1.0 Geo-Pilot 7600-9600 Theory

Geo-Pilot 7600 9600 Theory
Geo-Pilot Training
A Little Bit of History

Remote Controlled Dynamic Orientating System-RCDOS
FOR INTERNAL USE ONLY
Remote Controlled Dynamic Orientating System-RCDOS
Build / Drop Performance in Concrete

Drilling Test, Dec. 18/98
64 Concrete Block Drilled
Inclination (Degrees)
93.0
4.38/100' Build Rate
92.0
91.0
90.0
89.0
88.0
87.0
5.2/100' Drop Rate
86.0
0
20
40
60
80
Measured Depth (Feet)

LowSide
HighSide
GEO-PILOT 7600 AND 9600 SERIES TOOLS
7600 SERIES
9600 SERIES
7600-9600 Main Components
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Intermediate Housing
Reference Stabilizer
Drive Sub
Repeater
Flex
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
Geo-Pilot Driveshaft
Pin Down Driveshaft
9600 - 6 5/8 Reg, 7 5/8 Reg
7600 - 4 IF, 4 Reg
Solid through bore one piece shaft.
Nickel-based precipitation hardened super-alloy forgings (Alloy 718)
Radial and
Thrust
Bearings
Compensator
Bearing
Cantilever
Bearing
10
Eccentric rings
Focal Bearing
11
Tension
Shaft Catcher
Thrust Ring
Eccentric Rings
Cantilever Bearing
Compensator Bearing
Octagon
Locknut
Driveshaft Tension-Compression
Compression
Solid through bore one piece shaft.
100 to 200 psi pressure drop through tool.
Shaft ID is 1-5/8 (7600) & 2 3/8 (9600).
Shaft OD (upper) is 3 (7600) & 3.8 (9600).
Upper driveshaft remains in tension to prevent buckling.
Octagon insert transfers torque to driveshaft from drive sub.
Highest stress point is at the thrust plate where the shaft goes from tension to
compression, there is a shaft catcher below this point.
Driveshafts are manufactured from a nickel-based precipitation hardened super-alloy

forgings (Alloy 718)
12
Octagon
13
Tension and Compression Locknuts
Compression Nut
14
Locknut
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
15
Reference Housing
Decoupled from the drillstring.
Rotates slowly, typically 5-10 rph.
Provides a stable reference for toolface control.
Reference stabilizer provides resistance to rotation.
9600 - 9 5/8 OD
7600 - 7 5/8 OD
16
Reference Housing
Reference
Stabilizer
Lower
Housing
Intermediate
Housing
17
18
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
19
Rotary Seal Assemblies
One at top of housing and one at bottom.
Rotary seals are designed to keep drilling fluids out of the housing and keep
lubricating oil in.
Seals are designed to pump 1 ml of oil per hour at 60 rpm out of the tool. Action
flushes the seal face and protects it from damage from fines thus prolonging
operating life.
Kalsi seal is the primary seal between rotating and non-rotating interface.
20
Upper and Lower Rotary Seals
21
Rotary Seals
Diaphragm
Debris Seal
Barrier Seal
Kalsi Seal
22
Kalsi Seal
The Kalsi Seal is installed in a housing that compresses it

against the shaft eliminating clearance and establishing static
sealing in the same manner as other interference type seals,
such as o-rings. When the shaft rotates, the seal remains
stationary and the seal to shaft interface becomes dynamic.
The dynamic sealing lip has a wavy shape on its lubricant side,
and an abrupt circular exclusionary shape on its environment
side. This unique geometry dramatically improves seal life by
lubricating the dynamic seal-to-shaft interface while excluding
environmental contaminates.
23
Kalsi Seal
As rotation occurs, the waves cause the rotational velocity to

hydrodynamically wedge a thin lubricant film into the dynamic
sealing interface. This hydroplaning effect lubricates the seal
and shaft surfaces, and prevents the typical dry rubbing wear
and high friction associated with conventional seals. This
prolongs seal and shaft surface life and makes higher speed and
pressure practical. When rotation stops, the hydrodynamic
action stops and the static seal is reestablished.
The hydrodynamic wedging action causes a controlled lubricant

leakage rate during rotation. Leakage rate is dependant upon
rotary speed, lubricant viscosity, and differential viscosity.
24
Kalsi Seal
Single Kalsi Seals
Dual Kalsi Seals
Mechanical Seal metal to metal seal
25
Seal Covers
26
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
27
Lower Housing
Focal bearing
ABI-ABG
Bias unit
28
Focal Bearing
A spherical acting bearing assembly that acts like a fulcrum permitting the shaft to
pivot the bit in the opposite direction of the shaft deflection.
Acts in 360 degrees to allow toolface to be oriented in any direction.
Also is the location of the shaft catcher.
29
Focal Bearing
Split Thrust Ring (Shaft
Catcher)
Spherical
Bearing
Thrust
Ring
Focal Bearing Spherical

Bearing
30
Mounting
Adapter
Focal Bearing
31
Focal Bearing
32
At Bit Inclination
Same control electronics as a Series II ABI commonly used in SperryDrill Mud

Motors
Utilizes a 3-axis quartz-hinge accelerometer stack, similar to the kind used in PCD
probes but packed in a frame. Built specifically for the Geo-Pilot by JAE.
+/-0.1 degrees accuracy 2 sigma, 0-180 degrees.
Sensors located 3 feet from bottom of Geo-Pilot.
33
At Bit Inclination
Monitors inclination and highside of hole relative a scribed reference point on lower
housing.
Highly accurate and much more stable in comparison to motor version.
Allows for toolface control down to .2 degree of hole angle.
No magnetic toolface at present.
34
ABG - At Bit Gamma

The closest to the bit gamma-ray measurement in the industry
Azimuthal measurement.
The ABG sensor is available for both the 7600 Series and the 9600
Series Geo-Pilot system to cover hole sizes from 8-3/8 inches to
26 inches.
1m
35
ABG - At Bit Gamma
Image can be generated realtime and recorded.

Image quality dependant on roll rate of housing, sample rate etc.
36
Bias Unit
It is core to the tools design concept. Understand this and you know whats
going on.
The bias unit braces against the lower housings inner diameter to push the
shaft off of the center line of the housing.
It is referenced to the scribe line on the lower housing for a reference position
which the ABI uses.
Assembly is braced against the lower housing of the tool to prevent it rotating
37
Bias Unit
Fundamentally the bias unit pulls rotational energy from the shaft by engaging
electro-mechanical clutches which transmit the torque from the shaft through a gear
box to the eccentric rings to make the eccentric rings move from their current
position relative to the housing.
This activity controls the toolface and % deflection.
38
Bias Unit
There are 7 core elements to understand:
Eccentric Ring Assembly

Home Sensor
Harmonic Gear
High Speed Counter
Clutch Assembly
Oldham Coupling
Taper Lock Ring
Has 2 halves. Upper half controls outer ring. Lower half controls the inner ring.
39
It is an eccentric ring within a ring. Each ring deflects the shaft 2mm for a
maximum shaft deflection off of the center line of the housing of 4mm for 7600,
7mm for 9600.
The eccentric ring is a core element made in Japan.
The home position for the outer ring is 0 and the home position for the inner ring is
180 .
40

Full Deflection
Cams in line
Zero Deflection
Cams at 180 deg
Outer Eccentric Cam
C
L
Inner Eccentric Cam
7600 - 2 mm deflection per ring for a total of 4 mm (4.5 for EDL 7600)
9600 - 3.5 mm deflection per ring for a total of 7 mm
41
When ever the 2 rings are exactly 180 different in angle the shaft has 0%
deflection. For example Outer = 60 and Inner = (60 + 180) = 240
When ever the 2 rings have exactly the same position the shaft has 100%
deflection off of the center line of the housing. For example Outer = 40 and Inner
= 40
42
Home Sensor
The outer and inner eccentric ring each has a home sensor. The sensor provides
position information for each ring.
At home position the outer ring is at 0 and the inner ring is at 180 and the
deflection is 0%.
Each time the home magnet goes by the hall effect sensor the electronics updates
its position counters for the particular eccentric ring that sensor is responsible for.
In this manner the electronics maintains a running reference point for each eccentric
ring.
43
Home Sensor
Home is always zero % deflection.
Home is a very specific position of the eccentric rings at zero
deflection.
44
Home Sensor
Home Position
Inner Home
Outer Home
Zero Deflection
IH Sensor
H
H II
OH
45
OH Sensor
Home Sensor
Outer Home
Inner Ring 180offset
100% Deflection
HI
IH Sensor
46
OH
OH Sensor
Home Sensor
Inner not Home

Outer not Home
Outer
Home
Position
Rings Home
180
offset
Inner
Ring
Home180offset
Zero Deflection
100%
Outer
Home
Deflection
NOT HOME
Zero Deflection
OH Sensor
IH Sensor
47
Home Sensor
48
Harmonic Gear
The Harmonic gear is a core element that is built in Japan.
The gear provides a 180:1 gear ratio. This means we put 180 right hand
turns into the input side and we get 1 left hand turn out.
This gear reduction enables a large mechanical advantage in moving

the eccentric rings.
The output side is attached to the home sensor magnet hub and the
associated eccentric ring. Again, there is one for each side of the bias
unit.
49
Harmonic Gear
50
Harmonic Gear
The wave generator imparts a continuously moving elliptical form
or wave-like motion to the Flexspline.
This causes the meshing of the external teeth of the Flexspline
with the internal teeth of the Circular Spline at their two
equidistant points of engagement to progress in a continuous
rolling fashion.
Since the Flexspline has two less teeth than the Circular Spline
and because full teeth disengagement is made possible by the
elliptical shape of the Wave Generator, each complete revolution
of the Wave Generator causes a two tooth displacement of the
Flexspline in relation to the Circular Spline.
This displacement is always in the opposite direction of the
rotation of the Wave Generator (see diagram)e.g if the Wave
Generator is rotating in a CW direction, the two-tooth-perrevolution displacement of the Flexspline will be in a CCW
direction and vice versa
Harmonic Gear Animation
51
High Speed Counter
Consists of 2 hall effect sensors to track counts as well as direction of movement of

the clutch armature and a 16 magnet hub.
The sensors remain stationary with the housing while the hub spins underneath it.
On the high speed side of the harmonic gear.
Similar to the home sensor but more frequent and finer measurement to allow
accurate toolface control. This is the primary position indicator for the eccentric
rings and thus toolface and deflection.
52
High Speed Counter
The 2 sensors keep track of which direction the hub is moving and sends the
counts to the control electronics which keep track of how many counts the eccentric
ring is away from the home position.
There is one set for each half of the bias unit to keep track of each eccentric ring.
The counters count from 0 to (180 x 16 x 4) = 11520 counts max. 180 revs of the
high speed = 1 rev of the eccentric, 16 magnets on the hub, 2 hall effect switches,
counts both edges of the signal
53
High Speed Counter
54
Clutch Assembly
An electro-mechanical clutch moves an armature approximately 0.007 to enable

movement of the eccentric ring when turned on.
When off the armature rests on a brake plate preventing the eccentric ring from
moving relative to the housing.
When on the armature rotates transmitting torque from the shaft through the gear
box to the eccentric ring.
There is one clutch for each half of the bias unit.
55
Clutch Assembly
Each clutch pulls about:
500 mA of current at 20V for 7600 tool
300 mA of current at 20V for 9600 tool
The initial turn on is with full current but after

engagement the current is feathered to conserve
battery power while still maintaining proper clutch
engagement.
56
Clutch Assembly
57
Oldham Coupling
Allows for X-Y movement (cross axis) of the shaft inside the housing while still
transmitting concentric rotation to the clutch. This means the shaft can be off of the
centerline of the housing without binding the clutch.
58
Taper Lock Ring
Locks the ends of the bias unit rotating parts to the shaft to couple rotational energy
from the shaft into the oldham coupling.
Basically a Morse taper that compresses the ring onto the shaft to grip it.
59
Bias Unit
60
Bias Unit
Home Sensor
Eccentric Rings
Harmonic
Taper Lock
Oldham
Clutch
High Speed Hub
61
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
62
Electronics
Cantilever bearing
Battery
Compensator
EM Coupler
63
Electronics
Consists of 4 key boards.
Controller Module
Interface Board
Clever Board
Power Control Board
Contains 6 capacitor banks for driving the clutches.
64
Electronic Control Insert
Controller Module (aka CM board)
The brains. Controls the Geo-Pilot and interfaces with the FEWD. Most
firmware upgrades deal with software in this board. Contains 2 megabytes
of memory.
Same board as used for ABI Receivers, SLD, PWD...
Interface Board
Controls all the interfaces to sensors in the housing: Quadrature position

counters, home, rpm, oil level and ABI
Routes commands from CM board to Clever board to turn on and off

clutches.
65
Clever Board
Called clever because it was 10 years ago when it was first made.
Turns on and off clutches.
Uses stored energy in capacitor banks to assist in kicking on the clutches.
Same board used in MPT Pulser to control valve solenoid.
Also feathers clutch on current after initial kick.
66
Power Control Board
Takes power from the battery insert and converts it +5, +14, -14 Volts DC
Common board used in other tools.
67
Cantilever Bearing
Radial bearing that prevents the shaft from bending above that point. Acts as
upper end of bowing point of shaft for the 3 contact points (Cantilever Bearing,
Eccentric Ring Assembly, Focal Bearing)
Located between the battery and electronic control insert.
68
Lithium Battery Insert
Similar in design to the CIM Battery
7600 tool - Consists of 24 CC lithium cells containing 4.8g of lithium each for a total of
115.2 g of lithium per battery Offers 200 hours+ of steering time. De-rated for 48 Amp
Hours.
9600 Tool - 139.5 grams in the 12 tool - 60 Ahrs.
69
Lithium Battery Insert
Certified for cargo plane transportation.

MUST NOT USE PASSENGER PLANES
Must have hazardous goods declaration accompany tool.
Located inside housing - NOT rigsite serviceable/changeable. (Only at level 2)
Exception is Battery on Top Tools.
70
Hydraulic Compensator Assembly
Has 2 fundamental functions:

Balance piston allows the oil system inside of the housing to be the same pressure as
the hydrostatic pressure on the outside. This allows the rotary seals not to have to deal
with the high pressure of the hydrostatic head.
Spring adds to the internal pressure of the oil about 40 psi. This encourages the rotary
seals to pump 1 ml of oil/hour across the seal face.
Contains 2 oil level sensors.

First sensor is low oil which means 90% of the 2 litres of compensation volume is gone.
The second sensor is No Oil which means 100% of the oil compensation volume is
gone and the rotary seals no longer have a 40 psi bias pressure across them.
71
Hydraulic Compensator Assembly

Balance
Piston
Travel Stop Point

for Piston
Oil Level
Sensor
Drilling fluid fills this area to

exert circulating pressure on
piston
Vent Port
72
Oil Level Switch
73
Piston Position
3
Normal
Full
1 2
6 7
PP1 PP2
4
5 6
Mud
Piston
Oil
Measuring Stick
Downhole
74
Oil Level Switch
Shaft RPM Sensor
The RPM sensor measures the differential speed between the shaft, which is
coupled to the drill string and the housing, which is decoupled from the drill string in
the rotational sense only.
If the housing rotates at the same speed as the shaft then the RPM is zero even if
you have 60 RPM on surface. In such cases there will be other indicators that this is
happening
Consists of 16 magnets mounted on a hub that is attached to the drive shaft. The
sensor is mounted in the housing and is a hall effect sensor.
RPM is presently calculated by checking the counts every second and averaging the
last 15 seconds worth of counts.
75
Shaft RPM Sensor
76
RPM Sensor
RPM
Sensor
77
Electromagnetic (EM) Coupler
It is a coil within a coil providing a short-hop for comms.
It echoes the lower sub bus signals of the FEWD tool to and from the Controller
Module board inside the Geo-Pilot rotation resistant housing.
One coil rotates with the shaft while the other coil is fixed inside the housing.
The shaft rotation does not affect communication quality.
Not present in Battery on top tools.
78
Electromagnetic (EM) Coupler
EM Coupler
79
Compensator Bearing
80
Power Unit
81
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
82
Provides resistance to rotation
Roller carriage assemblies
Upper radial and thrust bearings
83
Reference Stabilizers
Rollers are designed to allow easy movement in and out of the hole but inhibit
the ease of rotation of the housing.
The rollers hold back about 75-150 ft-lb of torque from the shaft through to the
bearings.
The rollers completely tuck underneath the blades if required by hole diameter.
84
Reference Stabilizers - Fixed
85
7600 Reference Stabilizers - Pads
7600 Standard Reach Pad
7600 Extended Reach Pad
86
9600 Reference Stabilizers
87
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
88
Drive Sub
Drive Sub
Transfers torque to driveshaft
Octagon insert
Tension and compression nuts
89
Drive Sub
Acts as interface for torsion and weight on bit load transfers from the shaft and
housing respectively. Contains mating kelly like hole to connect to the top end of the
shaft.
Facilitates 2 wires from the EM coupler to be transferred from the shaft to a repeater
insert in the sub above it.
90
Upper Radial and Thrust Bearings
These take the 90% of WOB load from the housing and transfer it back into the drill
collars. The radial bearings keep the shaft top end centered in the housing.
The radial bearings are not designed for large bending moments from the collars
above so care must be taken in handling them on surface and how the BHA is
configured.
91
Drive Sub
92
Upper Radial and Thrust Bearings
93
Octagon
94
Tension and Compression Locknuts
Locknut
Compression Nut
95
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
96
Repeater
Repeater
Repeater insert passes MWD comms
Booster tube interfaces with driveshaft
Sleeve stab for 9600
97
Repeater Insert / Sub
An electronic board that isolates the lower communication bus of the FEWD tool
from the high inductive load of the EM coupler coil.
The flex collar assembly is screwed onto this. Box has a CIM hanger.
Battery On Top Tools will have an extended repeater sub to accommodate a BAT
battery.
Normally made up to flex prior to shipping.
98
Repeater Insert
99
Repeater Sub 9600
100
Driveshaft
Reference Housing
Rotary Seals
Lower Housing
Drive Sub
Repeater
Flex
101
Flex Sub
Flex Sub
Decouple Geo-Pilot from the rest of BHA
Electrical connection with MWD
Optional location of DM survey sensor
102
Flex Collar / Dummy DM
A standard 9ft PM/DM collar is flexed.
The flex collar protects the upper radial bearings in the Geo-Pilot from being over
stressed.
Also decouples any BHA bending from above.
The collar will contain either a Dummy DM or a Genuine DM
Dummy DM is a sonde dimensionally the same as a DM probe with the same

electrical connections on the top and bottom. The dummy DM has a single wire
running inside it to make up the communication link from the FEWD lower bus down
to the repeater insert.
Has a PM adapter tip type connection on top.
103
Flex Collar / Dummy DM
104
Electronic Functional Schematic
105
SDC or P4M
HCIM
FEWD String
Directional Module
Dummy DM / FLEX
Repeater Board / Sub
Geo-Pilot Non-Rotating Housing

EM Coupler
Electronics Insert
Lithium Battery
Power Control Board
CM Board
Clever Board
6 Capacitor Cans
Interface Board
Inner/Lower Eccentric
ABI Insert / GABI Insert
Outer/Upper Eccentric
Hall Effect Sensors

RPM Sensor
Low Oil
No Oil
Outer Home
Inner Home
106
Outer HS Quad
(2 Hall sensors)
Inner HS Quad
(2 Hall sensors)
Questions?
107

1.0 Geo-Pilot 7600-9600 Theory

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1.0 Geo-Pilot 7600-9600 Theory

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Copyright:

Verfügbare Formate

Geo-Pilot 7600 9600 Theory

A Little Bit of History

FOR INTERNAL USE ONLY

Remote Controlled Dynamic Orientating System-RCDOS

FOR INTERNAL USE ONLY

Build / Drop Performance in Concrete

64 Concrete Block Drilled

5.2/100' Drop Rate

Measured Depth (Feet)

FOR INTERNAL USE ONLY

GEO-PILOT 7600 AND 9600 SERIES TOOLS

FOR INTERNAL USE ONLY

7600-9600 Main Components

FOR INTERNAL USE ONLY

7600-9600 Main Components

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

Solid through bore one piece shaft.

100 to 200 psi pressure drop through tool.

Shaft ID is 1-5/8 (7600) & 2 3/8 (9600).

Shaft OD (upper) is 3 (7600) & 3.8 (9600).

Upper driveshaft remains in tension to prevent buckling.

Octagon insert transfers torque to driveshaft from drive sub.

Driveshafts are manufactured from a nickel-based precipitation hardened super-alloy

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

Tension and Compression Locknuts

FOR INTERNAL USE ONLY

7600-9600 Main Components

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

7600-9600 Main Components

FOR INTERNAL USE ONLY

Rotary Seal Assemblies

One at top of housing and one at bottom.

FOR INTERNAL USE ONLY

Upper and Lower Rotary Seals

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

The Kalsi Seal is installed in a housing that compresses it

FOR INTERNAL USE ONLY

As rotation occurs, the waves cause the rotational velocity to

The hydrodynamic wedging action causes a controlled lubricant

FOR INTERNAL USE ONLY

Single Kalsi Seals

Dual Kalsi Seals

Mechanical Seal metal to metal seal

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

7600-9600 Main Components

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY

Acts in 360 degrees to allow toolface to be oriented in any direction.

Also is the location of the shaft catcher.

FOR INTERNAL USE ONLY

Focal Bearing Spherical

FOR INTERNAL USE ONLY

FOR INTERNAL USE ONLY