium
leaf spring which pulls the
ribs back into the closed
position, a big advantage for
running in hole and reaming. However note that it takes several minutes (up to
6 minutes) for the hydraulic oil to drain back into the oil reservoir of each rib
and hence for the rib to return to the closed position. The ATK2 steering head
is changeable at the rigsite. It is also possible to individually change out each rib
though this will only be carried out at the rigsite in special circumstances after
consulting Technical Services Department in Celle.

The nomenclature for the ribs is as follows:

There is a small notch

above the Rib#1
hydraulic module. The
corresponding rib#1 is
to the left (downhole
view = view from top of
the tool to the bottom)
of this module and the
rib itself is denoted by
an indentation above
the rib hinge.
Ribs 2 and 3 are found
by going clockwise,
(looking downhole) or to
the right of rib#1

After each AutoTrak run flush the ribs and rib hydraulics with water,
especially through the lower port on the rib hydraulics!

AutoTrak Generation 2.5 Operation Manual 7

Flex Sub (FLX-10061322)

A Flex Sub incorporating a 1/8” undergage stabilizer is placed between the

steering unit and the BCPM to provide the correct steering geometry. The Flex
Sub has a M30 line connecting the modules above and below. When using the
tool in tangent or low dog leg applications, the Flex Sub can be omitted.

Sensor Sub (SHE-919103304)

The intended configuration of the AutoTrak tool in the future will include the
Hercules MWD system to provide the Master, Memory, Vibration and
Resistivity/Gamma modules. Until the Hercules system is available for commercial
use, a sensor sub has been designed to house these modules.

Due to the modular nature of the tool, it is important to keep on top of the tool
inventory on the rig and in the hole. Do not assume that the serial numbers on the
transfer sheets are correct. You should physically check the serial numbers on the
brass plates of each sub.

T2 Modular Connections

The 4 subs (BCPM, ATK2 Steering Head, Flex Sub and Sensor Sub) are
connected by T2 modular connections, similar, but not identical to the old NC46
modular connections. The new connection is designed to allow rotation through
15°/30m doglegs. The tool will normally be shipped in two sections so the T2
connection must be made up on the drill floor.

The preparation of the T2 connection prior to makeup is similar to the old M 30

modular connection, however there are some differences. On the T2 Pin, instead
of the Lende seal system, a 2-part seal system consisting of a Teflon Stop Ring
(p/n 917-600-075) and an O-Ring (p/n 006-210-124) is deployed.

AutoTrak Generation 2.5 Operation Manual 8

To place the Teflon Stop Ring on the thread you will need to use the Stop Ring
Mounting Wrench as the force required to get it to the correct position is quite
substantial. The Stop Ring Mounting Wrench consists of an Inner Ring, an Outer
Ring and a 10 mm Bar. The procedures for preparation, installation and removal
of the seal assembly are as follows:

Preparation of Mounting Wrench (p/n 917-600-078).

1. Make sure the T2 thread on the inner ring of the mounting device is clean.

2. Take the inner ring of the mounting wrench and screw it into the outer ring as
far as it will go.

Installation of Teflon Stop Ring (p/n 917-600-075).

1. Place the Teflon Stop Ring over the pin of the sub having it lightly lubricated
with Lubriplate and push it as far as it will easily go by hand.

2. Holding the Mounting Wrench by the inner ring, screw the wrench onto the pin
of the T2 connection until it is hand tight.

3. Slot the 10mm bar through the holes in the outer ring and use it to screw the
outer ring in towards the Teflon Stop Ring.

AutoTrak Generation 2.5 Operation Manual 9

4. Once the 10mm bar makes contact with the inner ring, the Teflon Stop Ring
should be in exactly the right position, 7mm from the shoulder of the
connection. Check the distance with a measuring device.

5. Back out the mounting device from the connection pin.

6. Lightly lubricate the O-Ring (p/n 006-210-124) with Lubriplate and push it over
the Stop Ring.

7. On the box connection, an axial O-Ring 567 (p/n 900005259) is inserted into
the groove of the T2 M30 box. Again this is not the same as in the old NC46
connection.

8. Having satisfactorily cleaned and Lubriplated the connection in the normal

manner it is made up to 29,500 ft/lbs. (40,000Nm).

Each time the connection is made up, both O-Rings (one on the pin, p/n 006-
210-124 and one on box, p/n 900005259) needs to be replaced. The Teflon Stop
Ring should last for a few connections and need only be replaced if visual
inspection shows it to be damaged.

If you have to remove the Teflon Stop Ring, the following procedure is applicable.

Removal of Teflon Stop Ring (p/n 917-600-075).

The Teflon Stop Ring can be removed by cutting however it is quite tough. An
alternative is to use the Removal Ring and the Removal Halfshells supplied with
the Mounting Wrench as follows.

AutoTrak Generation 2.5 Operation Manual 10

1. Place the Removal Ring over the small end of the Mounting Wrench. Make up
the mounting wrench inner ring to the T2 thread and then turn the outer ring
until it makes contact with the Teflon Stop Ring.

2. Fit the Removal Halfshells over the end of the mounting wrench and Teflon
Stop Ring as in the picture below. Once both removal Halfshells are in place,
slide the removal ring over the Halfshells to keep them in place.

3. Using the 10mm bar, back out the Mounting Wrench from the connection. The
Teflon Stop Ring should come off with the Mounting Wrench.

ATTENTION: Conventional M30 lift subs and lift caps cannot be used with
the T2 connection. Make sure you have T2 lift subs and lift caps in your
surface kit!

AutoTrak Generation 2.5 Operation Manual 11

Readout Sub

The Readout sub is part of the Sensor Sub and replaces the old readout port and
provides the communication with the tool at surface. It is located at the bottom of
the Sensor Sub.

The Picture shows an open

readout port. 8 pin male on
Readout Port and 8 pin female on
data cable to TCS or RiBoxIII.

A new style hatch cover is used. When fitting this cover lightly lube
and fit a new O-Ring (p/n 728-000-012). Apply a thin layer of silicon grease
around the outer edge of the hatch cover. To secure the hatch cover clean each
bolt (p/n 10068371) and the 4 thread boxes inside the Read Out Adapter Sub
with Loctite cleaner spray. Allow it to dry and then put all 4 screws through the
Read Out Plate.
Put the plate into its groove and torque the bolts crosswise to 10 Nm. (7.5 ft/lbs).
This is equivalent to hand tight (Engineer
strength not Roughneck) should a torque wrench not be available.

Readout Cover Plate

with O-Ring and Bolts

The bolts for the readout

plate require a ¼” double
hex socket.

AutoTrak Generation 2.5 Operation Manual 12

Tool Communications
Two systems, RiBoxIII and TCS (Tool Control System) can be used to
communicate with the tool. Note that due to a higher potential current draw
of the 2.5 Generation tools both Power Comms and earlier versions of the
RiBox cannot be used. As a general rule the tool should be tested as a
complete system. As a minimum, the four AutoTrak subs should be connected
after the initial resistance checks have been made but before the tool is
programmed and tested. The current configuration files for the tools do not allow
surveys to be written to the memory unless the BCPM is connected to the Sensor
Sub. This problem will be addressed in the next cut of configuration files but until
they become available it is necessary to have the tool connected as a complete
system prior to programming. It is also seen as a more realistic test of the tool’s
functionality.

ATTENTION: It is possible to test the complete tool from the readout port of the
Sensor sub with both the RiBoxIII or TCS systems. Do not power up the
complete tool from the M30 Ring on top of the Sensor Sub or any
additional Sub above this (MAP,CCN,ORD etc). This will cause excessive
current to pass through the center electronic and RNT, causing catastrophic
damage!

The additional current draw requirements of the Generation 2 steering unit

require a more robust cabling for connecting modules together on surface.
The new Surface Extension Kit for 6 ¾” AutoTrak 2.5 (p/n 10076873) will contain
two comm caps (T2 Testadapter assys p/n 10073016 for Pin and p/n 10073017
for Box) which can be connected to the bottom of the Sensor Sub and the top of
the BCPM sub if the AutoTrak tool is delivered in two pieces. Together with the
Cable “Box, Connection, M30 T2” (p/n 10075291, see picture below) it allows
direct contact to the programming computer. With this setup an opening of the
Readout port will not be necessary anymore (see T2 Comm Caps and Cabling,
page 15).

AutoTrak Generation 2.5 Operation Manual 13

Box, Connection, M30 T2; 10075291

RiBox III

RiBox III is rigged up as shown in the diagram below.

25 - 9 Straight Cable
(RIBox to Comm Port)

Laptop

Power Supply
(230V -110V)

RIBoxIII

Comm Port
BCPM RNT

Read Out Sub

A 25 pin - 9 pin straight cable connects the PC to the RiBox. The cable between
the RiBoxIII and the tool has a 7 pin male end to the RiBox and a 8 pin female
end, which plugs into the tool at the Readout Port on the Readout Sub.
Note that this setup is not intrinsically safe and a Hot Work permit may be
required. It has been found that a 100 ft 25 pin - 9 pin serial cable can be used
to connect the PC and RiBox without affecting communication. This makes it
possible to use the PC in a dry area.

AutoTrak Generation 2.5 Operation Manual 14

RiBoxIII can be used with 110V and 230V. It is self switching and fitted with a 4
Amp fuse. The ampere scale is 0-10.

TCS (Tool Control System)

This system replaces the existing Cabin Power Comms System. Unlike the
RiBox III, the TCS system can be used with a PC/Laptop from the AutoTrak
cabin.
(see Appendix F )

AutoTrak Generation 2.5 Operation Manual 15

Testing Procedure

Initial resistance checks

As with any AutoTrak tool, prior to
applying any power to the tool ensure
that all modular connections are clean
and dry.
Use comm caps to connect the steering
unit/BCPM to the RNT/probe section of
the tool.
Open the M30 readout hatch and test the
Ground M30 resistance between the M30 and ground
pins. The object of the exercise is not to
establish a certain value but to ensure
that a potentially damaging short circuit
does not exist.
Locating pin
Important: If at any time the power to
the tool is cycled, allow a minimum of
Downhole End
10 sec between turning the power off
and turning it back on again. This
gives time for any capacitance to be discharged and reduces the risk of
damage to both RiBox/TCS and Tool.

The resistances and current draws of the individual subs should be within the
following ranges

Sub Resistance Range Normal Current Draw

Sensor Sub 5 – 20 kohms 0.5 A
BCPM 5 – 20 kohms 0.1 A (0.5 A pulsing)
Steering Unit 5 – 20 kohms 0.6 A – 5 A*

*Steering Unit Current draw can be as much as 5 Amps when the Hydraulic Units
first power up, settling to the following approximate values.

Ribs Off 0.6 – 1.2 amps

Hold 1.5 – 2.0 amps
Steer 2.0 – 2.5 amps

Always allow some seconds after power up for all modules to switch on. These
values should be used as rough guidelines.

RiBox III Procedure.

1. Rig up the system as described above. As with all AutoTrak tools, try to keep
the M30 cabling used to the shortest lengths possible to avoid
communication problems.

AutoTrak Generation 2.5 Operation Manual 16

2. Turn the RiBoxIII on (main power) ensuring the AutoTrak/M30 supply switch
is in the Off position. Plug into the tool and toggle the AutoTrak/M30 supply
switch to the On (RiBox) position.
3. Note the current draw from the tool. It should be within the values listed
above. Depending on the steering control the tool has been programmed
with the current draw will the rise to between 2.0-5 Amps. 2.5 Amps for ribs
off and 3-5 Amps for Hold/Steer mode.
4. If in Ribs Off mode, the Ribs will not expand. The motors will be heard
working but only briefly before shutting down.
5. If the tool is in Hold or Steer mode the ribs should expand. A continuous
whirring sound will be heard from each of the rib motors. Check that all ribs
expand. If they do not, the relevant ribs should be considered as suspect and
further investigation should be made using the AT2 program as discussed
later.
6. Make sure the "Pulse" light indicates the tool to be pulsing.
7. Set up the tool using the relevant software.

TCS Procedure.

1. Plug into the tool with TCS and Tool Line Power in “off” position. Tool Comms
should be toggled to M30.
2. Toggle TCS power to “on”, wait a few seconds and then toggle Tool Comms
Line to “on”.
3. Note current draw. During field test it was noted that current draw seen
through the TCS was slightly less than that seen in an identical situation on
the RiBox. A residual current of around 0.4 amps was also noted. These are
known issues and will be fixed in future versions.
4. The rest of the procedure is identical to that of RiBoxIII and is covered in the
following discussion of software.

T2 Comm Caps and Cabling

ATTENTION: Conventional M30 lift subs and lift caps cannot be used with
the T2 connection. Make sure you have T2 lift subs and lift caps in your
surface kit!

A new set of communication caps has been designed for the T2 threads. It was
felt that the higher currents in use in the G2.5 tool warranted a more robust
system, which is less prone to have powered connections shorting on metal
decks. The comm caps are shown below

AutoTrak Generation 2.5 Operation Manual 17

The connections are Cannon style couplings. The connecting cabling will include
TCS box-cannon cables, extension cables and 4-way junction boxes as shown
below.
The 4 way junction box can
be used to connect two
sections of tool (with an
additional extension cable
if required) with a third
connection going to the
TCS box.

The naming convention of

these connectors is:
Line A M30
Line D Ground

Always bear in mind the

fact that the tool must
NOT be powered from
above the center
electronics due to the
high current draw
required by the Steering
Head.
The connection from the
TCS to the tool should be
made on the readout sub,
the joint between the
BCPM and the sensor sub
or below.

AutoTrak Generation 2.5 Operation Manual 18

Tool Communications Software
At the time of writing, just about everything you need to test, program, dump and
troubleshoot the tool is available as WinNT software in the Advantage software
package. If Advantage is not being used on the rig then ensure that there is a
laptop loaded with a released version of Advantage available on the rig.

The software has been designed in a modular format. There are separate utilities
for the Steering Sub, BCPM, Master and Vibration modules. There is an
additional NT tool communications utility called ToolComNT. This will usually be
the first program you will run and will serve as a launcher for the AutoTrak
specific programs. To run the AutoTrak specific programs from ToolComNT,
click on the AutoTrak icon near the middle of the launcher.

ToolCom NT

ToolComNT will be the launcher for all tool communications software. From here
you can poll all nodes and get status flags, dump and initialize memories and
perform sensor verifications.

Apply power to the tool, run ToolComNT. Enter ToolCom NT Properties and set
up the relevant options for testing AutoTrak. Make sure you have the options set
up as in the screen
below.

AutoTrak Generation 2.5 Operation Manual 19

Save changes and exit.

Click the POLL button. The routine will

find all the nodes connected, display
the part number of the node and
display any error status associated with
the node. When clicking on the error
status, an explanation of the displayed
code is given. In later versions of this
screen, the option of which nodes to
poll will be displayed at the bottom of
the screen. Ticking AutoTrak and
Modular should poll all the nodes
required.

Poll is also used to Initialize and

Download the memory files.

AutoTrak Generation 2.5 Operation Manual 20

The view data option allows you to see further information from the nodes. Select
the different tabs for a more in depth look at the various nodes.

This RNT sheet is shown here

as an example of what to
expect from the other
screens. Going through these
screens will give you an
overview of the state of the
tool before testing and setting
up the tool with the programs
dedicated to individual
modules which are discussed
later.

The Verify button and the Initialize Memory buttons do exactly what they say!

Assuming you have the sensor sub hooked up, you can perform the roll test to
confirm directional sensor and battery operation. Cycle tool power for 2 minutes
and turn the sensor sub by at least 10°. Cycle the power again for 2 minutes and
once powered up let the tool run for a minute. NOTE: All programs should be
switched off when cycling the power to take a survey. If any ToolComs
programs are still running the survey will not be taken due to the tool
master being in a passive mode.

Restart toolcoms NT and poll. Click the Dump Memory button. This will bring up
a screen with all of your options and settings. The tool will dump its 8 MB
memory at 19200 baud in spew mode. If desired, you can dump directly on to a
floppy disc or to the hard drive but you need to have a directory set up in
advance.

The memory files can be viewed

using the Advantage program
MemProc. Run the MemProc
program from the toolbar (Start-
Advantage System-MWD-
MemProc).

To view a file either click on the

file opening icon or on the tool
bar click File and Open. The
Open Memory File window will
appear. Select the memory file
directory either by typing the
path into the upper box or by
clicking on the box with three
dots and browse to the required

AutoTrak Generation 2.5 Operation Manual 21

directory. A list of all the files will appear in the lower box. Select the required file
(3307FFFF) and click on the open tab. You will sometimes get an error indicating
that the program could not open the associated error file, click on OK.

The data stored in the file will be displayed as follows.

Ensure that a new survey with different values was written to the memory when
the tool was powered up the second time.

AutoTrak Specific Programs

Clicking on “AutoTrak” folder will open up the following options. We are only
interested in the four 2.5 programs.

AutoTrak Generation 2.5 Operation Manual 22

BCPM

The Bi-Directional Communication

and Power Module fulfills the
functions previously performed by
the downlink controller, alternator
voltage regulator, pulser driver
board, alternator and pulser. It also
takes over from the ADS Master the
task of converting numbers into
ones and zeros. In order to do this
the BCPM must know what to
transmit and how to encode it; in
other words it needs a telemetry
format. This file is referred to as a
*.BCP file and must match a
corresponding file in the master
which is responsible for recorder
functions

(The ATM configuration files are stored in the

\INTEQ\ADVANTAGE\CTL\MWD\AUTOTRAK folder on the harddrive of the
MSS/Advantage computer. The matching BCP files are stored in the
\INTEQ\ADVANTAGE\CTL\MWD\BCPM folder, see ATM 2.5 section).

Click on the BCPM_Info tab to check the present config. file *.BCP in BCPM and
check BCPM firmware and P/N. If you are connected to the sensor sub, you will
also be able to check if the *.BCP file and the Master file configuration *.0h5
match. All these information and the other BCPM settings can be stored in a
report file by pressing the Floppy Disc button and choosing a suitable file name
and location.
By clicking on the CBR_CTL Lifetime or PDB_CTL Lifetime button you can view
the temperature exposure record of the sub.
Click on the PDB_CTL and CBR_CTL tabs to check that sensible values are
being displayed. Breaker voltages should be of the order of 30 – 33 volts. The
current on the upper breaker should be at least 0.7 Amp and will increase if any
modular subs are attached. Note if the tool is powered externally, the Upper
Current will be negative. The Lower Current will vary depending on the activity of
the motors powering the ribs and could be up to 5 Amp, but should not be less
than 0.6 Amp.

The “Change Settings” button at the bottom of each of these pages should not
be changed unless told to do so.

AutoTrak Generation 2.5 Operation Manual 23

 The next tab to the left is the BCPM-
Telemetry page. Here you can set
up the type of encoding required,
Split Phase or Combinatorial, and
the Split Phase data rate and four
Combinatorial data rate options. Two
options you will not be familiar with
are FID Bit Length and FID Error
correction. These are intended for
future use and should remain set to
4 and ECC on respectively. In order
to change data rate downhole, you
should always use the “Pulse Rate
& Encoding” downlink option and
not the “Pulse Rate” downlink
option. In the example below, the
tool will be reset to transmit
Combinatorial at the #2 data rate
which has been set to 0.50 seconds.

When a change in transmission type is sent, the pumps will have to be cycled for
the change to take place, giving time to get the correct decoding programs set up
on your surface system. This is also the case when a change in Split Phase data
rate is made. This is however not the case, when a change in the combinatorial
data rate is made. The HSTDecode program can recognise the data rate by the
number of data rate pulses sent, there is no need for any surface change to be
made and the tool will transmit the FID 6 and all subsequent data at the new data
rate.

As mentioned previously, you will need a

file called *.BCP in the BCPM to provide it
with the information required to transmit
data to surface at the right time. You will
also need to instruct the BCPM to which
FID’s you wish it to transmit and in what
order. Pressing the “Change Sequence”
button does all this. The Change FID Data
window will appear.

Having started in the BCPM program by

looking at the BCPM_Info page, you will
know if the *.BCP file currently in the
BCPM is the one you require. If it is not,
press the “BCP File” button and choose
the required file. Once this has been
loaded, you will return to the Change FID
Data window to set up the FID sequence.
The system allows you to put in several
different sequences of FID´s and you may downlink to the tool to choose different
starting points in order to choose the sequence set you wish to be transmitted. In

AutoTrak Generation 2.5 Operation Manual 24

the example, the pulser start index is set to 1, so the sequence FID15, FID7 x 5,
FID 11, loop-back to FID 7 x 5 etc will be transmitted. If this transmission
sequence is all that is required then you would simply set up index rows 1, 2 and
3 as above and finish with a 4th row with FID 6, Repeat 1 and Loop-back 255.
The last row should always be the FID 6 row.

Thus after a downlink, the tool would send an FID 6, before looping back to the
loopback point of the previous sequence. It is important that the loop-back index
of the last line should always be 255.

Should you wish to include alternative FID sequences, you can add them below
the first sequence but above the FID 6 row. There are 88 index slots in the page,
however at this stage, to change the start index downhole use the old replace
survey command and choose the pulser start index in the “New Survey” box (the
“Old Survey” box is always 0). This means that the maximum number you can go
up to is 15 so it is not allowed to have a sequence starting with an index greater
than 15.

As mentioned before, the tool

set up thus will transmit FID
15, 5 x FID 7, 1 x FID 11 and
loop-back to the FID 7. In
AutoTrak control, set the New
Survey to 4, leaving the Old
Survey box set to 0 like in the
example. As a rule, after a
downlink, the tool will send an
FID 6 and then restart at the
loop-back point of the previous
sequence. After you cycle the
pumps, the tool should start a
new sequence of FID 15 5 x FID 8, 1 x FID 12 and loop-back to 5 x FID 8.

This is all what is required for the BCPM_Telemetry page, as you can see it is
probable the most involved section of the BCPM setup and requires a bit of
forethought so have a good idea of what you need to put in here before you start.
Once you have finished, remember that you can get a record of the set-up you
have created by making a report file in the BCPM_Info page. This will allow you
to print the Transmission type/rate and FID sequences are for reference while the
tool is downhole.

The remaining pages in the BCPM program are for information purposes only.
The BCPM_DLC page gives the current state of the downlink controller node and
should be checked to ensure that communication is OK. Unless the tool is being
pumped through, all values should be zero, the downlink status should be “Wait”
and the Downlink Quality should read “No Signal”.

The BCPM-Test screen gives a brief summary of the PDB-CTL, BRK-CTL and
BCPM-DLC pages.

AutoTrak Generation 2.5 Operation Manual 25

ATM25

The ATM 25 program is used to set up and

test the functionality of the Master in the
Sensor Sub. When starting the program
you will be presented with three pages
Start with selecting the ATM Info page.
Check the ATM configuration file *.0h5, is
the one you require. There is also a floppy
disc icon you can press to generate a
report file. Wait until you have been
through the rest of the pages and set up
the master before generating the report
file.

Tick all the modules that will be connected

to the tool. NOTE: If you do not select a
module the master will not communicate
with it. I.e. no transmitted data and no
memory data.

Next, go to the ADS-Set page. If the

required ATM configuration file is not the
current setup, press the configuration
button. You will be asked to select the
required configuration file. Take care: with
pressing the “Burn Configuration” button,
the new configuration file will start loading,
no “are you sure” warning prompts are
shown. During this process, the buttons at
the bottom of the screen will be grayed
out. When they return to black the burn
process is complete. This is the only
indication that the configuration has
loaded and the process is finished Press
cancel to get back to the ADS-Set page.
The Flow off setup should be set to 90
seconds.

Since there are a small number of

configuration files available for
AutoTrak 2.5 it is very important to
check the memory file initial and cycle
times.

The DIR-Test page allows for the

checking of raw accelerometer and
magnetometer values from the directional
sensor and to view the values derived
from them.

AutoTrak Generation 2.5 Operation Manual 26

Setting Azimuthal Gamma Correction

On this screen the Toolface

Adjustment can set the for
azimuthal gamma readings.
Orient the sensor sub such that
the scribe on the RNT sub is
set to 90° right when looking
downhole. In this position,
Gamma 1 is pointing up and
Gamma 2 is pointing down.
Press the “Toolface Adjust” button to get the screen below.

By pressing the Auto Corr. Button, the corrected toolface should read zero, and
the required toolface offset to achieve this correction will be calculated. Now,
when an azimuthal gamma telemetry format is selected, the toolface transmitted
will be that of Gamma Sensor 1. The correction required can be set manually
using the Set Corr. Button.

Another option available on

this screen is the ability to
test the survey function. By
pressing the “Flow Off
Measurement” button, the
accelerometer and
magnetometer registers in
the directional sensor will be
read. These are the
numbers that the Master
looks at and transmits to
surface in the raw survey.
Check these figures and
make a note of the raw
values. Turn the tool a few
degrees, close all the
programs and then cycle
tool power for 2 minutes and check them again, if the raw numbers are different,
the tool has taken a new survey and you have verified the function of the tool's
battery. If the numbers are exactly the same, there is likely to be a battery fault
and the sensor sub should be changed out. Using this procedure will save
dumping and viewing the 3307ffff memory. NOTE: The programs must be
closed before the power is cycled to allow the tool master to take the
survey.

Now after all options have been set up which are required in the Master, go back
to the ATM-Info screen and press the Floppy Disc icon to create a report file to
document the changes made to the master.

AutoTrak Generation 2.5 Operation Manual 27

AT2

This program allows you to test the

functionality and set up of the
Steering Unit. The ADC Ctl screen is
an information screen showing the
raw and calculated outputs from the
accelerometers and temperature
sensor in the sleeve.

On the next page (AT Main Ctl), you

will preprogram the initial steering
parameters for the steering unit.
Normally, the tool will be run in hole
in Ribs Off mode. No pressure will be
applied to the ribs in this mode so in
order to test the unit properly set the
tool to Steer mode with an
appropriate force prior to continuing
to the next page.

If you set the Steering Unit to Steer or

Hold mode in the previous screen, the
ribs on the tool should now be
extended. The calculated pressure on
each rib may be compared to the
actual pressure being applied in the
Motor Ctl page. Also check the current
draw and motor RPM.

Guidelines for these values are as

follows:

Expected rib pressures and associated motor RPMs/Current draws

Target Pres. 50 bar 100 bar 150 bar 200 bar

Actual Pres. +/- 3 bar +/- 3 bar +/- 3 bar +/- 3 bar
Motor Current 0.075 A 0.200 A 0.400 A 0.625 A
Motor RPM 400 825 1125 1375
Actual test data, allow 10% tolerance on the Motor values.

If these values are outside the suggested ranges, the Steering Unit should be
considered suspect. Call Tech Services or the job coordinator for advice.

AutoTrak Generation 2.5 Operation Manual 28

 Next, select the Steering Unit Test
tab. Here you can test target rib
pressures against actual rib
pressures and motor Rpm’s. This
would mainly be of interest during
maintenance for checking rib
calibrations and functionality.
However it is worth checking at
the rigsite. The Gravity Toolface of
the sleeve may be changed by
turning the sleeve by hand or test
values may be input by checking
the manual button and typing in
the desired value.

The info button at the bottom of the

screen should always be checked.
The new screen will show the ADC
Gravity toolface offset. This should
be 90 degrees. There has been an
instance where this value was
incorrect, and thus it should always
be confirmed at the rigsite.

The last page of the AT2 program is the Tool Info page. There is no facility to
save this information to a text file so should you need these part numbers, serial
numbers, software revisions and dates for paperwork, you will need to make a
screen dump of the window.

AutoTrak Generation 2.5 Operation Manual 29

Vibration

To perform a communication test of

the vibration module, run the
Vibration program. This will simply
tell you if you can communicate with
the vibration module and should
display vibration values of 0. The tool
information page gives the VMM
module part number.

AutoTrak Generation 2.5 Operation Manual 30

DRILLING PROCEDURES
In Ribs Off mode with these tools, a titanium leaf spring under tension draws the
ribs back into the retracted position. This ability means that many of the
precautions like the trip in procedure when running 1.5 Generation tools are no
longer necessary with 2.5 tools. However, bear in mind that the leaf springs only
exert about 10 bar back pressure so it may take some time for the ribs to retract.
If in doubt, it is better to assume that the ribs are out after any period of pumping
in any mode other than Ribs Off and the usual precautions should be observed
until you are sure the ribs are in.

Running in Hole.
This will always be done in Ribs Off mode. The ribs will not extend even when
pumping through the tool at operating rate. Therefore:
1. There are no trip speed restrictions from the Autotrak tool.
2. No longer required to slowly rotate after filling the pipe.
3. The titanium springs should keep the ribs fully retracted when in Ribs Off
mode. However it is still good practice to know of any restriction in Hole I.D
and therefore you need to continue to complete the Hole Restriction I.D Form.

Reaming / Logging into Hole

1. In most circumstance Ribs Off will be used.
2. No restriction due to AutoTrak on reaming / logging speed. Use 90 - 100
RPM and monitor stick slip values. Change RPM as necessary.
3. If there is a risk of sidetracking, downlink to Steer Force 0 %, Steer direction 0
deg, and follow Autotrak 1.5 Generation procedure.

Reaming / Logging out of Hole

1. During any prolonged duration of backreaming Ribs Off mode should be

used. There are no AutoTrak specific backreaming speed restrictions when
in Ribs Off mode.

2. For backreaming on connections follow the AutoTrak 1.5 Generation

procedures.

3. If formation ledges/hole washouts are suspected that the ribs might expand
into it is possible to damage the ribs in the same way that 1.5 tools are
damaged. It would obviously be time consuming to downlink in and out of
Ribs Off on each connection. Therefore:
Check with the client and see if it is possible to backream at below the
operating flow rate of the tool. This will remove the hydraulic oil pressure on
the ribs. However note that it takes several minutes for the hydraulic oil
to drain back into the oil reservoir of each rib i.e. several minutes for the
ribs to retract. Therefore slow rotate for several minutes before pulling to
allow time for the hydraulic oil to drain and the pressure to go to zero

AutoTrak Generation 2.5 Operation Manual 31

 If the client does not accept backreaming at a reduced flow rate then 1.5
Generation procedure should be followed or if time permits downlink to Ribs
Off.

Drilling out Cement/Shoetrack/Shoe

1. Keep tool in Steer Mode 0% force. Drill out float equipment / shoe-track /
shoe at normal parameters. Control drill WOB and RPM only as dictated by
stick slip values and client request.

2. Downlink to Ribs Off to Wash / Ream any rat-hole and drill first 2m of new
formation until sleeve is in new hole before downlinking the required steering
commands and drilling ahead.

3. If an F.I.T. test is required, downlink to Ribs Off until the operation is complete
and ready to drill ahead again. As always care should be taken when pulling
back into the shoe, but there are no restrictions on flow rate / RPM other than
the operating limits of the tool.

AutoTrak Generation 2.5 Operation Manual 32

RE-RUN Qualification / Trouble Shooting
For the generation AutoTrak 2.5 tools similar re-run criteria’s as for the 1.5 tools have to
be applied. The numbers of circulation hours below are guidelines, which should be
checked with Technical Services in Celle from time to time in regard to the latest finding
in lifetime of ATK 2.5.

Lay down the tool after 75 circulation hours in case the next run is equipped a PDC Bit.
Lay down the tool after 100 circulation hours in case the next run is with a Tricone Bit.

Any difference from the criteria’s above needs to be discussed with Technical Services
in Celle.

Flush Rib Hydraulics

Problems have been encountered
during disassembly of the hydraulic
units due to mud sedimentation
inside the units. To minimize this
problem, each hydraulic unit should
be thoroughly washed out with a
high-pressure hose after each run.
The compensation ports and the
gap between the hydraulic unit and
the sleeve body should be
thoroughly washed.

Rib Hydraulics showing no pressure after post deck test

In some ATK 2.5 runs suspicious hydraulic unit behavior was observed even though no
downhole failure is reported so far. The hydraulic units were showing 100% functionality
downhole, while on surface the units were not able to build up pressure but running with
idle ~6000 rpm.

The rib hydraulics are still under Engineering observation. In case a back up Steering
Unit is available at the rig send the one with the “suspicious” rib hydraulics back to the
workshop and pick up the back up unit.

However, the Steering Unit can be re-run if no back up is available it. While running in
hole and with an increase in hydrostatic pressure, the gas (which went into the rib
hydraulic oil cycle while POOH) should escape and the rib hydraulic should recover its
function again.

AutoTrak Generation 2.5 Operation Manual 33

No communication to the Steering Unit
There have been rare occasions when the pumps come up and there is no
communication with the steering sleeve. This is manifested by system errors on one or
all of the following nodes ADC, PID and (or) AT2. If communication is lost with the
sleeve cycle the pumps for at least two minutes, which should reset the sleeve
electronics. Cycling the pumps may have to occur a couple of times to get
communication back with the sleeve.

Transmitted 0’s and 1’s.

If there is a problem with the tool communication between the master and any of the
other nodes you will get an error for the relevant node, a system error and all zeros or all
1’s will be transmitted from the effected node(s). In combinatorial all zeros means that
the tool will still pulse but the pulses will refer to the zero position in the look up table.
The displayed value will be the lower value possible for the word being transmitted, or
the first possible number. In the example above the lower value for RPMX is 32.

AutoTrak Generation 2.5 Operation Manual 34

APPENDICES
Appendix A: Connection Makeup Torques

AutoTrak Generation 2.5 Operation Manual 35

 Appendix B : Technical Data Sheet
Technical Data Sheet

6¾” AutoTrak 2.5RCLS

General Description
AutoTrak Generation 2.5 Rotary Closed
Loop System (RCLS) is a technically
advanced, modular drilling & MWD system.
Directional Collar

It opens new opportunities in all aspects of

Directional Sensor directional drilling, including both
geosteering and extended reach applications.
The tool can steer itself during continuous
rotation of the drill string. While drilling,
changes of the well trajectory are
communicated to the tool from the surface.
Gamma ray, multiple propagation resistivity
7.1m and vibration measurements support unique
(23.3ft) 3-dimensional control of the drilling
13.6m process.
(44.6ft)
Reservoir Navigation Sub

Service Benefits
• Continuous steering while rotating
Resistivity - minimised torque & drag
- improved hole cleaning
Gamma Ray
- higher ROP
- reduced differential sticking
Vibration - bit selection for performance
• Automated directional control
- improved horizontal TVD control
- reduced hole tortuosity
Power & Communication Module

• Formation evaluation
- Multiple Propagation Resistivity
- Gamma Ray
• Two way communication
9.4m - Multiple MWD commands
(30.7ft) - Adjustable direction (toolface)
- Adjustable dogleg severity
9.0m - Section can be drilled in one run
(29.5ft)
• Optional High Speed Nuclear /Triple
8.5m Combo FEMWD services in real time
7.5m (28.0ft) measurement
(24.7ft) - Density Lithology (ORD, MDL)
- Neutron Porosity (CCN, MNP)
- Flow On/Off Pressure (MAP)
- BHA Dynamics, Downhole WOB, RPM,
ECD. Real Time Torque & Drag
(CoPilot)
AutoTrak Steering Head

Inclination

1.0m
(3.1ft) The AutoTrak system was developed jointly by
Baker Hughes INTEQ and AGIP SpA

AutoTrak Generation 2.5 Operation Manual 36

 General Tool Specifications
Borehole Size:
Build Rate:
Tool OD:
Length:
Weight:
Connections:
8-1/2” hole size
Operating Specifications and Limits
Flow Rate: Low flow
Flow Rate: Standard
Flow Rate: High Flow
Flow Rate Low Flow Downlink
Operation
Flow Rate Standard Downlink
Operation
Flow Rate High Flow
Downlink Operation
Maximum WOB:
Maximum Tool Rotation:
Maximum Drilling Torque:
(at the Bit)
Maximum Torque To Failure:
Maximum Overpull
(Continued Operation):
Maximum Overpull To
Failure:
Max. Temperature: Operating
Survival*
Maximum Hydrostatic
Pressure:
Maximum Bit Pressure Drop:
Sand Content:
Max LCM
Higher concentration can be
run upon request
Maximum DLS For Tool
Passage:
Tool RPM
Axial & Lateral Vibration:
AutoTrak Generation 2.5 Operation Manual
Sesor Specifications
8-1/2” standard Propagation Resistivity
9-1/2”, 9-7/8” optional Distance From Bit 30.7 ft (9.4 m)
0 - 6.5 °/100ft (30 m)
2 MHz Resistivity
6-3/4”
Steerable Stabiliser 7-3/4” Phase Difference Range: 0.1 - 3000 ohm-m
Accuracy:
47.9 ft (14.6 m) ± 1% (0.1 - 50 ohm-m),
4,200 lb (1,900 Kg) ± 0.5 mmho/m (>50 ohm-m)
Up: NC50 Box Attenuation Range: 0.1 - 500 ohm-m
Down: 4-1/2” API Reg Box Accuracy:
± 2% (0.1 - 25 ohm-m),
± 1.0 mmho/m (>25 ohm-m)
290 - 450 GPM Vertical Resolution 8" (20cm) for 90% response
1,000 – 1,700 l/min in conductive beds
370 - 660 GPM 400 kHz Resistivity
1,400 – 2,500 l/min Phase Difference Range: 0.1 - 1000 ohm-m
400 – 900 GPM Accuracy:
1500 – 3400 l/min ± 1% (0.1 - 25 ohm-m),
330 - 450 GPM ± 1.0 mmho/m (>25 ohm-m)
1,250 – 1,700 l/min
Attenuation Range: 0.1 - 200 ohm-m
460 - 660 GPM
Accuracy:
1,750 – 2,500 l/min
± 5% (0.1 - 10 ohm-m),
630 – 900 GPM ± 5.0 mmho/m (>10 ohm-m)
2400 – 3400 l/min
Vertical Resolution 12" (30 cm) for 90% response in
55,000 lbs / 250 kN conductive beds
400 rpm
14,500 ft.lbs Gamma Ray
20 kNm Distance From Bit 29.5 ft (9.0 m)
22,000 ft.lbs / 30 kNm Sensor Type Scintillation (x2)
109,000 lbs Measurement API GR
487 kN Range 0 - 250 API
578,000 lbs Accuracy ± 3% of full scale
2,620 kN Statistical Repeatability ± 3 API @ 100 API and
300 °F (150 °C) ROP = 60 ft/hr (18.3 m/hr)
311 °F (155 °C) Vertical Resolution 6” (15.3 cm)
20,000 psi
1,380 bar Near Bit Inclination
No Limitation Distance From Bit 3.1 ft (1.0 m)
1%, max. volume, Sensor Type Tri-axial Accelerometer
(<0.5% recommended)
40 ppb = 114 Kg/m3 Directional
Fine nutplug
Distance From Bit 44.6 ft (13.6 m)
With Rotation: 9 °/100ft Sensor Type Tri-axial Accelerometer
Without Rotation: 11 °/100ft Tri-axial Flux Gate
±80% Maximum deviation
Vibration
from Operating RPM
(e.g. 100RPM: Operating Range=20–180) Distance From Bit 28.0 ft (8.5 m)
5 g RMS (1 - 250 Hz; 1 sec Sensor Type Tri-axial Accelerometer
integration) or equivalently
45 g peak (0.025 sec shock
pulse duration) *.Tool must not be exposed to either static or circulating
(from recorded memory or as flagged by
corresponding real-time severity level) temperatures which exceed 160 °C due to limits on lithium
battery component in the system
37
 Appendix C : Fishing Diagrams 6.3/4” AutoTrak 2.5
Run #____________ Client____________ Well____________
(please write down the S/N of Sensor Sub, BCPM, Flex Sub and Steerable Stabilizer)

Fishing Dimensions Measured in Field

L29 L30
Section Length Outer Æ Length Outer Æ
[m] [mm]
Sensor Sub L1 0,240 192,0
SHE____________
L28
L2 1,500 196,8
L3 0,430 178,2

L4 0,316 178,2
L27

L5 0,348 215,5
L26

L6 0,134 178,2
L7 0,937 127,0
L24 L25

L8 0,371 178,2
L9 0,350 178,2
L22

L23

L10 0,072 178,2

L11 1,246 184,8
L21
L20

L12 2,000 178,2

L13 0,426 178,2

Total Length = 15,10 m Standard Tool

L19

L14 0,425 157,8

L16

L18

L17

L15 0,203 163,8

L16 0,586 177,8
L13 L14

L15

L17 0,202 171,5

L18 0,027 177,8

L19 0,202 171,5

L20 0,586 177,8

L12

L21 0,203 163,8

L22 0,365 157,8

L23 0,177 178,2

L11

L24 0,353 212,5

BCPM
HBC____________ L25 0,490 171,8
L8 L9

L10

L26 0,546 171,8

L27 1,010 139,7

L7

L28 0,923 171,8

L29 0,330 175,5
Flex Sub
L4 L5

L6

L30 0,508 175,5

FLX____________

Field Measurement Total Length in [m]

L3

Stabilizer Data Item 24 in [inch]

Blade Length
Steerable Stabilizer
L2

Gauge Length
ASS____________ Gauge Width
Stabilizer Gauge
L1

AutoTrak Generation 2.5 Operation Manual 38

 6.3/4” AutoTrak 2.5
Run #____________ Client____________ Well____________
(please write down the S/N of Sensor Sub, BCPM, Flex Sub and Steerable Stabilizer)

Fishing Dimensions Measured in Field

L29 L30
Section Length Outer Æ Length Outer Æ
[ft] [inch]
Sensor Sub
SHE____________ L28
L1 0 787 7 559
L2 4.922 7.748
L3 1.411 7.016
L4 1.037 7.016
L27

L5 1.142 8.484

L6 0.440 7.016
L26

L7 3.074 5.000
L24 L25

L8 1.217 7.016
L9 1.148 7.016
L22

L23

L10 0.236 7.016

L11 4.088 7.276

L21
L20

L12 6.562 7.016

Total Length = 594,48 inch Standard Tool

L13 1.398 7.016

L19
L16

L18

L17

L14 1.394 6.213

L15 0.666 6.449
L13 L14

L15

L16 1.923 7.000

L17 0.663 6.752
L18 0.089 7.000
L19 0.663 6.752
L20 1.923 7.000
L12

L21 0.666 6.449

L22 1.198 6.213
L23 0.581 7.016
L24 1.158 8.366
L11

BCPM L25 1.608 6.764

HBC___________ L26 1.791 6.764
L9

L10

L27 3.314 5.500

L8

L28 3.028 6.764

L29 1.083 6.909
L7

L30 1.667 6.909

Flex Sub
FLX____________
L4 L5
L6

Field Measurement Total Length in [m]

L3

Stabilizer Data Item 24 in [inch]

Blade Length

Steerable Stabilizer Gauge Length

L2

ASS____________ Gauge Width

Stabilizer Gauge
L1

AutoTrak Generation 2.5 Operation Manual 39

Appendix D : New Terminology.
ADC: Analogue/Digital Converter

AT2: AutoTrak 2. Refers to the Steering Head.

BCPM: Bi-Directional Communication and Power Module.

CBR: Circuit breaker

P.I.D: Proportional Integral Derivative. Motor and rib pressure feedback controller.

PDB: Pulser Driver Board

_FlowOff:
This variable is for test purposes and simulates a flow-off condition to the master.
Consequently, the master initiates flow-off surveys according to the "initial" and "cycle"
parameters.
_MudPulser:
This variable determines the active status request from the ATM towards the BCPM, meaning
the ATM asks the BCPM for the time when the ATM has to supply which data word next. The
"cycle" value serves as a fall-back to the regular BCPM answers in case the answer do not
occur for any reason.
_DL_Trap:
Starting "initial" seconds after flow-on, the ATM sends reset commands every 10 seconds for
"cycle" times to the DLC node. This resets all DLC registers and effectively clears any
potentially received downlink pulse. The default values of "40" and "6" mean: The downlink is
active until 40 seconds after flow-on. This allows sending a downlink before the first data rate
pulse. Followed by a period of 60 (6*10) seconds where the DLC is continuously reset.
The "downlink trap procedure" is active every time when new data rate pulses are to be sent.
As such the downlink trap function also executes during the first survey after a downlink --
most commonly the downlink confirmation survey.
_AT2:
Requests "fresh" data from the steering head. This is soley a convenience procedure to have
up-to-date data in case you monitor the tool with busmon et al
_Get_DLC:
Start polling the DLC node "inital" seconds after flow-on and repeat requests every "cycle"
seconds. You may notice, that the downlink trap does not actually prohibit the downlink
requests rather than cancelling the DLC registers periodically.

AutoTrak Generation 2.5 Operation Manual 40

Appendix E : Tool Specific Telemetry Words
Telemetry Word From ADAM Bus Word

DATA ACTGZBX ADCnode AT2_GZMA Single Axis (z) Accel value. This can be calculated as
Z-axis Inclination and compared to the 3-axis
inclination value ACTINNX
DATA ACTHTFX AT2node AT2_GTFA Current High Side toolface stored in the AT2-Main
Node. Discrepancies between this and CURHTFX
signal that internal AT2 comms are not working!
DATA ACTINNX AT2node AT2_INCA 3-axis Accel Inclination value. This value is obtained
by the AT2node from the ADC node automatically. If it
never changes, Internal comms could be bad.
DATA NBABULDX AT2node AT2BULDA Build Force in Percent. This value is positive or
negative
DATA NBACNTLX AT2node AT2CNTLA Control Method. 0 = Hold, 1= Steer, 3 = Ribs Off
DATA NBAFRCEX AT2node AT2FRCEA Steering Force in Percent. This value is positive.
DATA NBATARGX AT2node AT2TARGA Target Inclination value for Hold Mode
DATA NBAVECTX AT2node AT2VECTA Steering Angle. Direction to steer to in Steer Mode.
DATA NBAWALKX AT2node AT2WALKA Walk Force in Percent. This value is positive or
negative, and determines how much "side force" to
apply while in Hold Mode
DATA TARG_PRES1X AT2node T_PRES1A Calculated pressure. This value is sent internally to the
PIDnode, which then builds up this pressure. Compare
with CUR_PRES1X to detect rib problems.
DATA TARG_PRES2X AT2node T_PRES2A Calculated pressure. This value is sent internally to the
PIDnode, which then builds up this pressure. Compare
with CUR_PRES2X to detect rib problems.
DATA TARG_PRES3X AT2node T_PRES3A Calculated pressure. This value is sent internally to the
PIDnode, which then builds up this pressure. Compare
with CUR_PRES3X to detect rib problems.
DATA CBR_B1X CBRnode CBR_B1A CBRnode Upper Breaker Status. 0 if Open, 1 if Closed
DATA CBR_B2X CBRnode CBR_B2A CBRnode Lower Breaker Status. 0 if Open, 1 if Closed
DATA CBR_PWRAX CBRnode CBR_PWRAA Current flowing through CBRnode Upper Breaker. In
Amperes.
DATA CBR_PWRBX CBRnode CBR_PWRBA Current flowing through CBRnode Lower Breaker. In
Amperes.
DATA CBR_TCDX CBRnode CBR_TCDA Measured temperature in DegC
DATA CBR_VOLTAX CBRnode CBR_VOLTAA Voltage Present at Upper Breaker
DATA CBR_VOLTBX CBRnode CBR_VOLTBA Voltage Present at Lower Breaker
DATA CBR_VOLTCX CBRnode CBR_VOLTCA Voltage Present Internally to CBRnode
DATA DLC_RPMX DLCnode TRPMA The measured RPM signal for decoding Downlinks.
Since this value is taken from two phases of the
alternator, the tool could still run if one of the phases is
bad. DLC_RPMX could then be zero.
DATA PDB_ALTX PDBnode PDB_ALTA CBRnode Alternator input voltage. This is the Supply
Voltage for the Tool
DATA CUR_HTFX PIDnode C_HTFA Current High Side toolface of the Non-Rotating Sleeve.
DATA CUR_PRES1X PIDnode C_PRES1A Pressure currently present on Rib #1. Averaged 2
seconds
DATA CUR_PRES2X PIDnode C_PRES2A Pressure currently present on Rib #2. Averaged 2
seconds
DATA CUR_PRES3X PIDnode C_PRES3A Pressure currently present on Rib #3. Averaged 2
seconds
DATA ADCM30ERX STATnode STAT_ADCERRA Flag for bad M30 comms with ADCnode
DATA AT2M30ERX STATnode STAT_AT2ERRA Flag for bad M30 comms with AT2node
DATA CBRERX STATnode STAT_CBRERRA Slave Status
DATA DIRERRX STATnode STAT_DIRERRA Slave Status
DATA DLCERRX STATnode STAT_DLCERRA Slave Status
DATA PDBERX STATnode STAT_PDBERRA Slave Status
DATA PIDM30ERX STATnode STAT_PIDERRA Flag for bad M30 comms with PIDnode
DATA SENSFLAGX STATnode Mode of PID. 0=Pressure, 1=Power
DATA SWWPERRX STATnode STAT_SWWPERRA Slave Status

AutoTrak Generation 2.5 Operation Manual 41

Appendix F : Hercules TCS System
Hercules TCS
Tool Control System
Jim Ripolone
Feb. 21, 2001

The TCS was designed to satisfy the greater demand of power and communication speed
required by the new fleet of downhole tools. It is capable of providing 300 watts of DC power with
an output voltage of +33 volts. In addition to the IO1039 communication line which is used for
diagnostics and program upgrades, there is an Ethernet line which allows for high speed memory
dumping ( > 5Mbytes/minute ).

The following block diagram illustrates the two possible configurations for connecting the TCS.
The limitation of 300 feet for the cabin is dictated by the Ethernet communications. When logistics
don’t allow for the cabin setup the laptop version can be used. In the laptop version pulser
decoding is omitted.

Hercules - TCS
Tool Control System Cabin

Hercules Tool String

Decode
1039

Dump
Breakout
50 Feet 300 Feet
TCS Memory Dump
+33VDC or optionally Pulse Detect
M30 Dump Speed >5MBytes/min. Diagnostics
100 Feet
IO1039 DC Power = 300 Watts
*HOT WORK PERMIT REQUIRED
Ethernet
Breakout
Volts Amps
Dump
1039

100 feet Laptop

2/21/01 115/230 Volt AC Power Source

AutoTrak Generation 2.5 Operation Manual 42

The picture below illustrates the cabling of the suitcase version of the TCS. Note the absence of a
connector on the power cable. Because of the variety of connectors worldwide no connector is
provided. For making connections observe the following list:
Black L1
White L2
Red Earth

AutoTrak Generation 2.5 Operation Manual 43

The next picture illustrates the front panel of the TCS. When applying power to the TCS for the
first time observe the following procedure:
Ensure both power switches are in the off position.
Ensure the tool cable is removed from the TCS.
Activate the input power switch and observe power LED is lit and both meters read ~ 0.
Activate the tool power switch and observe the voltmeter reads ~ 33 volts and verify tool LED is
lit.
De-activate the tool power switch and verify voltmeter reads ~ 0.
Connect the tool cable and verify voltmeter still reads ~0. Another voltage indicates power is
coming from the tool and the tool power switch should not be activated. Communication to the
tool is still possible.
If no voltage is coming from the tool, activate the tool power switch.

AutoTrak Generation 2.5 Operation Manual 44

The next simplified diagram illustrates the functionality of the TCS box.

Hercules - TCS
Tool Control System
To Tool Ethernet 2 TP To PC
IO1039 1TP RS485 1 TP
5 TP +33 VDC COMMS Communications 4 TP
18 AWG Converter 24 AWG
V
2 TP

A DC Modem/
OUT Local P.S.

Pulse Pulse Signal 1 TP

Detect

Power System
M33 AC IN

To AC Power
2/21/01 3 Cond 18 AWG

AutoTrak Generation 2.5 Operation Manual 45

The final picture shows the cabling to the breakout box.

AutoTrak Generation 2.5 Operation Manual 46