Extreme Networks PowerDrive Orbit Benutzerhandbuch

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PowerDrive Orbit & X6

Quick Operations Guide

Revision 1.4

6 March 2020

 
PowerDrive Orbit & X6 
Quick Operations Guide - rev1.4 
 
Extreme Equipment Rentals 
Page 2 of 35 
 
 
This document should serve as a basic guide for Extreme Equipment Rental clients for 
planning and executing a successful PowerDrive Orbit or X6 job in North America. 
 
Contents 
 
1JOB PLANNING...........................................................................................................................................3 
1 BHA DESIGN.........................................................................................................................................3 
1.1 Stabilization....................................................................................................................................3 
1.2 Motor Selection..............................................................................................................................3 
1.3 Bit Selection...................................................................................................................................3 
1.4 Additional Considerations ..............................................................................................................3 
2 HYDRAULICS .........................................................................................................................................4 
2.1 Optimizing Hydraulics ....................................................................................................................4 
2.2 Pressure Calculator on the PowerDrive App .................................................................................4 
2.3 Flow Restrictor Use and Availability ..............................................................................................5 
3 MAGNETIC MATERIAL REMOVAL .............................................................................................................5 
4 TOOL SPECIFICATIONS...........................................................................................................................5 
2TOOL PREPARATION.................................................................................................................................6 
1 REVIEWING TOOL PAPERWORK ..............................................................................................................6 
1.1 Tool Configuration..........................................................................................................................6 
1.2 Flow Loop Results .........................................................................................................................9 
1.3 Operating Envelope.....................................................................................................................10 
2 FLOW RESTRICTOR INSTALLATION........................................................................................................11 
3 BHA MAKEUP......................................................................................................................................11 
4 SURFACE TESTING –NOT ADVISED ......................................................................................................11 
3JOB EXECUTION.......................................................................................................................................12 
1 TRIPPING IN /FILLING PIPE...................................................................................................................12 
2REAMING /BACK-REAMING ..................................................................................................................12 
3 CASING DRILLOUT ...............................................................................................................................13 
4 DOWNLINKING .....................................................................................................................................13 
4.1 Downlinking Basics......................................................................................................................13 
4.2 Sending the Downlink ..................................................................................................................14 
5 KICKING OFF FROM VERTICAL ..............................................................................................................15 
6 INCLINATION HOLD (IH) &HOLD INCLINATION AND AZIMUTH (HIA)..........................................................15 
6.1 Inclination Hold (IH) .....................................................................................................................15 
6.2 Hold Inclination and Azimuth (HIA)..............................................................................................16 
6.3 Rate of Penetration Ranges ........................................................................................................17 
7 POWERVLOCK/UNLOCK......................................................................................................................18 
8 SIDETRACKING ....................................................................................................................................19 
9 CLEANUP CYCLES................................................................................................................................22 
10 RE-RUN EVALUATION ..........................................................................................................................23 
4TROUBLESHOOTING................................................................................................................................24 
1 LOW DOGLEG WORKFLOW...................................................................................................................24 
2 ANTI-JAMMING PROCEDURE.................................................................................................................24 
3 SHOCK &VIBRATION............................................................................................................................25 
5REQUIRED END OF RUN DATA...............................................................................................................26 
6DOCUMENT REVISION HISTORY............................................................................................................27 
APPENDIX 1 –REAL-TIME D-POINTS:..........................................................................................................28 
APPENDIX 2 –FISHING DIAGRAMS:.............................................................................................................29 
 

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 3 of 35

1 Job Planning

1.1 BHA Design

1.1.1 Stabilization

All PowerDrive BHA’s should have at least 2 stabilizers.The first stabilizer should be located on

the PD control collar or directly behind it. The 2nd should be 30-40 feet behind the first. Proper stabilizer

placement ensures optimal steering response and minimizes shock & vibration damage. Depending

on the BHA design, a 3rd stabilizer may be added another 30-40 feet behind the 2nd stabilizer. This

may aid in shock & vibration mitigation on the MWD but will have minimal effect on steering.

The first stabilizer should be 1/8” Under-gauge from the hole-size. The additional stabilizers may

be 1/8” or ¼” Under-gauge depending on the application.

Stabilizers should have spiral wrap, short gauge, and long tapers. A good rule of thumb is to aim

for a gauge length that is 50% of the hole-size and 60 degree taper. This design optimizes steerability

while preventing stabilizer jamming.

Roller Reamers may be used in place of stabilizers to reduce torque and stick-slip. Do not use

eccentric reamers or hole-openers in place of stabilizers.

1.1.2 Motor Selection

Bearing sections must be fixed-straight, not adjustable dialed to zero. Adjustable motors, even

when dialed to zero bend, have an offset that can initiate vibration.

Consider the PowerDrive RPM specification (220 for X6, 350 for Orbit) when choosing rev/gallon

of the power section. Exceeding the RPM specification will lead to reduced dogleg and tool damage.

1.1.3 Bit Selection

Extremely aggressive bits can cause stick-slip and whirl. These dynamics may lead to tool

damage, reduced dogleg, and lower ROP.

Tapering or under-cutting the back end of the gauge pad is recommended to maximize dogleg

and prevent excessive torque or stick-slip. This also allows for longer gauge lengths in

tangent/horizontal sections to improve stability.

“Active Gauge” bits should be avoided as the negative effects outweigh any benefits.

Depth of cut management features can aid in minimizing stick-slip but avoid placing them on the

shoulder of the bit as this may reduce dogleg significantly.

1.1.4 Additional Considerations

Flex Ponies and Collars should generally be avoided, especially in tangents or horizontals, as they

increase the odds of shock and vibration damage. A short Flex Pony directly on top of the PD tool will

increase the maximum dogleg by 1-2 degrees but should only be used if truly necessary.

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 4 of 35

1.2 Hydraulics

1.2.1 Optimizing Hydraulics

The Bias Unit uses the mud ﬂow to activate the steering

pistons or pads, exerting a side force on the bit. This

operational principle requires a pressure drop between the

steering unit and the annulus, which can be achieved by a

combination of bit nozzling and a ﬂow restrictor inside the

steering unit.

The amount of steering force is proportional to the

differential pressure across the pistons or pads. Insufﬁcient

piston or pad pressure will result in a reduced BHA steering

response, and excessive pressure will increase the risk of

causing damage to the tool. The following table should be

used when optimizing hydraulics.

Recent US Land experience has shown that excessive

pressure with Orbit may also lead to reduced steering

response by breaking down the formation rather than

pushing off of it. For this reason, it is advised to stay in the

green or lower-yellow regions unless local experience

suggests that running in the upper-yellow range is truly

necessary.

1.2.2 Pressure Calculator on the PowerDrive App

The Pressure Calculator on the PowerDrive App should be used during

the planning stages and on the rig for real-time hydraulics adjustments.

PD2is the old hydraulic calculation method, it requires installing a

separate program on a personal computer. The PowerDrive App has

the most accurate output and is the preferred method for calculating

PowerDrive hydraulics.

When planning an Orbit job, it is safe to use 0.08 mm as a default ball-

sleeve radial gap. But the DD’s must be sure to re-run hydraulics once

they know the gaps for their specific tool. These can be found on the

first page of the PD Outgoing Systems Test (OST) paperwork. Entering

incorrect ball-sleeve gaps can lead to inaccurate pad pressures.

Request the calculated bearing loss from the motor vendor for all mud-

lubed or sealed bearing motors. Be sure the motor vendor considers

the mud properties and higher than normal pressure drop below the

motor when providing their estimate. These should be entered into the

PowerDrive App for accurate pad pressure calculations. “Sealed”

Bearings may have more leakage than mud-lubed bearings. It is

suggested to request new radial bearings when ordering motors to

avoid excessive leakage. Some motors may leak over 25% fluid and

still meet the vendor’s re-use criteria.

The PowerDrive App is color coded as shown in the top image to turn

green when the pressure drop is within the optimal range. The

pressure drop will increase/decrease as the nozzle sizes are changed

or a flow restrictor is added. Important: The number of nozzles and

their sizes must be reflected on the downhole setup of the bit.

The Pressure Drop Chart can be utilized while drilling to update the

Real-Time Pressure Drop across the PowerDrive. This is critical as the

Mud Weight, Pump Rate and Total Leakage change during a run. It is

important to maintain a Pressure Drop in the green zone as these

parameters change.

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 5 of 35

1.2.3 Flow Restrictor Use and Availability

If the desired pad pressure cannot be achieved by nozzling the bit alone, a flow restrictor can be used.

A PowerDrive Flow Restrictor provides additional pressure drop at the RSS tool to increase pad

pressure and force without affecting the bit TFA. PD2includes the ability to suggest a flow restrictor

size to achieve a desired pad pressure. Be sure to verify the suggested size is available in the standard

restrictor kit list below.

475 Restrictors (x/32“) - 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20, 22, & 24

675 Restrictors (x/32“) - 16, 18, 20, 22, 24, 26, 28, 30, & 32

900 Restrictors (x/32“) - 26, 28, 30, 32, 34, 36, & 38

1.3 Magnetic Material Removal

Magnetic material present in the mud is highly detrimental to the performance of the PowerDrive control

unit. Magnetic material passing through the torquers causes excessive friction and can lead to toolface

stability issues or complete torquer jamming. To mitigate magnetic material related issues, it is

mandatory to run ditch magnets in the circulating system and clean them at least twice daily.

Ditch magnets should be installed in the flow line, header tanks, and/or possum belly of the shale shakers.

Ditch magnets should be installed and cleaned prior to picking up PowerDrive to ensure the tool is

introduced to a clean system. When adding pre-mixed mud from an outside source, efforts should be

made to run that mud across the magnets prior to pumping it downhole for the first time.

1.4 Tool Specifications

Specifications

PowerDrive X6

PowerDrive Orbit

475 X6

675 X6

825 X6

900 X6

1100 X6

475 Orbit

675 Orbit

Mechanical

Nominal OD, in

4 3/4

6 3/4

8 1/4

4 3/4

6 3/4

Overall Length, ft

13.65

13.47

13.84

15.22

13.5

Hole Sizes, in

6 - 6 3/4

7 7/8,

9 7/8

10 5/8 –

11 5/8

12 ¼ –

18 1/2

20 - 28

6, 6 1/8,

6 ¼, 6 3/4

8 1/2,

8 ¾, 9 7/8”

Bit Speed, rpm

0 - 220

0 - 350

Max WOB, lbf

31,000

180,000

270,000

370,000

225,000

31,000

180,000

Max Torque on Bit, ft.lbf

9,000

18,500

45,000

70,000

9,000

18,500

Max Overpull, lbf

340,.000

1,100,000

1,800,000

2,500,000

340,000

1,100,000

Pass Through DLS (Sliding)

Bit Connection

3 1/2 Reg

4 1/2 Reg

6 5/8 Reg

7 5/8 Reg

3 1/2 Reg

4 1/2 Reg

Hydraulics

Flow Range, gal/min 1

120 - 310

210 - 970

280 - 2,000

170-310

210-970

Max Sand Content, %

Max Low Gravity Solids, %

Max LCM Material, ppb 2

Acidity, pH

9.5 - 12

Oxygen, ppm

Pressure &

Temperature

Max Temp, F

302

Max Pressure, psi

20,000

Measurements

Inclination Offset to Tool

Bottom, ft

6.76

7.13

7.60

7.70

9.00

6.93

7.19

Azimuth Offset to Tool

Bottom, ft

8.86

9.33

9.80

9.90

11.20

9.03

9.39

Gamma Ray Measurements

Average & 4-Bin

Average & 8 or 4-Bin API

Gamma Ray Range, cps

0 - 1,000

Shock Range, gn

0 - 625

Shock & Vibration Axis

Triaxial

Automation

Automated Loop

Inclination

Inclination & Azimuth

Downlinking Method

Flow & RPM

Specification Notes:

1. The Operating Envelop is heavily dependent on mud weight. Heavier mud allows for a lower

minimum flow rate. Be sure to consult the tool-specific paperwork to acquire the critical flow rates

for each tool.

2. Fibrous LCM such as cotton seed hulls and cedar fiber should be avoided entirely to prevent filter

plugging and flow kit jamming.

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 6 of 35

2 Tool Preparation

2.1 Reviewing Tool Paperwork

The Rotary Steerable Outgoing Systems Test (OST) paperwork is a valuable document for the Directional

Driller. This paperwork will be provided by the Extreme Equipment Rental coordinator by the time tools

arrive on location. If not, contact the coordinator with the tool serial number so that the correct paperwork

can be provided. The tool serial number is stamped in the junk slot area of the bias unit, between two of

the PowerDrive pads as shown below.

2.1.1 Tool Configuration

The OST paperwork is full of information, not all of which is useful to the DD. Below is a list of the few

critical things to verify from each section. A PowerDrive should NEVER be picked up without first

verifying the tool is configured to meet the requirements of the job

Tool in Control Collar Load Out Sheet

1. Hole Size –This must match the hole size.

2. Bias Unit Serial Number and Type –Verify the BU type and serial number match what you have.

3. Orbit Ball/Sleeve Gaps –Enter these values into PD2as previously described in section 1.2.2.

Field Information Sheet

4. Battery Expiration –This is only relevant in the

rare event that the client needs recorded mode

gamma logs. PowerDrive does not use the

battery for normal operation.

5. RealTime Transmission –If running a MWD

capable of transmitting PD data, confirm this does

not say “Non RealTime” or “NRT”.

6. Gamma –Verify the tool contains a gamma

sensor if logging is planned.

PD Serial Number

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 7 of 35

PDCU-xx Tool Configuration Report

7. Tool Firmware Version –The tool firmware version is entered into the downlink timing sheet

because different versions have different downlinks available.

8. Downlink Bit Period –The bit period the tool is initially configured to accept. Remember, the tool

will always accept 60 second bit period regardless of whether it’s in 18 or 36 second mode.

9. Desired Steering Mode –If PowerV, a specific downlink sequence must be sent to “unlock” the tool

and allow deviation from vertical. See section 3.8 for more details.

10. Desired Toolface –Initial Toolface setting. Typically, 0 or 180.

11. Desired Steering Ratio –Initial Steering Ratio. Typically, 0% (neutral) or 100% (PowerV Lock).

12. Desired Toolface Mode –Initial Toolface mode. Typically, Gravity.

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 8 of 35

13. Uplink Type –Use the following Compatibility Matrix to determine what MWD receiver the

PowerDrive is compatible with.

MWD

Receiver

Uplink Type

Notes

Standard

ShortHop

Extended

ShortHop

Flex

ShortHop

Clink

Extended

Clink

Flex CLink

ShortHop

Yes

X-Hop

Yes

Confirm MWD is configured to receive &

send Standard, Extended, or Flex data or

communication issues will occur.

H-Hop

Yes

C-Link

Yes

CLPS

Yes

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 9 of 35

2.1.2 Flow Loop Results

Purpose

The Flow Loop Analysis provides the critical flow rates for each specific tool and allows the DD to adjust

these rates depending on mud weight as the run progresses.

Flow Loop Analysis Verification

1. Mud Weight –Minimum flow and tool turn on rates are dictated by the flow loop results as well as the mud

weight. The higher the mud weight, the more torque that will be exhibited on the flow kit, and the lower flow

the tool can handle. If this is not within 0.5 ppg of the planned or current mud weight, the operating envelop

on the following page should be used to adjust these critical flow rates.

2. Maximum Drilling Flow Rate –Damage or toolface instability can occur if pumping above this rate.

3. Density Corrected Minimum Drilling Flow Rate –Never pump below this flow rate if drilling. Try to stay at or

above this flow rate as much as possible when circulating off bottom to avoid torquer jamming.

4. Density Corrected Minimum Tool Turn on Flow Rate –This is the flow rate at which the control unit will turn

on and record data. While the tool will be on, it cannot steer nor is it cleaning as optimally as it is when flow

is kept above the Minimum Drill Flow [4] and therefore the risk of torquer jamming is higher. Never go below

this value when downlinking or the tool will turn off and the downlink will be dropped.

PowerDrive Orbit & X6

Quick Operations Guide - rev1.4

Extreme Equipment Rentals

Page 10 of 35

2.1.3 Operating Envelope

The Flow Loop Analysis provides the critical flow rates for each specific tool and enables the DD to

adjust these rates depending on mud weight as the run progresses. The operating envelop contained

in the OST package is specific to that particular tool and is based on the torque measurements taken

while flowing that tool in the shop. The DD must be careful to use only the Operating Envelop that

matches the exact tool being run since all tools have slightly different ranges.

PowerDrive’s steering performance is based upon a balance of frictions. Internal frictions exist within

the tool’s many bearings and assemblies which the tool must be able to overcome in order hold a

steady toolface. This is determined by the Torque output from the flow kit. As mud weight increases,

the flow kit generates more torque. Therefore, the tools minimum flow rates will decrease with

increasing mud weight.

Before picking up tools, the DD must refer to the specific tool’s Operating Envelop and adjust

the minimum flows accordingly. This is especially important if a tool was transferred from a

different job with different mud weight. If the mud weight is less than what the tool was

originally planned for, its minimum flows will be higher. If the flow rates are not adjusted for

mud weight, there is a high probability of tool failure due to insufficient torque.

1. Telemetry, Not Drilling Zone: This region can only be used for downlinking (Telemetry) off-bottom. The tool

cannot generate enough torque to hold a steady toolface in this range and therefore drilling cannot be done

at flow rates below the “Min Drilling Flowrate”.

2. Drilling and Telemetry Zone: This region can be used for both downlinking (Telemetry) and Drilling.

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