PSA PERFORACION

Copyright Geolink (UK) Ltd.This Training Manual is supplied in confidence and may not (1) be used for any other purpose than that of its supply, (2) be copied,reproduced or electronically stored by any means and (3) be communicated to any other person or organisation without specificwritten permission from Geolink (UK) Ltd.

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MWD SYSTEMS

Power Supply AssemblyMaintenance Manual

CONFIDENTIAL GEOLINK 1999

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MWD SYSTEMS

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Contents

Introduction

WorkshopInspection &Assembly

Post-JobInspection &Test

Pre-JobInspection &Test

Parts List

Appendix

CONFIDENTIAL GEOLINK 1999i

WorkshopMaintenance& Test

Index

Table of Contents Pages

1. Introduction1.0 Power Section Assembly - General Description ......................................... 1-11.1 Physical Description.................................................................................... 1-11.2 Functional Description ................................................................................ 1-3

2. Workshop Inspection and Assembly Procedures2.1 Workshop Inspection ................................................................................... 2-12.2 Assembly Procedures .................................................................................. 2-1

3. Workshop Maintenance and Test Procedures3.0 Power Pack Maintenance ............................................................................ 3-13.1 Battery Test Procedures ............................................................................... 3-13.2 Battery Life Calculations ............................................................................ 3-3

4. Pre-job Inspection and Test4.1 Physical Inspection ..................................................................................... 4-14.2 Electrical Tests ............................................................................................ 4-14.3 Final Installation in the Housing with Coupling Connector ....................... 4-1

5. Post-job Inspection and Test5.1 Physical Inspection ..................................................................................... 5-15.2 Tests on the Battery Cartridges ................................................................... 5-1

6. Parts ListParts List ............................................................................................................ 6-1

7. Appendix7.1 Appendix A: General Battery Handling and Safety

7.1.1 General Battery Information .................................................................... 7-17.1.2Battery Composition ................................................................................. 7-17.1.3 Workshop Practices ................................................................................ 7-17.1.4 Battery Storage ......................................................................................... 7-37.1.5 Battery Shipping and Disposal ........................................................... ..... 7-3

7.2 Appendix B:Safe Handling and Return of Equipment Damaged by BatteryPack Venting

7.2.1 Introduction .............................................................................................. 7-47.2.2 Damage, Products and Hazards associated with Battery Venting.. .......... 7-47.2.3 Battery venting at the Wellsite - Identification................................ ........ 7-57.2.4 Identifying battery venting is not always straightforward.............. ......... 7-57.2.5 Battery Venting at the Wellsite - Procedures ....................................... 7-57.2.6 Dismantling the Equipment ................................................................... 7-67.2.7 What can be Salvaged? ............................................................................ 7-77.2.8 How to return Contaminated Items .......................................................... 7-7GEOLINK MATERIAL SAFETY DATA SHEET ........................................... 7-9

7.3 Appendix C: Example Tool Hours Worksheet 7-12

8. Index

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CONFIDENTIAL GEOLINK 1999ii

List of Illustrations Pages

Section 1: Introduction

1-1 MWD Down Hole Assembly ...................................................................... 1-21-2 Standard Power Section Assembly ........................................................ 1-41-3 Double-D Power Section Assembly ....................................................... 1-5

Section 2: Workshop Inspection and Assembly Procedures

2-1 Standard (Single D) Battery Assembly ....................................................... 2-22-2 Wiring Schematic for Standard Power Section ........................................... 2-22-3 PSA Test and Load using the Battery Monitor Box ................................... 2-32-4 Double-D Battery Assembly (UPPER)................................................... .... 2-42-5 Wiring Schematic, Double-D Power Section .............................................. 2-4

Section 3: Workshop Maintenance and Test Procedures

3-1 Normal Battery Voltages ....................................................................... 3-23-2 Testing the Battery Voltages ('Step Down' Procedure)..................... .......... 3-3

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Contents

Introduction




Parts List

Appendix


Section 1

Introduction


Index

PERFOLAT

Contents

Introduction



Pre-jobInspection& Test


Parts List

Appendix

CONFIDENTIAL GEOLINK 19991-1

Index

1. Introduction

1.0 Power Supply Assembly (PSA) - General DescriptionThe Power Supply Assembly is the part of the down hole MWD tool string

which supplies power to the Survey Electronics and charges the capacitors in the APCelectronics in order to operate the Transmitter (refer to Fig 1-1). The Power Supplycontains cartridges of high temperature, long life, lithium-thionyl-chloride batteries(generally known as lithium batteries).

Currently, two types of cartridge are supplied by Geolink:-

Standard cartridge - one cartridge section containing 10 single 'D' size lithium batteries.

DD cartridge - a pair of upper and lower cartridge sections each containing 5 DD size lithium batteries.

The Standard cartridges are supplied with blue heat shrink and fit inside onepressure housing. The DD cartridges are supplied as an Upper and Lower pair andrequire two pressure housings, one for each cartridge. The upper cartridge (+ve) issupplied with red heat shrink and the lower cartridge (-ve) with black heat shrink.

The individual cells come in three varieties:

a) Standard (D) cells rated to 150C.

b) Long Life (DD) cells rated to 150C

c) High temperature cells rated to 165C (DD only).

Note: cells or cartridges of different types cannot be mixed in a downhole tool.

Like all batteries, the Power Supply Assembly has a finite life which is variableand is based on the tool operating mode and the total number of pulses. Due to thephysical make-up of the individual battery cells, the battery cartridges must be han-dled with care. If the cartridges are overheated or ruptured special precautions must befollowed to minimize the potential danger (refer to the Battery Safety Section in theAppendix).

Once depleted the battery cartridge must be safely disposed of in accordancewith the local regulations in the country of operation.

1.1 Physical Description

Both Power Supply Assemblies consist of four main components:-

The Pressure Housing - machined from BeCu alloy.

The Coupling Connector - connects the PSA to the SEA.

The Battery Cartridge

The Bulkheads and Wiring Harness

See Appendixfor return of batter-ies to Geolink fordisposal.

Gamma Raypower packs aredealt with in theGRA Operating

and MaintenanceManual

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MWD Down Hole Assembly (Fig.1-1)(70-00-100 Standard Assembly, 70-00-110 Double D Assembly)

Transmitter Assembly (70-30-000)The MWD Transmitter generates a series of mud pulses to transmit the down-

hole information to the surface. The transmitter is housed inside a specially machinednon-magnetic drill collar or Transmitter Sub.

Actuator Power Controller Assembly (APC) (70-30-010)The APC assembly directs the power to actuate the transmitter solenoids for

generation of the mud pulses.

Power Supply Assembly (PSA) (Standard 70-30-020; Double D 70-30-022)The Power Supply Assembly supplies power to the down-hole tool utilising

high temperature long-life Lithium Thionyl Chloride batteries. The PSA is availablein Standard, DD and High Temperature versions.

Survey Electronics Assembly (SEA) (70-30-030)The Survey Electronics section contains triaxial magnetometers, inclinom-

eters, a temperature sensor and control electronics which allow full directional sur-veying and steering operations over the complete range of 0 deg. to 180 deg.

Note: standard assembly shown in diagram

(not drawn to scale)

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Contents

Introduction





Parts List

Appendix


Index

1.1 Physical Description (contd)The Standard and DD Power Sections contain essentially the same components

(refer to Fig 1-2 and Fig 1-3). However because of the size of the cells the DD packrequires two each of the above components to make one Power Section. It should alsobe noted that apart from the Coupling Connectors and Pressure Housings the Standardand DD packs are not interchangeable.

In both cases the Battery Cartridge is connected to the Bulkheads and WiringHarness. The whole assembly is contained within the Pressure Housing. The CouplingConnector attaches to the Bulkhead at the bottom of the pressure housing and locks theassembly to the MWD tool face. When the cartridge is depleted the Bulkheads andWiring Harness are reusable.

1.2 Functional Description

The PSA supplies all the power required to operate the complete down-holeassembly.

The output voltage of the PSA is approximately 34 volts total or (+) and (-) 17volts (Standard and DD packs). Due to the characteristics of the individual batterycells, the voltage will vary slightly from this figure. Also, the batteries will exhibit a NOLOAD and a LOADED voltage. It is the LOADED voltage that is of concern to the tooloperation; therefore, when testing to determine the usefulness of a PSA, the voltagemeasurement should be made with the correct loading on the PSA.

The life of the PSA is dependent on the selected tool operating mode and thenumber of pulses transmitted (refer to Section 3.2). The initial energy capacity (meas-ured in Joules) is dependent on the type of battery assembly selected. The theoreticalenergy capacity is given as:-

Standard Assembly - 1.0 M Joules

DD Assembly - 2.4 M Joules

Note: the above figures are for battery assemblies made with the standard (150C)cells.

High Temperature (DD only) assembly - 1.2 M Joules

In practise the actual energy capacity may vary from the theoretical figures.This variation in battery life is caused by several factors:-

Down-hole operating temperature and temperature cycle history Use cycle history Variations in cell manufacture and supplier Component of total energy dissipated by pulsing or quiescentconsumption (quiescent consumption is energy used supplying power tothe sensors in the downhole tool)

Battery life can be calculated at the completion of each run, and the operator canestimate the battery life required to complete the next hole section prior to the start ofthe run (refer to Field Operations Manual and to the Appendix for an example ToolHours Worksheet).

A record of theenergy remainingin each pack that isat the rig must bekept to ensure thatthe pack to be nextused has enough re-maining energy tocomplete the run.

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Standard Power Supply Assembly (PSA) (70-30-020) (Fig. 1-2)

MWD Downhole

Toolstring (Standard)(70-10-100)

PSA Housing

(23-11-0020)

D Connector

and Harness

(73-23-100)

D Battery Cartridge

(72-23-110)

Coupling Connector

(72-22-220)

Standard (D) Power SupplyAssembly, Field Ready

(70-30-020)

O-ring (25-00-018)

GT-ring (25-10-003)

Stan

dard

(D) P

ower

Sup

ply

Inte

rnal

s (n

o ba

tterie

s) (7

2-23

-100

)

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Contents

Introduction





Parts List

Appendix


Index

DD Power Supply Assembly (70-30-022) (Fig. 1-3)

MWD Downhole Toolstring (DD)(70-10-100)

DD (Upper) Connectorsand Harness (72-23-020)

DD (upper) PSA

DD (Lower) Connectorsand Harness (72-23-030)

DD (lower) PSA

Coupling Connector

(72-22-220)

Coupling Connector

(72-22-220)

(not to scale)

DD

Bat

tery

Car

tridg

e (7

2-23

-211

)D

D B

atte

ry C

artri

dge

(72-

23-2

11)

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Contents

Introduction




Parts List

Appendix


Section 2

Workshop Inspectionand Assembly


Index

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Contents

Introduction



Pre-JobInspection& Test


Parts List

Appendix


Index

2.Workshop Inspection and Assembly Procedures

2.1 Workshop Inspection

Power Supply Assemblies are shipped from Geolink with the battery cartridgereplaced by a transit spacer, to which the upper and lower bulkhead and wiring harnessis attached. It is necessary to ship the cartridges this way (and separately, in specialcrates) due to special regulations and procedures regulating the shipment of batteries(refer to Battery Shipping in the Appendix). The spacer should be removed (and storedfor future transit of battery harnesses), prior to use, and the bulkhead and harnesschecked for any damage that may have occurred during transit.

The Standard and DD harness assemblies are easily distinguished by the numberof connectors on the wiring harness. A Standard harness has three connector pins anda DD harness has one connector pin and one connector socket (refer to Fig 2-1 & 2-4).In addition, the DD Power Section requires an Upper and Lower harness assembly tomake one complete operating power pack assembly. The Upper and Lower harnessesare distinguished in the following ways:

a) The Upper (positive) harness will have an A engraved on the top bulkheadand the Lower (negative) harness will have a B engraved on the top bulk-head.

b) The Upper (positive) harness has Red and White wires attached to the smallconnectors. The Lower (negative) harness has Black and White wires attachedto the connectors.

The coupling sub should be removed from the pressure housing. The O-rings,GT-rings, and back-up rings should be checked for transit damage. The connectorsshould be checked for continuity from pin to pin and for any leakage to ground. Theinternal edges of the coupling screw holes must be checked to ensure that no sharpedges or burrs are present which might damage 0-rings. The screw hole threads shouldbe free from grease and dirt.

The battery cartridges are supplied separately as Standard (D) packs (10 cells)or DD packs (5 cells). Two DD cartridges are required for a DD assembly. The DDcartridges are identical and may be used for the Upper or Lower assembly. Howeveronce the harness is attached, the Upper and Lower assemblies are not interchangeable.The cartridges must be checked for signs of physical damage or faulty manufacture.

2.2 Assembly Procedures

The assembly procedure is similar for both Standard and DD Power Sections.Standard battery pack harnesses have a positive and negative power take-off pin and acentral power take-off pin. DD harnesses have a positive and negative power take-offpin only, but an Upper and Lower harness is required for a complete DD assembly.

Due to wiring differences the Upper and Lower harnesses are not interchange-able (refer to Fig 2-2). The following equipment is required for the assembly process:-

Tools and Equipment

Battery Cartridge (1x72-23-110, 2x72-23-21, or 2x72-23-222) (Standard, DD, or Hi Temp cartridges) Battery Harness (1 x 73-23-020 or 1 x 72-23-020 plus 1 x 72-23-030) (Standard or DD Upper and DD Lower)

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(not to scale)

+ve -ve

Upper

Bulkhead

Lower

Bulkhead

Chassis buffer O-ring x 2

(25-00-008)

Standard Wiring Harness

Socket x 3

Connector x 3

Single-D Cells x 10

Standard (Single-D) Battery Assembly (Fig. 2-1)

Standard (Single-D) Power Supply Assembly

Wiring Schematic for Standard (D) PSA (Fig. 2-2)PERFOLAT

Contents

Introduction





Parts List

Appendix


Index

Tools and Equipment (contd)

2.5mm Allen key Razor Knife Contact Cleaner 1 " Kapton Tape (11-70-001) RTV 3744 (13-50-002) Small Pair Needle Nose Pliers Super O-Lube (13-30-001) 5mm Allen key Batt. Monitor Box (75-50-054) Multi-Meter Heat Gun 2 Heat Shrink (Blue or Red and Black) Loctite 242 (13-40-001) V-blocks

Assembly Process:

a) Each battery cartridge is marked with the positive and negative end. Thebattery cartridge should be laid out alongside the wiring harness with the posi-tive end to the top bulkhead on the wiring harness (refer to Figs 2-1 and 2-4).

b) The top and bottom bulkheads should be inserted in the end of the batterycartridge. The bulkhead slots should be aligned with the channel on the car-tridge. Care should be taken not to pull the wiring harness where it feeds fromthe connector, or pinch the wiring between the cartridge and the bulkhead.

c) The wiring harness power connectors should be inserted in their correspond-ing sockets in the battery cartridge. The DD-harness has one male and onefemale connector. The Standard harness has three male connectors.

d) Before proceeding further the battery voltage must be tested under NO LOADand LOAD conditions.This check can be performed with one Standard car-tridge but requires both the Upper and Lower DD-cartridges to be joined with aCoupling Connector or a male-male test cable from the STB2. Connect the INside of the Battery Monitor Box to the top bulkhead (positive end of the batteryassembly). A multi-meter should be connected across VB+ and VB- on thebattery test box (refer to Fig 2-3).

e) The initial NO LOAD voltage should be in the range of 34 to 36 volts whichis the voltage over the entire pack.

2.2 Assembly Procedures (cont)

PSA Test and Load using the Battery Monitor Box (Fig. 2-3)

(not to scale)

Multi-meter

Standard Power Supply Assembly

Battery Monitor Box

ISOL/PWR Switch

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DD Power Supply Assembly

+veUpper

Bulkhead

DD wiring harness

ConnectorLower

Bulkhead

-ve

Chassis buffer o-ring x 2DD cells x 5

(not to scale)

Socket

ConnectorSocket

DD Battery Assembly (UPPER) (Fig. 2-4)

Wiring Schematic for DD Power Section (Fig. 2-5)

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Parts List

Appendix


Index

Assembly Process (contd.):

f) Reconnect the multi-meter leads across test points VB+ and GND to read thevoltage across the positive side of the pack (or Upper cartridge in a DD assem-bly). The multi-meter should read between +17 and +18 volts.

g) Re-connect the multi-meter leads across test points GND and VB- to read theNO LOAD voltage across the negative side of the pack (or lower cartridge in aDD assembly). The multi-meter should read between -17 and -18 volts.

h) Re-connect the multi-meter across test points VB+ and VB-. Activate theLOAD switch on the test box. This places a load across the cartridge(s). In anew cartridge the initial load voltage may drop below 30 volts but will buildback up towards 33-36 volts (D cartridges will be slower to regain their voltagelevels than DD cartridges). If the cartridge is already LOADED the voltage willdrop very slightly under load but should remain between 33-36 volts across thepack (refer to fig 2-4). If the battery voltage is too low to operate the BMB onLOAD (the BMB will make a clicking noise), load the battery by connecting toa transmitter (in a tool string or via the STB) and operating the transmitter forhalf an hour. Re-connect to the BMB and check the voltages on LOAD.

i) Check the positive and negative sides (upper and lower cartridges for DD)under Load conditions as in f) and g) above. The voltage should be between16.5-18 volts.

Note: The BMB will automatically switch to OFF-Load after 30 minutes. Checkthe LED to see if the BMB is loading the PSA or not. If necessary, reset the BMBand switch to LOAD again.

j) Remove the Battery Monitor Box taking care not to pull on the bulkhead.Line up the screw holes on the top bulkhead with the holes in the cartridgehousing. Insert the screws and tighten with the allen key, checking for align-ment between the bulkhead and the cartridge (the screw holes in the cartridgemay be gently filed to ensure the screws do not protrude). Do the same for thelower bulkhead (repeat the process for the Lower cartridge in a DD assembly).

k) Lay the wiring harness in the cartridge channel taking care not to overlap thewires as this may cause the wires to crush during drilling operations. Carefullybundle excess wire into the storage space provided in the bulkheads.

l) Apply a small amount of RTV 3744 to the top of the power take-off connec-tors to prevent them from backing out.

m) Secure the wire harness in the cartridge channel using several 2 pieces ofKapton Tape, starting in the center and working out to the bulkheads.

n) Recheck the battery NO LOAD and LOAD voltages using the battery testbox and multi-meter. This will confirm all the electrical connections are good.

o) Insert the cartridge into the correct colour coded Heat Shrink. The HeatShrink is colour coded as follows:-

Blue - Standard cartridge (and Gamma).Red - Double-D Upper cartridge.Black - Double-D Lower cartridge.


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Assembly Process (contd.):

p) Hold the assembled cartridge vertically and use the heat gun to heat the Heat Shrinkwhile slowly rotating the cartridge. This will ensure an even shrinkage of the HeatShrink.

q) When the assembled cartridge has cooled, trim and remove the excess Heat Shrinkjust inside both bulkheads using a single, smooth, cut to avoid creating weak pointswhich may split the Heat Shrink. Be very careful not to damage the wires as the cutis made across the gap in the cartridge.

r) Check the condition of the rubber isolation rings on both bulkheads (chassis bufferO-rings). Replace them if they show signs of deterioration or damage.

s) Recheck the battery NO LOAD and LOAD voltages (both Upper and Lower car-tridges are required for a DD assembly).

t) The battery batch number and build date should be written on the Heat Shrink withan indelible marker pen and the batteries should be tagged as ready for field use.


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Contents

Introduction




Parts List

Appendix


Section 3

Workshop Maintenance and Test


Index

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Contents

Introduction

WorkshopInspection& Assembly




Parts List

Appendix


Index

3. Workshop Maintenance and Test Procedures

3.0 Power Pack Maintenance

Regular maintenance of the Power Supply Assembly will help to optimize thelife obtained from the batteries. When the Power Section is returned to the workshopafter down hole use the following checks must be carried out.

a) Remove the battery assembly from the pressure housing and check the HeatShrink for visual damage or signs of excessive abrasion. Remove the Heat Shrink.

b) Make sure the screws fixing the cartridge to the bulkhead are tight.

c) Check both electrical connectors (10 pin connector) for damage. Look forpushed or bent pins.

d) Check both electrical connectors for tightness and alignment. Ensure the setscrews holding the connector in place are tight. If any set screw is found to beloose remove, clean, and replace using Loctite242. Do not over tighten theset screw or this will pinch the connector.

e) Check the battery voltage under NO LOAD and LOAD conditions (refer tosections 2.2 and 3.1 for details).

f) Remove the Coupling Connector from the pressure housing. Check the tenpin connectors for damage. Look for pushed or bent pins.

g) Check both electrical connectors on the Coupling Connector for tightness.Ensure the set screws that hold the connectors in place are tight. If any set screwis found to be loose remove, clean, and replace using Loctite242. Do not overtighten the set screw or this will pinch the electrical connector.

h) Check the Coupling Connector for continuity between both electrical con-nectors, leakage to ground and for leakage between pins.

i) Check the O-rings and GT rings for damage (refer to Geolinks manual, Careand Protection of Seals).

j) Clean the Coupling Connector screw holes. Remove any dry Loctite with acotton swab. Inspect the screw holes for sharp edges or burrs that might causedamage to the O-ring sealing areas.

k) Inspect the half-shells for washing. Replace if damaged.

3.1 Battery Test Procedures

The PSA must be fully LOADED and tested before being passed for field op-erations. LOADING removes the passivation layer which is present in used and un-used Lithium batteries. The same test procedures should be used when a PSA has beenreturned from the field irrespective of whether the batteries are depleted or not.

Battery Test Procedures:

a) With the PWR/ISOL switch in the ISOL position, attach the IN side of theBattery Monitor Box to the positive end (top) of the battery assembly. In the

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a) (contd.) case of a DD assembly, connect the Upper and Lower cartridges with a Cou-pling Connector or test lead from the STB2 and attach the Monitor Box to the top of theUpper battery bulkhead. Use the multi-meter to record the battery voltages.

b) Record the initial NO LOAD voltage from the positive and the negative sides of theassembly: Positive across test points 1 & 3, Negative across test points 4 & 6.

c) Switch the BMB to PWR. After 5 minutes, record the LOADED voltage for both sides.If the voltage is not within the accepted range (refer to Fig 3-1), wait an additional 30minutes and record the voltage reading again (the BMB may switch to OFF-load after 30mins. in which case it will be necessary to reset the BMB and LOAD the battery again).

d) If the battery voltage has not reached the minimum acceptable value disconnect the testbox and remove the heat shrink and Kapton tape to gain access to the Wiring Harness. Checkthe Harness for crushed or loose wires. Ensure the connectors are fully seated in the sockets.

e) Re-connect the BMB to the positive end of the battery. Apply the load and let the LOADEDvoltage stabilize. If the voltage continues to slowly drop under load the batteries are mostprobably fully depleted and the pack should be set aside for disposal.

f) If the voltage stabilizes at some lower value below the acceptable minimum it is prob-able that one or more cells are depleted or damaged. To check, place the batteries underLOAD and leave the positive probe from the multi-meter connected to test point 1 and usethe negative probe to step down the battery pack (refer to Fig 3-2). Note that the insulationmust be broken in order to get to the battery terminals. Start with the first battery nearestthe top of the cartridge and keep the probe connected for several seconds until the voltagestabilizes. Note the voltage and move down to the next battery in line. The voltage shouldincrease in almost equal increments as you step down the pack. For example: 3.5v, 7.0v,10.4v, 13.9v, 17.3v (refer to Fig. 3-2).

g) To check the individual cell voltages disconnect the multi-meter from the Battery Moni-tor Box. Again step down the pack but this time connect the multi-meter probes betweentwo adjacent cells and note the voltage. For example: 3.5, 3.4v, 3.5v, 3.4v, 3.5v, 3.5v .

Normal Battery Voltages (Fig. 3-1)

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ediSevitisoP ediSevitageN kcaPelohW

stnioPtseT 3&1 6&4 6&1

DAOLON V81-71 V81-71 V63-43

DAOLhtiWsetunim5retfa

V71-51 V71-51 V43-03

DAOLhtiWsetunim03retfa

V5.71-5.61 V5.71-5.61 V0.53-0.33

3.1 Battery Test Procedures (contd.)

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Contents

Introduction





Parts List

Appendix


Index

3.2 Battery Life Calculations

3.2.1 Introduction

Lithium-Thionyl-Chloride batteries have the design characteristic that once fullyloaded they produce a consistent voltage output for the majority of their operating life. It isextremely important that the battery life is tracked to avoid downhole battery depletion.

Geolink use the energy capacity of the batteries, measured in Joules, to monitorbattery life.

In general the theoretical energy capacity of the Power section from the manu-facturers specifications is given as:-

h) The test performed in f) and g) above will indicate the condition of the bat-tery assembly. If all the cells read the same or similar low voltage the pack isdepleted and should be set aside for disposal. If one or more cells display anabnormally low voltage while the majority show acceptable voltages this indi-cates probable mechanical failure of the individual cell(s). The cells must thenbe disposed of in an approved manner.

3.1 Battery Test Procedures (cont)

Refer tothe Appendix forinformation on

Battery Disposal

Testing the Battery Voltage - Step Down Procedure (Fig. 3-2)

17.5

Multi-meter

Negative Probe

Power Section (upper and lowerrequired for DD battery)

(not to scale)

Battery Monitor Box(75-50-054)

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Standard Assembly = 1.0 million JoulesDD Assembly = 2.4 million JoulesHi Temp Assembly = 1.2 million Joules

3.2.2 Battery Life Calculations - Standard and 3-1/2 (Ultraslim) Tools

From a knowledge of the energy consumption of the MWD assembly it is possible tocalculate the theoretical operating life of the Power Section. Using the manufacturers data, thetool power consumption can be calculated from:-

Pulse Energy per Static Survey = 281.6 Joules

Pulse Energy per Dynamic Survey = 105.6 Joules

Sensor Energy per Static Survey = 29.4 Joules

Sensor Energy per Dynamic Survey = 17.6 Joules

Quiescent Consumption (0.52 watt) = 1872 Joules/hour (plugged-in)

An estimate of the remaining battery life remaining can be calculated using the followingsimplification:-

JoulesNEW = JoulesOLD - (1872 x Hr. P.I.) - (20.5 x No. Pulses)

where: Hr. P.I. = Number of hours the battery has been plugged in

No. Pulses = Total number of pulses

For example:

Standard Power Section Assembly, initial energy = 1.0 million Joules

Plugged-in hours = 77

Number of pulses = 36,000

Est. Energy Remaining = 1,000,000 - (1872 x 77) - (20.5 x 36,000) = 117,856 Joules

3.2.3 Battery Life Calculations - 2-7/8 (Ultralite) Tools

The energy consumption (per pulse) of the 2-7/8 Transmitter is less than that of the Stand-ard and 3-1/2 Transmitters. Thus the equation used for battery life calculations is as follows:

JoulesNEW = JoulesOLD - (1872 x Hr. P.I.) - (5.7 x No. Pulses)

3.3 Factors Affecting Battery Life

The actual battery energy remaining is affected by a number of factors which may combineto reduce the effective battery life:

a) Operating temperature:The Lithium batteries used in the Geolink tool are rated to 150 C. However because of thebattery chemistry an operating temperature between 80 - 125 C has an adverse effect on

3.2 Battery Life Calculations (contd)

For GammaRay Assembly

power usage, referto the GRA

Operations andMaintenance

ManualPERFOLAT

Contents

Introduction





Parts List

Appendix


Index

3.3 Factors Affecting Battery Life (contd)a) (contd) battery life. This is especially true for Standard battery cells. In addi-tion the temperature cycle history can affect overall battery life with an in-crease in passivation layer build-up i.e. tripping out and in a hot borehole withsubsequent cooling and re-heating of the batteries or storage outside in a hotclimate.

b) Use Cycle History:Variations in the tool operating mode may effect battery performance. Longperiods with no pulsing can cause a passivation layer to build up in the battery.Again this is especially true for Standard cells.

c) Variations in Manufacture: Battery performance can vary slightly betweendifferent batches produced by the manufacturer (and does vary between differ-ent manufactures).

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Contents

Introduction




Parts List

Appendix


Section 4

Pre-job Inspectionand Test


Index

PERFOLAT

Contents

Introduction


Post-JobInspection& Test



Parts List


Appendix

Index

4. Pre-job Inspection and Test

Prior to sending a new or previously used Power Section Assembly to the fieldthe following test operations must be performed:-

Physical Inspection Electrical Tests Final Installation in the Pressure housing with the Coupling Connector Cartridge identification with energy remaining.

4.1 Physical Inspection

The battery cartridge assembly must be carefully inspected to ensure that theupper and lower bulkheads are tight and the heat shrink is undamaged. Check thealignment of the electrical connectors and readjust if necessary.

4.2 Electrical Tests

The Power sections must be tested under NO LOAD and LOAD conditions (Re-fer to section 3.1 for full details). If the Power section has been previously loaded theLOAD voltage should stabilise very quickly to approximately 32-35V across the pack. Ifthe voltage stabilises at some lower level or continues to fall under LOAD, one or moreof the cells is depleted or damaged and the pack cannot be used. If a battery cartridge isbeing rerun the amount of energy used should be calculated and marked on the heatshrink with an indelible pen (Refer to section 3.2). It is an operations decision whether torerun a battery pack and will depend on the following criteria:-

Passing all the physical and electrical checks The amount of energy already consumed The estimated battery life remaining The operational history of the pack (operating mode, downhole temperature etc) The proposed run length and tool operating mode

It is not a good practice to re-run cartridges that have already consumed morethan 70% of their estimated total capacity unless the operator has calculated it is safeto do so based on the history and proposed usage of the pack.

4.3 Final Installation in the Housing with the Coupling Connector

When the cartridge has passed the physical and electrical checks it can be fully assem-bled in the pressure housing with the coupling connector. It is assumed that the PressureHousing and Coupling Connector have already been inspected (refer to section 2.1).

Tools & Components:

Pressure Housing (23-11-002) Lube, Super O ((13-30-001) Coupling connector (72-22-220) Loctite (Nutlock 242) Battery cartridge assembly Set of Allen keys Screw M6x6 SKT CAP (x4) (20-00-012) Contact cleaner

Installation Process:

a) The ten pin electrical connector on the Coupling connector should be in-serted into the bottom bulkhead connector on the cartridge assembly. The align-ment pins on the Coupling connector will ensure the connectors are properlyaligned.



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4.3 Final installation in the Housing with Coupling Connector (contd.)

b) Apply a light smear of O-lube to the upper O-ring and GT-ring on the Coupling Connector.

c) Insert the combined assembly into the Pressure housing. Carefully support the CouplingConnector to avoid undue stress on the electrical connectors. Align the tool face key on theCoupling Connector with the key slot on the pressure housing and push fully home.

d) Clean any excess O-lube from the pressure housing screw holes with a cotton bud soakedin non-deposit contact cleaner.

e) Apply a small drop of Loctite242 to the end of a pressure housing screw and insert intothe Power section assembly. Tighten the screw with the Allen key to 12 ft-Ibs. Repeat theprocess for the other three pressure housing screws.

f) Place Silica Gel sacs in the open end of the housing followed by rubber protection caps onthe end of the pressure housing and Coupling Connector. Clearly tag the completed assemblywith the content details. e.g. Standard battery assembly, New, Energy remaining: 1 MJ.

g) If assembling a DD Power Section repeat steps 1 to 6 for the second cartridge assembly.Tape the completed Upper and Lower Double-D assemblies together for shipping to thefield as one DD pack.

h) Before the Power Supply Assembly is finally passed for field operations, a full stringtest must be performed (refer to String Test Manual).

Note: it is a good idea to load and check the PSA at least 10 minutes before connectingthe tool on the rig floor. This ensures the batteries are pulled up enough to operate thetool during the shallow test which occurs just a short time after plugging in.

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Introduction




Parts List

Appendix


Section 5

Post-Job Inspectionand Test


Index

PERFOLAT

Contents

Introduction





Parts List


Appendix

Index

5. Post-Job Inspection & Test

When a Power Supply Assembly is returned from the field it must be checkedregardless of whether it has been used downhole. If the Power Section was unused aquick physical inspection and a LOAD test should be performed. If the Power Sectionpasses the checks it should be re-tagged as fully operational and put aside for future use.

A Power Section assembly that has been used downhole must undergo thor-ough testing irrespective of whether there has been any downhole problem.

5.1 Physical Inspection

The Coupling Connector should be disconnected and the battery cartridge re-moved from the Pressure Housing. The following checks should be carried out:-

a) Thoroughly clean the Pressure Housing and Coupling Connector. Removeany old Loctite present in the pressure housing screw holes.

b) Check the housing and Coupling Connector for any signs of washing (re-place any half-shells that are damaged).

c) Carefully inspect the O-rings and GT rings on the Coupling Connector. Re-place any O-ring that is damaged or has taken a permanent set.

d) Check the alignment and tightness of both ten pin electrical connectors onthe Coupling Connector. Re-align and tighten if necessary. Do not over-tightenthe locking screws as this will pinch the ten pin connector resulting in difficultyin mating the connector.

e) Inspect the cartridge assembly for signs of abrasion or damage to the heat-shrink.

f) Check the alignment and tightness of the ten pin connectors on the upperand lower bulkheads. Do not over-tighten the locking screws.

5.2 Tests on the Battery Cartridges

a) Check the continuity and leaks to ground through the upper and lower tenpin connectors on the Coupling Connector (Coupling Connector disconnectedfrom the cartridge).

b) Test the battery cartridge under NO LOAD and LOAD conditions (refer tosection 3.1).

Note: With a DD assembly the Upper and Lower cartridges must be joined witha Coupling Connector to perform this test.

c) If the battery assembly passes the LOAD test it should reassembled in thePressure Housing with the Coupling Connector. Place protective rubber capson the end of the Coupling connector and Pressure Housing. Re-tag as partiallyused, with the number of Joules remaining, and set aside for future use (seeAppendix for information on storage of new or used battery packs).

d) If the assembly fails the LOAD test the pack is probably depleted or one ormore cells may be internally damaged. To confirm this remove the heat shrinkand perform the step-down test (refer to section 3.1).



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5.2 Tests on the Battery Cartridges (cont)

e) Unplug the harness connectors and remove the upper and lower bulkheads. Try not totwist or tangle the wiring harness as this will make it difficult to reassemble on a newcartridge. Check the harness thoroughly for pinched wires or any other sign of damage(refer to section 2.2 on re-assembly).

f) If the wiring harness is damaged or pinched the damaged section should be removed andreplaced. Replace any wiring harness connectors that may be damaged (when removingthe connectors, be sure to get all the old RTV out first. Small long-nose pliers may then beused to ease out the connector).

Note: Do not attempt to remove the connector without first removing the RTV and be sureto grip the connector and NOT the wires or solder connections.

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Introduction




Parts List

Appendix


Section 6

Parts List


Index

PERFOLAT

Contents

Introduction





Parts List


Appendix

Index

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6. Power Supply Assembly Parts List

The following list details the spare parts available for the customer to serviceand maintain the Power Supply Assembly. Except where noted all components applyto both Standard and Double-D Power sections. Any parts not listed are available at theGeolink service center only.

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Introduction




Parts List

Appendix


Index

Appendix

Section 7

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Contents

Introduction

WorkshopInspection &Test




Parts List


Appendix

Index

7. Appendix

7.1 Appendix A: General Battery Handling and Safety

If you are dealing with a known overheated or damaged batteryassembly, protective clothing, rubber gloves and a respirator must be worn.If you are dealing with a battery assembly and it becomes clear that theassembly has been overheated or damaged, STOP and put on protectiveclothing, rubber gloves and a respirator. If the battery cells are involved ina fire, do not use water to put out the flames. The fire should beextinguished with a Lith-X (Graphite Class D fire extinguishing agent)powder. Sodium Carbonate should be spread over all exposed parts thatare not burning.

7.1.1 General Battery Information

The Power Supply Assembly of the Orienteer MWD system utilises industrystandard, high energy, long life Lithium batteries. The voltage of these batteries is notcomparable to that of manganese or alkaline batteries. Therefore, never mix batter-ies of different types or model or chemistry in a battery pack.

Batteries have a shelf-life of greater than ten years if stored at the manufactur-ers recommended temperature of 0 - 25 deg. C and in a dry, well-ventilated area. Ifprolonged storage is anticipated, batteries should be protected against excessive hu-midity.

The battery storage area in a workshop or warehouse should be secure, clearlymarked as Battery Storage and be provided with the correct class of fire extinguisher.

Passivation of cells occurs during any period of storage or non-use. An oxidelayer builds up on the Lithium cathode. This has the advantage of minimising thedegradation of the cells performance over time but this passivation layer must bebroken down by appropriate loading (refer to Section 2.2 for details) before a batteryassembly is ready for field use.

Individual cells may swell slightly in use depending on the load applied and themaximum temperature to which they are exposed.

7.1.2 Battery Composition

The batteries contain a Lithium ( or, in the case of higher temperature ratedcells, a Lithium alloy) cathode immersed in a Thionyl Chloride electrolyte. Lithium isa metallic element that reacts violently with water, releasing hydrogen gas. ThionylChloride is a toxic organic liquid which, in the presence of water or water vapour,decomposes into the toxic gases sulphur dioxide and hydrogen chloride.

The individual cells are constructed so as to withstand internal pressures gen-erated during operation and it is important to remember that the cell contents are highlypressurised at elevated temperatures.

If the batteries should become damaged or ruptured, sulphur dioxide, hy-drogen chloride and hydrogen will be released. Should the battery be ruptured tothe extent that the internals are exposed to the atmosphere, Lithium and ThionylChloride saturated carbon would be present in addition to the above.

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7.1 Appendix A: General Battery Handling and Safety7.1.3 Workshop Practices

Lithium batteries are not re-chargeable and it is hazardous to apply a reverse voltageto them.

If you have to deal with individual cells for any reason (Geolink normally sends out fullyassembled battery cartridges) double-check the orientation of each cell for correct polarity toensures that you do not reverse the cells.

When the battery cartridges are no longer useable, they should have a normal load appliedto them to deplete them prior to being stored for disposal. A battery is depleted when it reaches 0VDC under LOAD conditions. Under NO LOAD conditions, the open circuit voltage should stabi-lise at less than 0.5V DC after one hour. If the voltage recovers, the load should be re-applied for24 hours or until such time as the voltage does not recover to more than 0.5V.

It must be remembered that the batteries are never 100% depleted and should still behandled with care in all susequent operations.

Overheating or self-heating: a violent chemical reaction takes place if Thionyl Chloridecomes into contact with molten Lithium metal. A battery cell will rupture or explode if the lithiumwithin it reaches its melting point. A substantial safety margin is essential in order to allow forinternal self-heating in normal operation, the possible occurrence of hot-spots and unexpectedchanges on operational conditions. For these reasons, the maximum operational temperaturelimit for cells which have not been specifically designed for higher temperatures is 150 deg. C(302 deg. F).

If a battery cartridge or cell is hot for any unknown reason, it must be cooled to ambienttemperature before being handled. The cartridge or cell should be taken outdoors and cooled byimmersion in a large volume of water or by hosing down with copious quantities of water.

Damaged Power Sections: If the Power Section Assembly has been ruptured or floodedwhilst down hole, it is probable that one or more individual cells is also damaged. Hosing downthe battery assembly will complete any chemical reaction, and will reduce the temperature so thatthe assembly can be safely handled and disposed of. Never attempt to open or disassemble a cellor use undue mechanical force when dealing with the battery cells or cartridges.

Notes:

i) An intact cell or cartridge can safely be immersed in water or hosed down. This isthe best and safest way to deal with it.

ii) If the electrolyte and or/lithium metal is exposed, these materials can be ren-dered harmless by immersion or hosing with large volumes of water, but there willbe a more or less violent reaction depending on the quantities involved. Personnelshould not approach closer than 20', and the work must be done out of doorsbecause the water lithium reaction liberates hydrogen which may burn transiently.

iii) If electrolyte is exposed in any significant quantity, protective clothing must beworn and breathing apparatus may be necessary.

The following procedures should be adopted when dealing with damaged or overheatedbattery cartridges:-

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Appendix

Index

If these procedures are followed, the risk of explosion or harm from a damagedbattery assembly will be minimised.

7.1.4 Battery Storage

Due to the chemical composition of the batteries, there are precautions thatmust be adhered to when storing the battery cartridges:

New/Re-useable cartridges: cartridges should be stored in a cool (10-25 deg.C),dry, weatherproof facility. Storage of the cells at temperatures above 32C (90F) couldadversely affect the life of the cartridges. Do not store in direct sunlight.

The cartridges should remain in their protective covering until they are readyfor use. This will protect the batteries from possibly becoming part of a short circuit.

Used (depleted) Cartridges: these cartridges should be discharged under normalload conditions until the battery has reached 0V on LOAD (refer to section 7.1.3). Thecartridge is then ready for disposal in the correct manner.

Used battery cartridges should be stored in a lockable steel container, filled withvermiculite, located away from main traffic areas. The container should be waterproofand be kept cool and dry. It should be labeled as containing battery cartridges or haz-ardous materials. Do not store in direct sunlight. Use protective tape on the ends andwireway to prevent accidental shortcuts. Damaged or ruptured cells can be stored withother used batteries provided they have been properly isolated.

7.1.5 Battery Shipping and Disposal

Lithium batteries are subject to special procedures regarding their shipping anddisposal. The rules and regulations for each country are different and it is the responsi-bility of the user to see that laws and regulations are fully complied with.

The customers freight and shipping department should be aware of all IATAand DOT Dangerous Goods Regulations that may apply (see Section7.2) regarding theshipping of lithium batteries

Lithium batteries must be disposed of through an authorised company thatspecialises in the disposal of hazardous waste.

1. Keep all non-essential personnel away from the assembly.

2. Work outdoors.

3. Have correct fire fighting materials to hand (Sodium Carbonate and Lith-XGraphite powder for extinguishing Class D fires.

4. Wear protective clothing: protective coveralls or lab apron, rubber gloves andboots, respirator and face shield (preferable over goggles).

5. Hose down the damaged assembly until the chemical reaction is completeand the assembly has cooled.

6. Disassemble the PSA. When the damaged cartridge(s) has been isolated,dispose of in the correct manner.Fig. 7-1

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7. Appendix (contd.)7.2 Appendix B: Safe Handling and Return of Equipment Damaged by

Battery Pack Venting

7.2.1 Introduction

Geolink lithium battery packs, properly used, are a safe and efficient power source de-signed to operate under today's drilling conditions. However, due to the unpredictable nature ofthe drilling operation, from time to time they are exposed to conditions beyond the safe operatinglimits and this can result in battery venting or even an explosion.

When such an incident happens the first priority is the safety of personnel. Lower on thescale of priorities, but still important, is the recovery of the equipment. This document for Geolinkcustomers gives guidance on procedures for safe handling of equipment so affected, what is worthreturning and what is not, how to notify Geolink and how to ship the material once Geolink haveagreed to accept it.

Please abide by these procedures for the convenience and safety of both your and Geolink'semployees. If you have any questions or suggestions, please contact Geolink Customer Support inAberdeen on one of the following numbers:

Telephone: +44 (0)1224 778850Fax: +44 (0)1224 772333Out of Hours: +44 (0)7850 786671

7.2.2 Damage, Products and Hazards Associated with Battery Venting

Because of the high energy density inherent in lithium/thionyl chloride batteries, the po-tential for hazardous situations does exist. Most hazards are due to external or internal (caused byinternal or external shorting of the battery circuit) heating of a hermetically sealed battery. Over-heating causes liquid electrolyte to expand beyond the volume allowed for in manufacturing,increasing hydrostatic pressure inside the can, which might cause the battery to burst. Furtherheating (well above the rated temperature for the battery) can cause the lithium anode to meltwhich, in turn, will react spontaneously with the electrolyte and bring about explosive behaviour.

Please note that a High Temperature version battery pack is available which is capable ofoperating to 165C and withstanding temperatures to 180C although this is achieved by a com-promise on performance, especially at lower temperatures. Contact Geolink Customer Supportfor more information.

When a battery ruptures the electrolyte breaks down into Sulphur Dioxide and HydrogenChloride fumes. In a confined space these fumes can be very irritating and hazardous if they arebreathed at high concentrations. Details can be found on the data sheet attached. In the presence ofmoisture (e.g. humidity in the air) these substances hydrolyse to Sulphuric Acid and Hydrochloricacid respectively. By the time that this has occurred (except for extremely confined spaces) thereis very little hazard. If, however, venting takes place inside a tool there are two further hazards toconsider:

1. Acid residues (and by-products of the acid attack on the internal parts of the tool) willstill be present when the tool is broken out.

2. Despite the fact that there are no hermetically sealed connectors below the transmitterbulkhead, the combination of heat and rapidly expanding acid gases can cause pressured

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Index

gas to be trapped in tool sections. This might result in rapid release of gases andthe contents of the tool section once it is broken into.

Finally, any remaining lithium can react with water to produce lithium hydrox-ide (which is relatively safe) and hydrogen gas, which is highly flammable. However,exposing a ruptured battery to copious amounts of water in a well-ventilated area willserve to neutralise the lithium at the same time as dispersing the resulting hydrogen.

7.2.3 Battery Venting at the Wellsite - Identification

Wellsite battery incidents typically result from exposure of the battery pack totemperatures or shocks outwith the safe operating range of the cell. Therefore it isoften possible to predict that you have a potential for a problem according to wellsiteoperations. Most such incidents result from long periods on bottom without circula-tion when the circulating temperature has been near the operating limit of the tool(150C) combined with jarring or other shocks to the drill string. Note that stabilisedbottom hole temperatures are normally in the region of 20C above those recorded bythe MWD tool during circulation. These circumstances will usually occur when thestring has been stuck on bottom for some time. The effects will normally be observedwhile breaking out the tool string on surface.

7.2.4 Identifying a battery-venting incident is not always easy:

When the Transmitter/APC combination is parted from the PSA you may observedamage/blackening in the area of the LEMO connectors and you may smell or observeacid fumes.

In extreme cases you may observe the perforation of one or more of the pressurehousings.

You may observe that the coupling connector screws are hard to remove and that thepressure housings appear to be being forced apart. This indicates that pressure may betrapped inside the tool string.

7.2.5 Battery Venting at the Wellsite - Procedures

Once it is recognised that a battery pack has vented or exploded the first actionis to move all personnel into a safe area. Explain the hazard clearly so as not to causeundue alarm. Often, the reaction will have stabilised or mud ingress into the tool stringwill have neutralised possibly harmful substances by the time the tool has returned tosurface. However, it is possible that remaining cells are still unstable.

Once you have cleared the area, you must make an assessment of the potentialhazard and plan how you are going to deal with it. Once a plan has been established, allthose involved must be fully briefed so that everybody knows exactly what they arerequired to do during its execution. Appropriate protective equipment (Acid Gas FilterMask, Butyl Rubber Gloves, Chemical Worker Safety Glasses and Chemical Labora-tory Apron) should be worn during all procedures. The following are the only recom-mended courses of action at the wellsite:

1. If the battery incident is recognised from the external appearance of the tool(e.g. perforation of pressures housings, pressure housings pushing out fromcouplers, screws difficult to remove, etc.);

7.2.2 Damage, Products and Hazards Associated with Battery Venting(contd)

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a) Re-make the Transmitter Sub/Drill Collar connection. Break the assembly out of thedrill string, fit steel thread protectors on both ends and lay the assembly down on thecatwalk.b) Remove the assembly to a remote/safe area and arrange for water to be run through theassembly. This will have the effect of cooling the battery pack and diluting/neutralising theby-products.

2. If the incident is recognised when the tool string is broken out, remove the 'O' rings fromthe APC/SEA coupling connector, make the string up again and then follow steps 1a and1b above.

The condition of the battery pack should stabilise once it has had a chance to cool andwater has reached exposed internal components. It would be reasonable to leave the tool for aminimum of 24 hours from the point at which it was laid down to the point where consideration isgiven to moving the equipment. Once the water has been switched off, leave the tool for a further6 hours. If there are any signs of temperature rise, change in the symptoms of internal pressurisa-tion or other activity that may be associated with battery damage, continue the water flow for afurther 24 hours before repeating checks. The checks can reasonably be omitted in cases wherethe battery pressure housing is perforated or the tool has been opened at the ends. No attemptshould be made to dismantle the equipment at the wellsite. This is better done in controlled con-ditions at base.

The entire assembly should be dispatched back to base by surface transport. Local regula-tions concerning shipment of hazardous goods should be observed.

Note: it is very important that personnel dealing with equipment that may have beeninvolved in a battery venting incident stay clear of the ends of drill collars and pressurehousings. The contained items may be under extreme pressure which can be releasedviolently.

7.2.6 Dismantling the Equipment

Before dismantling a tool string that has been involved in a battery venting incident thefollowing potential hazards must be recognised:

1) The possibility that some batteries are still live and potentially unstable.

2) The possible presence of acidic gases or by-products.

3) The possibility that gases under pressure are trapped in the tool string. It is surpris-ing how good the seal formed by battery debris and coupling connectors can be.

A plan of action must be drawn up before work starts and everybody involved must befully briefed so that they understand their part in the procedure. The work should be carried out inthe open air, if possible, and appropriate safety apparel must be worn.

If, at any point during the process, something unexpected or unplanned for occurs, theprocedure should stop, the area made safe and the plan of action modified according to the newcircumstances.

It is difficult to offer specific advice on how to dismantle a tool in this condition. However,if there is any suspicion that pressure is trapped in the tool it must be released under controlledconditions. There is a real danger that uncontrolled release of pressure could result in personalinjury by the release of gases under pressure or flying debris. Any attempts to relieve pressure

7.2.5 Battery Venting at the Wellsite - Procedures (contd)

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Index

must be made remotely so that personnel are in a safe area when the pressure housingis punctured, perforated or communication with atmosphere otherwise achieved. Ad-equate ventilation must also be available in order to disperse any gases without dangerto personnel.

Under no circumstances should you attempt to dismantle the actual PSA/Bat-tery Pack involved. This item should be removed to a safe area, immersed in a solutionof Bicarbonate of Soda in water for one week and then sent for packing (in Bicarbo-nate of Soda) and disposal according to local regulations pertaining to the disposal oflithium batteries. In the event that the PSA is suspected as being unstable, proper pre-cautions should be taken to ensure that it does not present a hazard to anybody han-dling the assembly.

Note: it is very important that personnel dismantling equipment that may havebeen involved in a battery venting incident stay clear of the ends of drill collarsand pressure housings. The contained items may be under extreme pressurewhich can be released violently.

7.2.7 What can be Salvaged?

Because of the conditions prevailing when battery venting occurs all tool sec-tions, even those which appear to be working and uncontaminated, should be consid-ered as candidates for refurbishment. Pressure housings which have been exposed toacid gases should be scrapped as the wall thickness may have been affected and 'O'ring surfaces may be damaged.

The transmitter can almost always be salvaged from a vented battery stringbecause the high-pressure bulkhead prevents the ingress of venting by-products.

Any tool section which displays charring of internal components or heavy con-tamination by battery by-products should be treated as hazardous waste and disposedof accordingly.

Tool sections which are only lightly contaminated or apparently uncontami-nated can be returned to Geolink for repair/refurbishment. Before they are shippedthey should be placed in a bath of Bicarbonate of Soda solution for 24 hours to neutral-ise acid residues.

Under no circumstances will Geolink accept vented or exploded battery packsfor salvage. In exceptional circumstances Geolink may be able to arrange for disposal.Contact Geolink Customer Support before taking any action to move a battery pack inthis condition.

7.2.8 How to Return Contaminated Items

The following procedures must be followed when returning contaminated equip-ment to Geolink:

1. Fax Geolink with full details of equipment to be returned and its condition.Geolink will acknowledge with a fax stating whether the equipment will beaccepted for repair or not. Under no circumstances must contaminated equip-ment be shipped without this acknowledgement.

7.2.6 Dismantling the Equipment (contd)

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2. If you suspect that pressure may be trapped in an item (e.g. the transmitter), make surethat all pressure is relieved before packing the equipment.

3. The equipment should be packed in sealed polythene tubing containing Bicarbonate ofSoda powder.4. The packaging should clearly state:

"HAZARD - GOODS CONTAMINATED BY BATTERY VENTING BY-PRODUCTS".

5. The equipment should be shipped according to local and international regulations per-taining to hazardous goods.

7.2.9 Conclusion

Vented or exploded battery packs can be safely dealt with in all circumstances as long asthe following rules are observed:

1. Safety of personnel comes first.

2. Make a plan and follow it. If circumstances change, stop, change the plan. Make sureeverybody involved knows his or her part in the plan.

3. Always observe local and international rules and regulations pertaining to hazardousgoods.

4. Always inform Geolink if you intend to ship contaminated equipment for repair.

5. Use plenty of water to cool the equipment and flush away contaminants.

7.2.8 How to Return Contaminated Items (contd)

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Index

GEOLINK MATERIAL SAFETY DATA SHEETPRIMACELL LITHIUM/THIONYL CHLORIDE BATTERY

1. Material Identification and Information

LithiumThionyl Chloride SOCl2Aluminium Chloride AlCl3Lithium Chloride LiCl

2. Physical/Chemical Characteristics

Boiling Point SOCl2: 77CSpecific Gravity SOCl2: 1.63Vapour Pressure SOCl2: 92mm Hg @ 20CMelting Point SOCl2: -105CVapour Density (air=1) SOCl2: 4.1Solubility in Water SOCl2: DecomposesWater Reactive SOCl2: Hydrolyzes to form SO2 and HClAppearance and Odour SOCl2: Colourless to pale yellow; sharp

irritating odour

3. Fire and Explosion Hazard Data

Extinguisher Media: Dry Lithium Chloride, graphite powder, pyrene G-1,Lith-X

Special Fire Fighting Cover with dry Lithium Chloride or Lith-X powder.Procedures: Do NOT use water, moist sand, carbon dioxide or

soda-acid extinguisher. Wear protective breathingapparatus

Unusual fire and Do not short circuit, recharge, over-discharge,explosion hazards: puncture, crush or expose to temperatures above

150C.

4. Reactivity Hazard Data

Stability: Stable

Conditions to Avoid: Temperature in excess of 150CHigh humidity for extended periods of time

Hazardous Decomposition Sulphur Dioxide, Hydrogen ChlorideProducts:

5. Health Hazard Data

Primary routes of entry Inhalation

Health Hazards: Acute - vapours very irritating to skin, eyes andmucous membranes

Chronic - Overexposure can cause symptoms ofnon-fibrotic lung injury

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Signs and Symptoms Eye and mucous membrane irritationof Exposure:

Medical Conditions Asthma, other respiratory disorders, skin allergies,Generally Aggravated by eczemaExposure:

Emergency First Aid Seek medical assistance for further treatmentProcedures:

Eye Contact: Flush with running water for at least15 minutes. Hold eyelids apart. Seek immediate medical

treatment

Skin Contact: Rinse with large amounts of running water. Ifburns develop, seek medical treatment

Inhalation: Remove to fresh air. If breathing is difficult,administer oxygen and seek medical treatment

6. Control And Protective Measures

Respiratory Protection: Acid Gas Filter MaskProtective Gloves: Butyl Rubber GlovesEye Protection: Chemical Worker Safety GlassesVentilation To Be Used: Local exhaustOther Protective Clothing Chemical Laboratory Safety Glasses and Apronand Equipment:

7. Precautions For Safe Handling and Use

Steps To Be Taken If Do not breathe vapours or touch liquid with bare handsOr Released:

Waste Disposal Methods: Neutralise spill with soda lime, seal leaking battery andsoda lime in plastic bag and dispose of as hazardous waste

Precautions To Be Taken Do not short circuit, do not expose to temperaturesin Handling and Storage: above 150C. Do not recharge, over-discharge, puncture or

crush

Other Precautions and/or Do not store batteries in high humidity environmentsSpecial Hazards: for long periods

8. Transportation Information

US DOT (per 49CFR 172.01)Proper Shipping Name: Lithium Batteries, Liquid CathodeUN#: UN 3090Hazard Classification: Flammable Solid or Class 9 (Miscellaneous)Labels Required: FLAMMABLE SOLID or MISCELLANEOUSOther: DOT E-7052 Exemption required

CARGO AIRCRAFT ONLY

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ICAO or IATA

Proper Shipping Name: Lithium Batteries, Liquid CathodeUN#: UN 3090Hazard Classification: Class 9 (Miscellaneous)Labels Required: MISCELLANEOUSOther: CARGO AIRCRAFT ONLY

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7.3 Appendix C: Example Tool Hours Worksheet

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EM.PERFOLAT


Contents

Introduction




Parts List

Appendix


Index

Index

Section 8

PERFOLAT

Contents

Introduction





Parts List


Appendix

Index

A

Appendix ABattery Composition 7-1Battery Handling & Safety 7-1, 7-2General Battery Information 7-1Workshop Practices 7-2

Battery Depletion 7-2Battery Storage 7-3Shipping and Disposal 7-3

Appendix B 7-4Personnel Safety 7-6Return of Equipment 7-4Safe Handling 7-4Salvage 7-7

B

Battery Assembly. See Workshop Procedures: Assembly ProceduresBattery Harness Identification

Lower Harness 2-1Upper Harness 2-1

Battery Life. See Battery Life CalculationsBattery Life Calculations 3-3

2-7/8 (Ultralite) Tools 3-4Factors Affecting Battery Life 3-4Standard and 3-1/2 (Ultraslim) Tools 3-4

Battery Life Variation 1-3Battery Rupture. See Appendix BBattery Safety. See Appendix A: Battery Handling & SafetyBattery Venting. See Appendix B

C

Chemical Characteristics. See Safety DataControl Measures. See Safety DataCoupler Inspection. See Workshop Procedures: Inspection

D

D Battery Diagram 2-2D Battery Wiring 2-2D cells 1-1Damaged Batteries. See Appendix A: Battery Handling & SafetyDD Battery Diagram 2-4DD Battery Wiring 2-4DD cells 1-1Double D Cartridge 1-1

E

Explosion Hazard Data. See Safety Data

F

Fire Hazard Data. See Safety Data

H

Health Hazard Data. See Safety DataHigh Temperature Cells 1-1

8. Index

PERFOLAT


8. Index (contd)I

IATA. See Safety DataICAO. See Safety Data

L

Lithium Batteries. See Appendix A: Battery Handling & SafetyLower Harness (D). See Battery Harness Identification

M

Maintenance & Test 3-1Battery Test Procedures 3-1

Normal Battery Voltages 3-2Step-Down Test 3-3

Power Pack Maintenance 3-1Material Identification. See Safety Data

O

Output VoltageDD Assembly 1-3HT Assembly 1-3Standard Assembly 1-3

P

Parts List. See PSA PartsPersonnel Procedures. See Appendix BPhysical Characteristics. See Safety DataPost-Job Inspection & Test 5-1

Physical Inspection 5-1Tests on the Battery Cartridges 5-1

Pre-job Inspection and Test 4-1Tool Installation 4-1

Pre-Job Inspection and TestElectrical Tests 4-1Physical Inspection 4-1

Protective Measures. See Safety DataPSA

DD Assembly 1-5Downhole Assembly 1-2Functional Description 1-3

Output Voltage 1-3Physical Description 1-1Standard (D) Assembly 1-4

PSA Parts 6-1

R

Reactivity Hazard Data. See Safety Data

S

Safe Handling. See Safety; Safety DataSafety. See Appendix A: Battery Handling & SafetySafety Data 7-9Salvage of Parts. See Appendix B: SalvageStandard Cartridge 1-1

PERFOLAT

Contents

Introduction





Parts List


Appendix

Index

T

Temperature Limit. See Appendix A: Battery Handling & SafetyTransit Damage

Inspection. See Workshop InspectionTransit Spacer. See Workshop Procedures: InspectionTransportation Information. See Safety Data

U

Upper Harness (D). See Battery Harness Identification

W

Appendix BBattery Venting at the Wellsite 7-5

Workshop Maintenance and Test. See Maintenance & TestWorkshop Procedures

Assembly Procedures 2-1Assembly Process 2-3Load Test 2-3Tools and Equipment 2-1

Inspection 2-1

8. Index (contd)

PERFOLAT

PSA PERFORACION

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