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Table of Contents

2 General Description and Specifications .....................................................2-1


2.1 General Description ............................................................................................................. 2-1

2.2 General Specifications......................................................................................................... 2-1


2.2.1 Software..................................................................................................................... 2-1
2.2.2 Operating Range........................................................................................................ 2-2
2.2.3 Measurement Range ................................................................................................. 2-2

2.3 PowerDrive PD675 / PD900 Specifications ........................................................................ 2-3


2.3.1 Specification summary............................................................................................... 2-3
2.3.2 Pressure Drop through Collar .................................................................................... 2-9
2.3.3 Hanger Bolts and O-Rings....................................................................................... 2-10

2.4 PowerDrive Xtra .................................................................................................................. 2-10


2.4.1 PowerDrive Xtra Specifications Summary............................................................... 2-11
2.4.2 PowerDrive Xtra Electrical Specifications................................................................ 2-12
2.4.3 ShortHop Data ......................................................................................................... 2-13

2.5 Torque Specifications – General....................................................................................... 2-15


2.5.1 PowerDrive Connection Torques............................................................................. 2-15
2.5.2 System Diagrams .................................................................................................... 2-16
2.5.2.1 System Diagram – 8.5" PowerDrive .................................................................. 2-16
System Diagram – 9.5" PowerDrive .............................................................................. 2-17
System Diagram – 9.875" PowerDrive .......................................................................... 2-18
System Diagram – 12.25" PowerDrive .......................................................................... 2-19
System Diagram - 14.75" PowerDrive........................................................................... 2-20
System Diagram – PD675 PowerDrive Xtra.................................................................. 2-21
System Diagram – PD900 PowerDrive Xtra.................................................................. 2-22

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List of Tables

Table 2-1 Surface Software..................................................................................................... 2-1


Table 2-2 Downhole Software ................................................................................................. 2-2
Table 2-3 Mechanical Specifications ........................................................................................ 2-3
Table 2-4 Alternative Bias Unit Sizes for PD675..................................................................... 2-4
Table 2-5 Alternative Bias Unit Sizes for PD900..................................................................... 2-5
Table 2-6 Operational / Environmental Limits ......................................................................... 2-6
Table 2-7 Other Operational Specifications ........................................................................... 2-7
Table 2-8 Sensor Specifications (Control Unit)...................................................................... 2-8
Table 2-9 Flow Rate Ranges and Limits................................................................................ 2-9
Table 2-10 Pressure Drop Across System (PD675)................................................................. 2-9
Table 2-11 Pressure Drop Across System (PD900)................................................................. 2-9
Table 2-12 Hanger Bolts and O-Rings................................................................................... 2-10
Table 2-13 PowerDrive Xtra Specifications........................................................................... 2-11
Table 2-14 PowerDrive Xtra Electrical Specifications ........................................................... 2-12
Table 2-15 V1 ShortHop Dpoint Data (Tool ID=132) ............................................................. 2-13
Table 2-16 V2 ShortHop Dpoint Data (Tool ID=132) ............................................................. 2-13
Table 2-17 V2 ShortHop Dpoint Data (Tool ID=133) ............................................................. 2-14

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2 General Descri ption and Specifications


2.1 General Descriptio n
The primary components of the PowerDrive Steerable Rotary Drilling system are a Bias Unit
(BU), a Control Unit (CU) and a Surface Unit (SU).
The BU guides the drill bit connected to it. Its function is to displace the bit relative to the
hole just drilled and hence, to steer the new hole as required. It is controlled hydraulically by
mud flow through a valve which is mechanically coupled to the CU.
The CU is mounted on bearings inside a dedicated non-magnetic drill collar, normally located
just above the BU. The CU turns independently of its collar. It can be held non-rotating while
its collar rotates around it with the rest of the drill string.
The Surface Unit (SU) is used to program the required drilling and data logging parameters
into the CU. It is also used to download data stored in the CU memory when the tool is
removed from the hole.
The ShortHop addition to the basic PowerDrive system allows positional data (inclination,
azimuth etc.) from the PowerDrive sensors to be sent to the surface via the Low Power Tool
Bus (LTB). This allows the near real-time monitoring of the BHA within the Integrated
Drilling Evaluation and Logging (IDEAL) system. It should be noted that the functionality of
the ShortHop system does not affect normal PowerDrive operation.
The PowerDrive tools utilise the same principles of operation and allow a number of
components to be common to both types. The PowerDrive PD675 system is designed for 8½
inch holes with variants for 8¾, 9½ and 97/8 inch. The PowerDrive 900 system is designed for
12¼ inch holes with variants for 14¾.

2.2 General Specificati ons


These specifications define the operating and measurement range of the PowerDrive tools.
Diagrams are included for reference.
Note that PowerDrive with ShortHop is referred to as PowerDrive Xtra (PDX).

2.2.1 Software
The surface and downhole software requirements for supporting PD jobs are:
Table 2-1 Surface Software

Software Version
PD surface unit 9.0
IDEAL / SPM 6.1
Toolscope (patch) FS4353AB
PowerPlan 3.8

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Table 2-2 Downhole Software

Software Sensor Comms


Comms Mk I + Any sensor 1.90 2.30
(Non short hop)
Comms Mk I + Any sensor 1.91 2.31
(ShortHop Mk1)
Comms Mk I + Any sensor 1.91 2.41
(ShortHop Mk2)
Comms Mk II + Any sensor 1.91 3.21*
(no ShortHop or ShortHop Mk1)
Comms Mk II + Any sensor 1.91 3.31*
(ShortHop Mk2)
* Requires module downloader.

2.2.2 Operating Range


The PD system has been designed to operate under a wide range of conditions. These
conditions are described in detail in this section of the manual. Operation of the tool outside
the intended operating parameters may result in unreliable operation of the tool and/or
damage to the drill string.

2.2.3 Measurement Range


The PowerDrive Systems are designed the to meet the specifications as defined in Table 2-3.

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2.3 PowerDrive PD675 / PD900 Specifications

2.3.1 Specification summar y


The following section contains specifications and tool diagrams for the PD675 and PD900
systems.
1
Parameter Units PD675 PD900

Filecode - Bias Unit PD675BU-AA PD900BU-AA


Filecode – Control Unit PD675CU-AA PD900CU-AA
Filecode – Control Unit Collar PD675CC-AA PD900CC-BA
Nominal (API) Collar OD (in) 6.75 9.0
Hole size range -
Nominal bit size (in) 8.5 12.25
Max. Body OD (in) 6.75 9.0
Minimum ID (in) - -
External upset –
Maximum (pads in / out) (in) 8.32 – 8.71 11.8 – 12.7
Upset type Actuator pads Actuator pads
2
Fishing neck (from top sub) (ft) 12.5 16.0
3
Build rate (°/100ft) 8 5
Dimensions (nominal) –
4
Tool Length (ft) 12.7 14.6
Control Collar (ft) 9.3 10.1
Ext. Sub (ft) 1.05 1.3
Bias Unit (ft) 2.33 3.2
Weight (in air) (lbs) 1720 2370
Thread connection –
Joint yield torque (min. of top/btm) (ft-lbf) 28000 70000
4
Average moment of inertia (BU/ES/CC) (in ) 288 990
5
Equivalent bending stiffness (BU/ES/CC) (ft) - -
6
Maximum collar dogleg –
Rotating (°/100ft) 10 10
Sliding (°/100ft) 20 20

Table 2-3 Mechanical Specifications

1. For alternative Bias Unit sizes available for PD675, see Table 2-4.
2. Fishing neck is the distance from the face seal of the top connection to the start of the external
upset on the sub.
3. Dependent on formation - assumes use of dedicated BeCu flex collar.
4. System length is that of the minimum self-contained operating configuration, excluding stabiliser,
float subs, crossovers, etc. Assumes no recuts.

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5. Equivalent bending stiffness required is that of the equivalent API collar (as specified in PEI
tables).
6. Maximum collar dogleg refers to maximum collar curvature, not hole curvature. This is a collar
fatigue limit.

Specification Units PD675 Bias unit variations

Schlumberger file code - BU PD675BU-BA PD675BU-CA


Schlumberger file code - CU PD675CU-AA PD675CU-AA
Schlumberger file code – CU Collar PD675CC-AA PD675CC-AA
Nominal (API) Collar OD (in) 6.75 6.75
Hole size range -
Nominal bit size (in) 9.5 9.875
Max. Body OD (in) 6.75 6.75
Minimum ID (in) - -
External upset (BU) –
Maximum (pads in / out) (in) 9.32 – 9.71 9.70 – 10.09
Upset type Actuator pads
1
Fishing neck length (BU) (in) 11.5 11.5
Build rate – (°/100ft) 8
Dimensions –
Length BU (ft) 2.58 2.58
Weight BU (in air) (lbs) - -

Table 2-4 Alternative Bias Unit Sizes for PD675

1. Fishing neck is the distance from the face seal of the top connection to the start of the external
upset on the sub.

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Specification Units PD900 Bias unit variations


Schlumberger file code PD900BU-BA TBD
Schlumberger file code – Control PD900CU-AA
Unit
Schlumberger file code – CU Collar PD900CC-AA
Nominal (API) Collar OD (in) 9.0
Hole size range -
Nominal bit size (in) 14.75
Minimum ID (in) 3.00
External upset (BU) –
Maximum (pads in / out) (in) 14.51 - 14.99
Upset type Actuator pads
1
Fishing neck length (BU) (in) 13.0
Build rate (with flex sub) – °/100ft 5
Dimensions –
Length BU (ft) -
Weight BU (in air) (lbs) -

Table 2-5 Alternative Bias Unit Sizes for PD900

1. Fishing neck is the distance from the face seal of the top connection to the start of the external
upset on the BU.

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Parameter Units PD675 PD900

D&I offset distance - (ft) - -


1
Maximum dogleg severity –
Rotating (°/100ft) 10 10
Sliding (°/100ft) 20 20

Maximum –
Operating RPM (rpm) 40 – 220 40 – 200
Operating torque (at bit) (ft-lbf) 16000 48000
Tensile load (overpull) (lbs) 1100000 1400000
Maximum operating pressure (hydrostatic) (psi) 18000 18000
2
Maximum differential pressure –
Internal to external (psi) 750 750
3
External to internal (psi) - -
Sub pressure drop constant (C) 56000 259000
Maximum operating temperature (°C) 120 120
Maximum –
Mud sand content (max.) (%) 1 1
Maximum LCM –
Size Medium Nut Plug Medium Nut Plug
Concentration, tool operating (lb/bbl) 50lbs/barrel 50lbs/barrel
4
Concentration, tool pass through (lb/bbl) N/A N/A

Table 2-6 Operational / Environmental Limits

1. Maximum dogleg severity refers to borehole curvature, not collar curvature.


2. Indicates the maximum safe differential pressure in both directions across the sub
wall before gross plastic yielding (permanent deformation) takes place.
3. Not applicable due to presence of float in drill string.
4. The tool provides no restriction to LCM material - limitation will be bit nozzle size.
LCM passage may cause tool operation failure or other component damage.

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Parameter Units PD675 / PD900

Power source (operating) Turbine alternator


Downwards telemetry Mud flow variation
(typically 20%variation)
Pulsation dampener required? (Y/N) No
(May be required for monitoring SHT)
1
Recommended pre-charge (psi) 800
2
Flow-in filter screen recommended? (Y/N) Yes
Drillpipe filter screen recommenced? (Y/N) Yes
3
Downhole filter screen available? (Y/N) No
Pressure relief sub available? (Y/N) No
4
Clamp on stabiliser permitted? (Y/N) No

Table 2-7 Other Operational Specifications

1. This is the recommended pre-charge as a pressure only. Higher values are generally
better.
2. This is a filter screen placed in line between the pump and the standpipe manifold.
3. Filter assembly present within bias unit for mudflow diverted to the BU actuators.
4. No provision has been made for the fitting of a clamp-on stabiliser.

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Parameter Units PD675 / PD900


1
Battery -
Type Lithium Lithium
sulfuryl thionyl
chloride chloride
2
Maximum Battery Shelf Life Months 4 4
Comms module Mk I Mk II
Cell Size / Weight AA (16g cell) AA (19g cell)
Lithium content (g) 0.5 0.6
Voltage (v) 3.9 3.6
3
Downhole memory? (Y/N) Yes
Mbytes 4.0 2.5
Requirement to change from magnetic to (°) 5.0
gravitational sensors
SENSORS
Tri axial accelerometer – (°) 0.05
Resolution
Tri-axial magnetometers –
Resolution (°) 0.1
ACCURACY (+/-)

Near-bit inclination (°) 0.5


Near-bit azimuth (°) 1.0

Table 2-8 Sensor Specifications (Control Unit)

1. Supports Real Time Clock, memory data (MK1 comms) and diagnostic data (Mk2 comms)
2. The recommended battery shelf life is 3 months. See data on CU sticker.
3. Recorded data in Control Unit (Mk1 Communications Module). Logged data channels and
partitions are dependent on SCB set-up.

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1
Impeller set Limits Units PD675 PD900
A Maximum – tool limitation (gpm) 650 1900
(High) Maximum – operating (gpm) 650 1500
Minimum – operating (gpm) 450 800
B Maximum – tool limitation (gpm) 500 920
(Low) Maximum – operating (gpm) 500 920
Minimum – operating (gpm) 320 480
C Maximum – tool limitation (gpm) 650 -
(Wide Range) Maximum – operating (gpm) 650 -
Minimum – operating (gpm) 360 -
D Maximum – tool limitation (gpm) - 1200
(Medium) Maximum – operating (gpm) - 1200
Minimum – operating (gpm) - 600

Table 2-9 Flow Rate Ranges and Limits


1. Figures given for guidance and planning purposes only. Specific flow rate performance for each CU is
confirmed during the outbound flow loop test procedure (refer to the CU data sticker).

2.3.2 Pressure Drop throug h Collar


The pressure drop across the PD675 and PD900 can be derived from the following formula:

MWppg x Q2
Pressure Drop = (Equation 2-1)
C

Where: MW = Mud weight in ppg


Q = Flow rate in gpm
C= pressure drop constant (56000 for PD675, 259000 for PD900)

PD675 Pressure drop (psi) though system @ MW (ppg)


Flow rate (gpm) 8.3 12.0 15.0 18.0
350 18 26 33 39
500 37 54 67 80
650 63 91 113 136

Table 2-10 Pressure Drop Across System (PD675)

PD900 Pressure drop (psi) though system @ MW (ppg)


Flow rate (gpm) 8.3 12.0 15.0 18.0
600 12 17 21 25
900 26 38 47 56
1200 46 67 83 100

Table 2-11 Pressure Drop Across System (PD900)

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2.3.3 Hanger Bolts and O-R ings


This section describes the hanger bolts required for securing the CU into the CC.
1 2 3
Units PD675 PD900 PD900

Part Number D1141 D1623 D4023 D4206


Description M20 BeCu Bolt M12 BeCu M20 BeCu Bolt M20 BeCu Bolt
Bolt
Where Used Standard Upper hanger Standard Standard
CU SH CU CU CU
Length (mm) 51.8 43.3 68.6 57.6
Associated O-rings –
Viton O-ring 8127 8127 8127 8127
Anti-extrusion ring 8128 8128 8128 8128
Make up torque (NM) 140 51 140 140
Socket size required (mm) 24 20 24 24

Table 2-12 Hanger Bolts and O-Rings

1. Includes PD675 variants.


2. Includes PD900 variants. Used with 7 5/8" necked CU. Requires two (2) O-ring sets.
3. Used with necked CU for 6 5/8" Reg. Requires two (2) O-ring sets.

Anchor bolt Anchor bolt Anchor bolt Anchor bolt


D1141 D1623 D4023 D4206

2.4 PowerDrive Xtra


The following tables list the specifications for the ShortHop addition to the PowerDrive
systems. Note that PowerDrive with ShortHop is referred to as PowerDrive Xtra.

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2.4.1 PowerDrive Xtra Spec ifications Summary

Parameter Units PD675(SH) PD900(SH)


1
File Code – ShortHop Receiver Stab Kit - PD6SRX PD9SRX
File Code – ShortHop Control Unit - PD6SCU PD9SCU
File Code – ShortHop Inline Flex Extender - PLF6-AA PLF9-AA
1
File Code – ShortHop Receiver Cartridge - PDSRC-AA PDSRC-AA
ShortHop LTB Flex Extender (PLFx)
- Length (ft) 10 10
- Weight (in air) (lbs) 515 645
4
- Moment of inertia (in ) 26 54
- Equivalent bend stiffness (ft) 34 33
ShortHop Stabilizer body
- Magnetic (Yes/No) No No
- Length (ft) 6.9 6.85
- Weight (in air) (lbs) - 760
ShortHop Stabilizer Sleeve
- Type Darron series 62 Darron series 85
4
Average moment of inertia (Stab) (in ) 100 200
Equivalent length (Stab) (ft) - -
Float valve required (yes/no) Yes (special) Yes (special)

Table 2-13 PowerDrive Xtra Specifications

1. A ShortHop Receiver consists of a Receiver Cartridge and the appropriately sized stabilizer.

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2.4.2 PowerDrive Xtra Elect rical Specifications

Parameter Units PD675/PD900

Link format - CU to Transmitter RS232 19200 Bd (8,N,1)


- Data type ASCII (tagged)
Data Link
- Link type Magnetic induction
- Modulation type Amplitude modulation (A1D)
- Modulation carrier frequency (Hz) 575
- Data rate (Bd) 10
- Range in air (ft) ≤20
1
- Range in collar (ft) PD675 ≤ 6, PD900 ≤ 3
2 4
- Rrror rate (bits) <1 in 10
- Receiver bandwidth (Hz) 20Hz (-3dB), 60Hz (-40dB)
Antenna - receiver
3
- DC resistance (Ω) 5.5 ± 0.5 Ω @ 23°C
- Inductance (mH) 40 ± 4 mH @ 1KHz
Antenna – transmitter
3
- DC resistance (Ω) 6.0 ± 0.5 Ω @ 23°C
- Inductance (mH) 35 ± 4 mH @ 1KHz
Link to PowerPulse LTB
Power to Receiver (via LTB)
- Voltage (V) 22 ± 3 VDC (max ripple 25omV p-p)
- Current (I) 50mA Nom.
Output Connectors/Cables A4833, Mk2 Cable, PowerDrive Surface
Equipment Adaptor
- CU ROP (at spindle)
H529875, Assembly, LTB/Bus Cable
- ShortHop Receiver Cartridge (LTB/BAT)

Table 2-14 PowerDrive Xtra Electrical Specifications

1. Dependant upon collar material, distance between transmitter / receiver and Upper Torquer
Generator output voltage.
2. Error rate is proportional to received signal strength. This may be affected by the distance between
the transmitter / receiver, the voltage supplied to the transmitter and the collar material. Error rate
quoted is for ranges detailed in table. Transmitter supply voltage must be > 12V (ie. Minimum
Upper Torquer operational RPM).
3. Resistance of windings will vary with temperature.

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2.4.3 ShortHop Data


At the time of writing, V2 of ShortHop will continue to use the GST Dpoints that are
employed with V1. It may be noticed that the scaling is different to allow clean
migration to bespoke PowerDrive Dpoints when IDEAL 7 and HSPM 7 become
established in the field. This move is anticipated during 2002.
The tool will remain with an ID of 132 and have the following Dpoints

ShortHop Variable GST Variable DATP ID No of bits Scale Units

inclination NBSSTAT 2641 16 .03125 degrees


inclination ACR_n 2645 12 .03125 degrees
Azimuth TF_n 2656 12 .125 degrees
GTotal INCL_n 2657 11 1 mG
Btotal BATT_n 2642 10 .0625 Micro Tesla
Btotal ACT_n 2646 12 .015625 Micro Tesla
Gravity TF GTOT_n 2653 10 .5 degrees
Gravity TF ACZ_n 2647 12 .125 degrees
Signal strength NBS2_n 2652 16 .03125 unitless
Inc quality GR_n 2654 8 .125 Degrees
Azim quality RPM_n 2680 9 .25 degrees
Count on good Rx GRF_n 2650 8 1 unitless
Receive quality GRFRL_n 2698 8 1 unitless
Steering Setting CRPM_n 2696 8 1 unitless

Table 2-15 V1 ShortHop Dpoint Data (Tool ID=132)

ShortHop Variable GST Variable DATP ID No of bits Scale Units


1
inclination NBSSTAT 2641 16 /20 degrees
1
inclination ACR_n 2645 12 /20 degrees
1
Azimuth TF_n 2656 12 /10 degrees
GTotal INCL_n 2657 11 x0.5 + mG
(984)
Btotal ACT_n 2646 12 0.48 Micro Tesla
Gravity TF ACZ_n 2647 12 0.1 degrees
Signal strength TEMP_n 2644 9 1 unitless
Inc quality GR_n 2654 8 0.1 Degrees
Azim quality RPM_n 2680 9 0.1 degrees
Count on good Rx GRF_n 2650 8 1 unitless
Receive quality GRFRL_n 2698 8 1 unitless
Steering Setting CRPM_n 2696 8 1 unitless

Table 2-16 V2 ShortHop Dpoint Data (Tool ID=132)

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Table 2-17 defines the PowerDrive Dpoints that are embedded into IDEAL 7 and
HSPM 7. Note that a ShortHop receiver sub modem software change to V7.0 is also
required to implement this change. A Mod Recap will be issued to cover this change
when appropriate.

Table 2-17 V2 ShortHop Dpoint Data (Tool ID=133)

Abbrev. Data No. Param. Conversion Eng.Units Full Name


Name Point of Algorithm
bits No. (after conv.)
(ID) X -> AX+B
A B
INC 3780 12 1 0.05 0 Degrees Inclination
1
AZIM 3781 12 2 0.1 0 Degrees Azimuth
GT 3782 6 3 0.5 984 Milli G Gtotal
BT 3783 11 4 48.0 0 Nano Tesla Btotal
Spare_1 3784 12 5 1 0
STEER 3785 8 6 1 0 unitless Steering setting (build,
turn and gravity or
magnetic mode)
Spare_2 3786 2 7 1
Spare_3 3787 4 8 1
2
PTF 3788 12 9 0.1 Degrees CU toolface
INCQ 3789 4 10 0.1 0 Degrees Inc standard deviation
AZIQ 3790 4 11 0.1 0 Degrees Azi standard deviation
SHKRSK 3791 2 12 1 0 unitless Shock risk
Spare_4 3792 4 13 1
Spare_5 3793 16 14 1
not used 3794 15 reserved for CU
checksum
1
AZIM_LO 3795 10 16 0.4 0 Degrees Azimuth (low res .4
deg)
2
PTF_LO 3796 6 17 6 0 Degrees CU grav/mag toolface
(low resolution 6 deg)
3
SIG 3797 12 18 1 0 unitless Received signal &
noise
3
SIG_LO 3798 6 19 1 0 unitless Received signal &
noise (low resolution)
SIGQ 3799 4 20 1 0 unitless Received signal quality
AGE 3800 16 21 1 data age from modem

1. AZI available in two resolutions, normal (0.1 deg) and LO (0.4 deg). The same source data is
available.
2. Control Unit tool face will be available in two resolutions, normal and LO resolution (6.4 deg) -
for use where bandwidth is limited.
3. SIG_LO, SIG_HI (Signal Strength) is also available in two resolutions, 12 and 6-bit. The 6-bit
version cuts off at approx. 50% receiver input saturation.

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2.5 Torque Specificatio ns – General

2.5.1 PowerDrive Connectio n Torques


The torque values listed for the PowerDrive tools, as up-dated in this issue, are
separate, distinct, and exclusive from other ANADRILL connections. These values have been
calculated in accordance with API Spec.7 requirements.
The fact that there has been a significant increase in some of these values from more historic
values lies in the fact that, as equipment and material improvements have been made, both in
the PowerDrive tools and in drill bits, the tools joints are now capable of withstanding greater
torque values.
These values are in no way contradictory to values depicted in specification S-288035.
Rather, these values are specific to the PowerDrive equipment, and are not necessarily
applicable to other ANADRILL collar connections.

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2.5.2 System Diagrams

2.5.2.1 System Diagram – 8.5" P owerDrive

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2.5.2.2 System Diagram – 9.5" P owerDrive

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2.5.2.3 System Diagram – 9.875 " PowerDrive

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2.5.2.4 System Diagram – 12.25 " PowerDrive

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2.5.2.5 System Diagram - 14.75 " PowerDrive

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2.5.2.6 System Diagram – PD67 5 PowerDrive Xtra

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2.5.2.7 System Diagram – PD90 0 PowerDrive Xtra

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