Section 06 - HEL 091003

Field Instruction
Section 6
Hostile Environment Logging

Version 1
© 2002 Contents of this document are proprietary to Computalog Drilling Services and may not be Page 1 of 63
reproduced or otherwise used in any manner whatsoever without prior written permission of Computalog.
COMPUTALOG DRILLING SERVICES Field Instruction
HEL FI0006 Rev. A
Revision History
Revision ECN Number Change Description

A April 1, 2003 - Original Release of Document
Prepared by: Christine Guerrero Date: April 1, 2003

Originated By: J. Reyna & C. Guerrero Date: January 8, 2003
Operations Approval: Date:
Changed By: Date:

Operations Approval: Date:
© 2002 Contents of this document are proprietary to Page 2 of 63

Computalog Drilling Services and may not be reproduced
or otherwise used in any manner whatsoever without prior
written permission of Computalog.
HEL FI0006 Rev. A
CONTENTS
1.0 Introduction 5
2.0 HEL Insert Assembly 5
3.0 Operation 6
4.0 Collar Configuration 10
5.0 Features 12
6.0 Applications and Benefits 12
7.0 Specifications 13
7.1 Mechanical…………………………………………………………………………………..….. 13
7.2 Measurement……………..…………………………………………………………………….. 14
8.0 Hardware 14
8.1 HEL Tool Build Procedure …………………………………………………...…….………….. 14
1.0 Collar Preparation……………………………………………………………………….. 14
2.0 IDS Centralizer Preparation ……………………………………………………………. 15
3.0 IDS Preparation and Verification ……………………………………………………… 15
4.0 IDS Flow Diverter Preparation …………………………………………………………. 15
5.0 IDS Installation onto the IDS Flow Diverter ………………………………………….. 16
6.0 IDS / IDS Flow Diverter Assembly Test ………………………………………………. 20
7.0 IDS / IDS Flow Diverter Assembly Installation ………………………………………. 21
8.0 BAP Insert Installation ………………………………………………………………….. 21
9.0 GAM Insert Installation …………………………………………………………………. 22
10.0 First Battery Installation ………………………………………………………………… 23
11.0 Second Battery Installation ……………………………………………………………. 24
12.0 Driver Insert Installation ………………………………………………………………… 25
13.0 Pulser Insert Installation ……………………………………………………………….. 26
14.0 Solenoid Resistance Inspection ………………………………………………………. 28
15.0 Installing the Orifice Into the Pulser ………………………………………………….. 32

HEL FI0006 Rev. A
16.0 Pulser Installation ………………………………………………………………………. 35

17.0 HEL Verification Test …………………………………………………………………… 36
18.0 Flow Ring Installation …………………………………………………………………… 36
19.0 Teflon Buffer Stack Calculation ……………………………………………………….. 36
20.0 Interconnects ……………………………………………………………………………. 37
21.0 External Data Port ………………………………………………………………………. 37
22.0 Wear Band ………………………………………………………………………………. 40
9.0 Software 40
9.1 Cabling Setup …………….…………………………………………………...…….………….. 40
9.2 PCI Serial I/O Settings ………………………………………………………………………… 46
9.3 Tool I/O …………………………………………………………………………………………. 48
9.3.1 Raising the Receive Threshold Value ………………………………………………… 48
9.3.2 Quality Check of Communication ……………………………………………………… 50
9.3.3 High Temperature Battery ……………………………………………………………… 51
9.4 HEL Surface Initialization ……………………………………………………………………… 52
9.5 Troubleshooting Coms ………………………………………………………………………… 63

HEL FI0006 Rev. A
1.0 Introduction
The LWD sector of the petroleum industry has steadily matured since the first MWD tool was introduced
in 1979. The increased application of horizontal and extended reach drilling has pushed oilfield service
companies to continually develop and expand existing technology to meet market requirements. In fact,
many wells currently under development would not have been possible without the real-time modeling,
data processing, and advanced interpretation techniques provided by LWD measurements. These
successes have promoted the general industry attitude that LWD can and will replace conventional
wireline logging methods for many future situations.
Today’s drilling challenges include extreme temperatures, hydrostatic pressures, and flow rates that
continue to stretch existing technology to its very limits and beyond. With rig costs exceeding $250,000 a
day ($10,000 per hour), dowhnole tool performance and reliability are major issues. So is BHA
turnaround time and data transmission / logging speeds to keep up with high ROPs. Over the past few
years, Computalog’s new generation PrecisionLWDTM logging suite has been engineered from the ground
up to meet these demands. No design goals had to be compromised to incorporate yesterday’s
technology. As a relatively new division of Precision Drilling, no legacy equipment was used – it’s pure
next generation LWD technology for the harshest of logging and drilling environments. Each tool is
vibration tested to 30 g on a slip table, baked at 200 °C, and designed to withstand 30,000 psi.
The Hostile Environment Logging (HEL) MWD is the heart of the PrecisionLWDTM logging suite. The HEL
provides all data transmission through positive pulse telemetry and houses an integrated directional
sonde which acquires 6-axis steering surveys and an environmental vibration severity measurement.
When needed, the HEL collar can also be equipped with a real time and recorded Gamma Ray sensor
and/or a Bore and Annulus Pressure measurement. When run inline with the AZD, TNP, and MFR, the
HEL rounds out a full triple combo LWD system. PrecisionLWDTM‘s precise family of formation sensors
and robust design provides the quality measurements critical for optimization of drilling mechanics,
geosteering, detection of abnormal pressures, and formation evaluation prior to extensive invasion.
2.0 HEL Insert Assembly
The HEL tool is composed of a number of sensor inserts, each serving a specific function. The insert
assembly affords rapid maintenance turnaround, quick field diagnosis and replacement of a failed
component as well as pulser maintenance. The individual inserts are as follows:
The Pressure Modulated Telemetry Pulser (PMT) uses the existing mud flow in the bore to assist in pulse
generation. This allows for a much simpler engineering design that contributes to increased reliability as
well as greatly reduced power requirements. The PMT is located at the top of the HEL tool and can
easily be removed for inspection and replacement of orifice.
The Driver contains the Controller Module (CM) – This sensor is known as the “Bus Master”. It has a
main processor (18C858) and a Comm processor (16C76). It is responsible for acquiring specific data
from each sensor and encoding the data for pulse transmission. Each sensor specific real time data is
programmed into the CM. The Pressure Switch (POPO) functionality also resides on this board as well
as an accelerometer/vibration switch which will be used in tandem with the pressure transducer to
determine the pumps status. The CM is the only sensor that has a Real Time clock (RTC). The CM
broadcast a universal time stamp which each sensor uses to resynchronize its internal timer.

HEL FI0006 Rev. A
The Dual Battery Module (DBM) is uniquely configured to provide continuous, redundant lithium battery
power for the HEL system. The system regularly toggles between two extended life batteries (BAT) in
order to maintain system power requirements under all drilling conditions. Software switching ensures
that in the event of cell failure, that backup power is readily available.
The Gamma Ray (GAM) sensor utilize Geiger Mueller tubes for formation identification. There is only one
PIC processor (18C252) on the board, no separate communication processor. A total of eight 32 kByte
I2C FRAM chips comprise the 512 kByte memory. Using a 10 second recorded sample rate, the memory
will last 14 days before it is full. The GAM sensor can only be included in the HEL tool when configured
with a long pulser collar as shown in Collar Configuration. For more information on the GAM sensor, see
Section 7 – Gamma Ray (FI0007).
The Bore and Annulus Pressure (BAP) sensor uses two quartzdyne pressure transducers, which provide
a very accurate (within +/- 1.0 psi) measurement. There are four PIC processors on this sensor: the
main processor (17C756A), a communication PIC (16C76) and two pressure transducer processors
(18C252). The data collected is stored to a 16 MegaByte NAND flash memory. Using a 5 second
recorded sample rate, the memory will last 229 days before filling. The BAP sensor can only be included
in the HEL tool when configured with a long BAP pulser collar as shown in Collar Configuration. For more
information on the BAP sensor, see Section 8 – Bore and Annulus Pressure (FI0008).
Integrated Directional Sonde (IDS) – The IDS orientation module consists of three orthogonal high
temperature accelerometers and magnetometers housed in a non-magnetic titanium alloy chassis
manufactured by JAE. There are three PCB assemblies housed in a 1.75” OD pressure barrel. (1) The
analog-digital controller (ADC) board’s primary function is to convert the voltage output from the
orientation module to a digital signal that is conditioned and sent to the controller board. (2) The
controller board uses the digital signal to calculate ray survey vectors and to calculate the survey
downhole. (3) The power board transforms and conditions the sub-bus voltage to +/- 12 volts DC and +/-
5 volts DC output to be used by the controller and ADC boards. The IDS is located at the bottom of the
HEL tool to minimize survey distance from the bit. For more information on the IDS, see the Survey
Quality Control Document (L3-CDS-US-LWD-TA00009).
The assembly has been developed with the objective of significant increases in reliability as well as
increased user friendliness for downhole hardware and software alike.
3.0 Operation
The HEL tool must be included in the BHA in order to acquire real-time data through mud pulse telemetry.
The HEL is the only tool equipped with a driver and a Pressure Modulated Telemtery Pulser (PMT). The
PMT physically creates a flow restriction within the HEL for pulse generation. The driver contains the
pressure and vibration switches for determining when to transmit data (recognizes pumps on and pumps
off conditions), it handles all the sensor data throughout the LWD system, and finally it tells the PMT
when and how long to pulse for transmitting the sensor data values to the surface for collection.
A simple way to envision how a pulse is generated is to image a garden hose. If water is flowing through
the hose and you place your finger over the end of it, the pressure will increase. The same is true for the
drillstring and BHA system, where the PMT is your finger. When the main valve is open (pulse OFF
position) the system is at standard operating pressure. When the main value of the PMT closes into the
orifice (pulse ON position), a backpressure is generated and pressure increases along the drillstring, back
to surface. Since the pulse OFF time is always at least 2.5 times greater than the pulse ON time, the

HEL FI0006 Rev. A
backpressure appears as a pressure pulse on surface, almost instantaneously (a pressure pulse will
travel at approximately 4100 feet per second in water).
The PMT uses the existing mud flow in the bore to assist in pulse generation. This allows for a much
simpler engineering design that contributes to increased reliability as well as reduced power
requirements. The PMT is composed of two pistons which work together for pulse generation: a Main
Valve and a Control Valve. The Main Valve is the component which closes into the orifice to create a flow
restriction. The Control Valve is electrically actuated as commanded by the CM. These two components
are physically separated by a hydraulic pressure chamber where the Control Valve is the back door. The
front door to the pressure chamber is through a channel along the bore of the Main Valve. In static
pressure conditions, the Control Valve is closed sealing the backside of the pressure chamber. Since the
chamber remains open at atmospheric pressure conditions, the Main Valve is mechanically forced down
(closed) by a spring.
1. NO Flow – Control Valve Closed – Main Valve Closed
As flow is introduced, the pressure drop through the orifice creates a low pressure zone below it. This
low pressure is transmitted up, along the bore of the main valve to the pressure chamber. Now, with a
low pressure trapped inside the chamber and a higher pressure surrounding the Main Valve above the
orifice, the spring will compress and the Main Valve will float in an open position.
2. Pulse OFF – Flow ON – Control Valve Closed – Main Valve Open
When commanded by the CM, the Control Valve will open the back door to the pressure chamber. This
is known as the pulse ON time, when the high pressure is allowed to equalize and the Main Valve is
again forced down into a closed position.
3. Pulse ON – Flow ON – Control Valve Open – Main Valve Closed
As soon as the Control Valve is closed again, the pressure chamber re-enters a state of lower pressure
and the Main Valve floats open.
To better illustrate this concept, let’s look at a cross-section of the PMT and Driver.

HEL FI0006 Rev. A
1. NO FLOW - Control Value CLOSED - Main Valve CLOSED

HEL FI0006 Rev. A
PH PH
Control Control
Valve Valve
Closed Open
PH PL PH
Differential
Pressure Pressure
Forces the Main Equalizes,
Valve Open Spring Forces
the Main Valve
Closed
PH PH
PL
2. Pulse OFF 3. Pulse ON

Flow ON Flow ON
Control Value CLOSED Control Valve OPEN
Main Valve OPEN Main Valve CLOSED

HEL FI0006 Rev. A
The pulse amplitude generated by the main valve is controlled by the pulser’s orifice size. The orifice to
be used downhole should be selected based on predicted flowrates. Too small an orifice, for the flowrate,
will cause excessive erosion. While too large an orifice will result in little erosion but weak signal. Other
factors to consider when choosing an orifice include: pulse ON time, LCM, Depth, Mud Type, and Mud
Solids content. Orifices are currently available in 5 sizes: 30°, 45°, 60°, 90°, and 120°.
Before sending the HEL downhole, the user will define two series of data trains into the CM. The data
trains are selected according to which sensors are included in the BHA and how often each data item is
needed. These series of data trains are referred to as Modes. Next, the user must select how to send
the data, or the Frequency at which to transmit data to surface. The Frequency is broken down into three
components: Time ON, Time OFF, and Decision Time. Time ON is the time that the main valve is closed
(pulse ON). Time OFF is the time that the main valve is open (pulse OFF). Decision Time is the encoded
data value window width as shown:
Td
On
Off
V= 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
4 bits / frame
For more information on data decoding, see Section 3 – Spectrum (FI0003).
4.0 Collar Configuration
The HEL tool has four separate pulser collar configurations. The first configuration consists of a short
pulser monel and should be used when providing Directional Services only. The insert assembly consists
of an IDS – Flow Diverter – DBM – Driver – PMT and has a total length of approximately 19 feet (5.8 m)
for all tool sizes.
PMT Driver BAT BAT Flow Diverter IDS

HEL FI0006 Rev. A
The second configuration consists of a slightly longer pulser monel and is used when providing
Directional and Gamma Ray logging services. The insert assembly consists of an IDS – Flow Diverter –
GAM – DBM – Driver – PMT and has a total length of approximately 22 feet (6.7 m) for all tool sizes.
PMT Driver BAT BAT GAM Flow Diverter IDS
The third configuration consists of a pulser monel which has been machined to include bore and annulus
ports and is used when providing Directional and Bore and Annulus Pressure logging services. This
pulser monel must only be used with a properly installed BAP to prevent the assembly from washing out
downhole. The insert assembly consists of an IDS – Flow Diverter – BAP – DBM – Driver – PMT and has
a total length of approximately 22 feet (6.7 m) for all tool sizes.
PMT Driver BAT BAT BAP Flow Diverter IDS
The fourth configuration consists of a long pulser monel which also has been machined to include bore
and annulus ports and is used when providing Directional, Bore and Annulus Pressure, and Gamma Ray
logging services. The insert assembly consists of an IDS – Flow Diverter – BAP – GAM – DBM – Driver –
PMT and has a total length of approximately 25 feet (7.7 m) for all tool sizes.
PMT Driver BAT BAT GAM BAP Flow Diverter IDS
Regardless of configuration, the standard directional monel is to be used whenever the RevolutionTM
Rotary Steerable is not included in the BHA. When being ran with the RevolutionTM, a flex directional
monel is used to achieve greater steering flexibility.
Pulser Monel Flex Directional Monel

HEL FI0006 Rev. A
5.0 Features
• The industry’s highest hydrostatic pressure rating – 30,000 psi.
• Reliable operation at temperatures of up to 356 °F (180 °C), with survival to 392 °F (200 °C).
• High flow rate capabilities for all size tools: 4 ¾ in. (400 gpm), 6 ¾ in. and 8 in. (1200 gpm).
• Can include a high temperature Gamma sensor (HAGR).
• Can include Bore and Annulus Pressure sensors (BAP).
• Can include an integral Environmental Severity Measurement (ESM).
• Long duration/redundant battery power (up to 29 days).
• Extreme lost circulation material tolerance (80 lb/bbl LCM).
6.0 Applications and Benefits

• System design affords efficient wellsite operation.
• High Temperature Gamma sensor (HAGR) provides accurate AAPI gamma ray measurements
both in Real-Time and Recorded modes.
• Bore/Annulus Pressure sensor (BAP) uses quartz transducers to provide highly accurate annulus
and bore pressure measurements.
• Environmental Severity Measurement sensor (ESM) monitors tool shock and drilling vibration.
• Dual Battery Module (DBM) assembly provides long duration, redundant power for extended
downhole operation.
• Pressure Modulated Telemetry system (PMT) uses mudflow and battery power to generate a
positive mud pulse.
• The Precision LWD system has been developed with the objective of significant increases in
reliability as well as increased user friendliness for downhole hardware and software alike.

HEL FI0006 Rev. A
7.0 Specifications
7.1 Mechanical
Nominal Tool OD 4 ¾ in. 6 ¾ in. 8 in.
Maximum OD 5 ¼ in. 7 3/8 in. 8 5/8 in.
Length 22 - 25 ft 22 - 25 ft 22 - 25 ft
Weight 1400 lbs 2850 lbs 4100 lbs
Top Connection 3 ½ IF Box 4 ½ IF Box 6 5/8 Reg Box
Bottom Connection 3 ½ IF Pin 4 ½ IF Pin 6 5/8 Reg Pin
9,900 – 10,900 28,000 – 32,000 52,000 – 56,000

Make Up Torque
ft-lbs ft-lbs ft-lbs
Max Torque 16,700 ft-lbs 48,200 ft-lbs 77,250 ft-lbs
Max Tension 750,000 lbs 1,800,000 lbs 2,850,000 lbs
Bending Strength Ratio 2.10 2.53 2.70
Dog Leg Severity – Rotating 20 deg / 100 ft 11 deg / 100 ft 10 deg / 100 ft
Dog Leg Severity – Sliding 36 deg / 100 ft 19 deg / 100ft 16 deg / 100ft
Equivalent Bending Stiffness

4.75 in. x 3.22 in. 6.75 in. x 4.24 in. 8.0 in. x 4.28 in.
(O.D. x I.D.)
356 °F 356 °F 356 °F

Max Operating Temperature
(180 °C) (180 °C) (180 °C)
392 °F 392 °F 392 °F

Max Survival Temperature
(200 °C) (200 °C) (200 °C)
Max Operating Pressure 30,000 psi 30,000 psi 30,000 psi
Max Flow Rate 400 gpm 1200 gpm 1200 gpm
Max LCM 80 lb/bbl 80 lb/bbl 80 lbs/bbl
Max Sand Content 3% 3% 3%

HEL FI0006 Rev. A
7.2 Measurement
MTF to GTF Switching 1 – 25 Degrees of Inclination
Toolface Update Period 3 seconds
Survey Update 30 seconds
Toolface Accuracy +/- 1.5 °
Azimuth Accuracy +/- 0.5 °
Inclination Accuracy +/- 0.1 °
Temperature +/- 0.5 °Celsius
Gamma Accuracy See Section 7
Bore and Annulus Pressure Accuracy See Section 8
8.0 Hardware
8.1 HEL Tool Build Procedure
1. Collar Preparation
9 Select the appropriate size HEL LWD Collar for the service(s) needed (DIR only, GAM,
BAP, ect.). Verify the total length for a non-cutback. The Collar Assembly is composed of
a box-box Pulser Monel collar and a pin-pin Directional Monel Collar which has been
torqued to specification.
Service Non Cut-Back Length – ALL Tool Sizes

DIR only 19.13 ft
DIR w/ GAM 22.14 ft
DIR w/ BAP 22.18 ft
DIR w/ GAP w/ GAM 25.27 ft
9 Remove debris from the outside and inside of the collar with cleaner/degreaser. Use a
hone brush to prepare the inside of the collar for insert installation.
9 Obtain the measurement from the inside shoulder of the collar to the box end.
9 Inspect the ID of the collar for pitting/washing and the connection threads for galling. Verify
that the connections using a thread gauge.

HEL FI0006 Rev. A
9 Liberally lubricate the collar bore with DC-200 to prevent o-ring damage during insert
installation.
9 Record each monel collar serial number on the Tool Build Sheet.
2. IDS Centralizer Preparation

9 Place the IDS Centralizer into the fin modification fixture and customize the OD of the
centralizer fins to fit the ID of the Directional Monel using a razor blade.
9 Install O-Rings (002083) and backup rings (000336), lubricating O-Rings with a thin coating
of DC-111 grease (001999).
3. IDS Preparation and Verification
Horizontal View of an IDS

9 Inspect and Clean Contacts.
9 Install O-Rings (002083, 002051), backup rings (000336), and ground spring (002009),
lubricating O-Rings with a thin coating of DC-111 grease.
4. IDS Flow Diverter Preparation
Vertical View of a Flow Diverter

9 Inspect and clean contacts.

HEL FI0006 Rev. A
9 Install O-Rings (002435. 002101), backup rings (000335, 000172), and ground spring
(002310), lubricating O-Rings with a thin coating of DC-111 grease (001999).
5. IDS Installation onto the IDS Flow Diverter

9 The following steps should be implemented in the shop and in the field in order to properly
assemble the IDS with the IDS Flow Diverter.
Step-By-Step procedures used for assembling the IDS to the Flow Diverter:
1. Align the IDS and the Flow Diverter

a. Make sure the electrical contacts and threads on the Flow Diverter and the IDS are
clean (use contact cleaner if necessary).
b. Situate the IDS on top of the Flow Diverter and make sure the key on the IDS goes
into the slot in the Flow diverter. See Figure 1.

HEL FI0006 Rev. A
IDS Key
IDS
Flow Diverter
Flow Diverter
SLOT
Figure 1
Note: Do no allow the IDS to drop into the flow diverter as this may damage the
threads. Slowly lower the IDS into the Flow Diverter.

HEL FI0006 Rev. A
2. Thread the IDS into the Flow Diverter

a. Setup the Parmelee wrenches as shown in Figure 2.
IDS
Jam Nut
Flow Diverter
Figure 2
b. The only Part which rotates is the “Jam Nut” on the IDS as shown in Figure 3. Be
sure to only grip the upper portion of the Jam Nut (which has a slightly larger OD)
with the Parmelee wrench.
Moveable
Portion of IDS
Figure 3
c. Once you have the Parmelee wrenches setup in the position shown in Figure 4 ,
turn Parmalee wrench #2 clockwise; if the IDS does not go in easily, a second
person may have to gently shake the IDS while the other person turns the wrench.

HEL FI0006 Rev. A
Parmelee Wrench #1
(Used to Backup up)
Parmelee Wrench #2
(Used to turn)
Figure 4
WARNING!: The top portion of the IDS should not rotate. If it does, STOP!!! Further
movement will destroy the connections inside the IDS.
3. Torque the IDS into the Flow Diverter.

a. Once you have finished screwing the IDS into the Flow Diverter, carefully lay the
assembly down into “V” blocks or insert stands.
b. Set the Parmelee torque wrench to 200 ft-lbs.
c. Situate the two wrenches (Parmelee wrench & Parmelee Torque wrench) as shown
in Figure 5.

HEL FI0006 Rev. A
Jam Nut
Torque Wrench
Parmelee Wrench
Figure 5
d. Apply the torque by pushing down on the end of the parmalee torque wrench until you
hear a “click”.
Note: You can use emery cloth if the torque wrench slips while applying torque.
6. IDS / IDS Flow Diverter Assembly Test

9 Set an external power supply to read 30 V, 0.17 Amps. Verify the setting by connecting the
red and black leads together and adjusting the current and voltage as needed
9 Connect the external power supply leads to the POPO box (red to “Ext. Tool Power In”,
black to “Ground”).
9 Connect the assembly to the surface computer using the communication probe, bullet,
extension cable, Bi-Phase box, and 9-pin serial cable. Turn on the power supply and Bi-
Phase box.
HEL FI0006 Rev. A
9 Using the appropriate software, verify that the “Sonde ID”, “Sensor ID”, and “Firmware ID”
are correct for the IDS that is being tested.
9 Perform an IDS Roll Check and Swing Test to verify the data generated by the probe is
reasonable for each orientation of the IDS and perform survey quality accuracy checks on
the data.
9 Record the IDS and IFD serial numbers on the Tool Build Sheet.
7. IDS / IDS Flow Diverter Assembly Installation

9 With a marking pen, draw a visible guide line along the IFD length near the external data
port to help align it with the Collar’s access hole during installation.
9 Measure the length of the IFD (should be 15.6” or 396 mm).
9 Orient the Collar’s access hole to the highside position.
9 Insert the centralizer end of the IDS assembly into the box end of the Collar with the
external data port oriented to the highside position.
9 Push the assembly far enough into the Collar so as to allow for the insertion tool’s thread
into the box end of the Collar.
Note: Pushing down of the IFD during insertion may help the assembly side into the collar
more readily.
CAUTION: Keep hands clear of the side of the insert while pushing into the collar to
prevent injury to fingers!
9 Using the insertion tool and the extension tool, insert the assembly into the Collar until the
external data port is aligned with the Collar’s access hole.
9 Using the communication port plug insertion tool (000314), install the plug (000284) into the
external data port threads of the IFD.
9 Once the plug has been installed, continue to insert the assembly into the Collar to insure
that it is firmly seated against the internal shoulder of the Collar. This is critical for properly
grounding. A poorly seated IFD assembly will result in sensor communication problems.
8. BAP Insert Installation (If Applicable)

9 Record the BAP Insert serial number on the Tool Build Sheet.
9 Insure that the insert nose has been fitted with the appropriate strength latch ring.
Note: Failure to install inserts with the appropriate strength latch rings (higher, first to
lower, last) will result in inserts being pulled simultaneously during disassembly.
9 Install nose O-Rings and backup rings, lubricating O-Rings with a thin coat of DC-111
grease.
9 Install J-slot O-Rings and backup rings, lubricating O-Rings with a thin coat of DC-111
grease.

HEL FI0006 Rev. A
9 Place the nose end of the insert into the collar with the alignment key hishside. Push the
insert far enough into the Collar so as to allow for the insertion tool’s thread into the box
end of the Collar. Be careful not to drag the insert sleeve along the threads of the Collar.
9 Using the insertion tool and the extension tool, push the insert in until it bottoms out on the
last insert. With slight pressure on the insert, turn it clockwise until the key engages into
the J-slot. A dull “POP” will be heard as the two inserts latch together.
9 Release the tension from the insertion tool and disengage the ears from the J-slot of the
insert. Remove the installation tools from the collar.
9. GAM Insert Installation (If Applicable)
Gamma Insert Preparation
1. Record the GAM Insert serial number on the Tool Build Sheet.
2 Inspect two backup rings and install in the large O-ring grooves on the J-slot end of the insert.
3 Insure that the insert nose has been fitted with the appropriate strength latch rings.
Note: Failure to install inserts with the appropriate strength latch rings (stronger first, to
weaker last) will result in inserts being pulled simultaneously during disassembly.
4 Inspect two backup rings and install in the O-ring grooves on the nose end of the insert.
5 Inspect and lubricate two O-rings with DC-111 and install to the outside of the backup rings in
the O-ring grooves on the J-slot end of the insert.
6 Inspect and lubricate two O-rings with DC-111 and install to the outside of the backup rings in
the O-ring grooves on the nose end of the insert.
Note: Do not pack grease in the O-ring areas as this will cause an O-ring failure when the
grease thermally expands.
7 Inspect and Clean and all kemlon contacts.
8. Sighting inside the bore with a flashlight, rotate the collar assembly as needed to position the
external data port to the high-side position.
9. Gently slide the insert in the bore of the collar by hand with the alignment key 315 degrees
from highside (45 degrees to the left).

HEL FI0006 Rev. A
10. Push the insert far enough into the collar so as to allow for the insertion tool’s thread into the
box end of the collar. Be careful not to drag the insert sleeve along the threads of the collar.
11. Install the insertion tool (and extension if using the short insertion tool) into the insert’s J-slots
and continue to push the insert in until you feel it “bump.”
12. If you cannot push the insert in until it “bumps,” engage the threads of the insertion tool in the
collar and drive the insert in by rotating the “tightening” handle on the insertion tool.
Note: To ensure that the offset nose stays positioned at 315 degrees, observe that the
“screw shaft” handle of the insertion tool does not rotate.
13. With slight pressure on the insert, rotate the “screw shaft” handle of the installation tool
slightly clockwise until the insert “drops” and seats in the receiver. A dull “POP” will be heard
as the latch ring engages.
14. Back out and remove the insertion tool after the insert is fully installed.
10. First Battery Insert Installation
Battery Insert Preparation
1. Select two field ready battery insert assemblies based on the proposed job specifications
(capacity, temperature, ect.). You should measure at least 29 - 30 volts off load for each
battery before you install them. The starting capacity for the LWD battery should be as
follows:
4 ¾ Batteries:
160 deg C – 25 Amp-Hours
6 ¾ Batteries:
For a multiple bit run job, chose full capacity batteries with no more than a 3 Amp-hr
difference between the two battery inserts.
2. Record the Battery Insert serial numbers on the Tool Build Sheet.
3. Inspect two backup rings and install in the large O-ring grooves on the J-slot end of each
insert.
4. Insure that the insert noses have been fitted with the appropriate strength latch rings.
HEL FI0006 Rev. A
Note: Failure to install inserts with the appropriate strength latch rings (stronger first, to
weaker last) will result in inserts being pulled simultaneously during disassembly.
5. Inspect two backup rings and install in the O-ring grooves on the nose end of each insert.
6. Inspect and lubricate two O-rings with DC-111 and install to the outside of the backup rings in
the O-ring grooves on the J-slot end of each insert.
7. Inspect and lubricate two O-rings with DC-111 and install to the outside of the backup rings in
the O-ring grooves on the nose end of each insert.
Note: Do not pack grease in the O-ring areas as this will cause an O-ring failure when the
grease thermally expands.
8. Inspect and Clean and all kemlon contacts.
slightly clockwise until the insert “drops” and seats in the transmitter. A dull “POP” will be
heard as the latch ring engages.
16. Record the battery insert’s install date/time and remaining life (Amp-hours) on the Tool Build
Sheet.
11. Second Battery Insert Installation

HEL FI0006 Rev. A
slightly clockwise until the insert “drops” and seats in the first battery. A dull “POP” will be
heard as the latch ring engages.
8. Record the battery insert’s install date/time and remaining life (Amp-hours) on the Tool Build
Sheet.
12. Driver Insert Installation

9 Record the Driver Insert serial number on the Tool Build Sheet.
9 Insure that the insert nose has been fitted with the appropriate strength latch ring.
Note: Failure to install inserts with the appropriate strength latch rings (higher, first to lower,
last) will result in inserts being pulled simultaneously during disassembly.
9 Install nose O-Rings and backup rings, lubricating O-Rings with a thin coat of DC-111 grease.
9 Install J-slot O-Rings and backup rings, lubricating O-Rings with a thin coat of DC-111 grease.
9 Place the nose end of the insert into the collar with the alignment key hishside. Push the insert
far enough into the Collar so as to allow for the insertion tool’s thread into the box end of the
Collar. Be careful not to drag the insert sleeve along the threads of the Collar.
9 Using the insertion tool, push the insert in until it bottoms out on the Second Battery Insert.
With slight pressure on the insert, turn it clockwise until the key engages into the Second
Battery’s J-slot. A dull “POP” will be heard as the two inserts latch together.
9 Release the tension from the insertion tool and disengage the ears from the J-slot of the insert.
Remove the installation tools from the collar.

HEL FI0006 Rev. A
13. Pulser Assembly Inspection
View of a Pulser Assembly

9 The following steps should be implemented in the shop and in the field in order to isolate pulser
assembly problems.
Step-By-Step procedures used for inspecting the Pulser:
1. PISTON / POPPET DISTANCE INSPECTION

Carefully situate the pulser assembly horizontally on the floor, locate the two parmalee
wrenches around the upper section of the pulser as shown in Fig. 1.
Sleeve Break Area
Permalee Wrench 1
Permalee Wrench 2
Figure 1
HEL FI0006 Rev. A
Note: If you experience problems getting the wrenches to “bite” the barrel, insert a
small piece of sand paper between the wrench and the barrel.
2. After breaking the connection, the pulser assembly will consist of three components.
(Figure 2)
Control Valve
Main Valve
Control Valve screen
Figure 2
3. Using a caliper, measure the distance between Ring “A” and Ring “B”. (Figures 3, 4)
Ring “A”
(upper)
Ring “B”
(lower)
Side View
Plan View
HEL FI0006 Rev. A
Figure 3
Figure 4
4. Measure the distance between Ring “A” and Ring “B” at least 2 or 3 times to ensure an
accurate reading. Then compare that distance with the following tolerances:
Ideal Piston/Poppet
MIN Value MAX Value
Distance ~ 0.375 inches
0.350 inches Ring “A” to Ring “B” 0.400 inches
5. Using a socket and extension wrench, carefully compress the poppet two or three times.
Then quickly re-measure the distance between Ring “A” and Ring “B”. The difference
between this measurement and your original measurement should not be more than 0.05
inches.
6. Re-assemble the pulser assembly. The torque requirement for the Main Value to Control
Value component is 200 lbs.
Note: After a pulser has fired for 400,000 cycles, it should be sent back to R&M for an
oil change.
14. Solenoid Resistance Inspection

9 The following steps should be implemented in the shop and in the field in the event that a
new Pulser is shipped to location or to troubleshoot and isolate the origin of a downhole
problem where the HEL tool failed to pulse.

HEL FI0006 Rev. A
Step-By-Step procedures used for Testing a Pulser Assembly with an External Power
Supply:
1. Situate the Pulser with the downhole side pointing directly vertical (orifice section
pointing directly up). Make sure that the tool is placed on a smooth surface to avoid the
occurrence of it accidentally dropping on its side (see Figure 1).
Figure 1. Pulser Must Be Situated Vertically
2. Verify that the kemlon connections are clean and free of any type of moisture or dirt.
Kemlon Connector Pins
Kemlon Protectors
Figure 2. Gold Plated Kemlon Pins Connect to Pins 8 and 9

on the Driver Insert (Solenoid Control).
3. Coil Resistance Check: Obtain an ohmmeter and place the leads on each Kemlon pin
(Make sure not to touch the Kemlon pin protectors). The resistance across the pins
should read between 3.2 to 3.6 ohms at room temperature. If the readings are
drastically different, there may be a problem with the coils.

HEL FI0006 Rev. A
4. Insulation Check: Obtain an ohmmeter and place one electrical lead on one Kemlon
Pin and the other lead on the metal surface of the pulser body. The readings should
indicate an infinite resistance. If the readings indicate continuity, there is a problem
with the electrical insulation of the pulser. Perform the procedure for both kemlon pins.
5. Obtain an external power supply and pre-configure the settings to the following:
Voltage = 28.0 to 29.0 V DC, and 4.0 to 5.0 Amps. To configure the voltage simply
adjust the voltage dial to 28.0 to 29.0 V DC. Do not exceed 30 V DC.
Adjust Dial to
Required Voltage
Figure 3. Adjusting Voltage on External Power Supply.
To configure the amperage simply connect the two leads and adjust the amperage dial
to 4.0 to 5.0 Amps.
Adjust Dial to
Required Amperage
Connect Leads
Figure 4. Adjusting Amperage on External Power Supply.
Once the external power supply is configured, switch off the power.

HEL FI0006 Rev. A
6. Connect the positive (+) and negative (-) alligator clip leads to each Kemlon
connection. To reduce the risk of damaging the gold plating, do not drag the alligator
clips across the Kemlon pins.
Make Sure
Alligator Clip
Leads Are Only
Touching The
Kemlon Pins
Figure 5. Connect Alligator Clip Leads to Each Kemlon Pin.
Figure 6. Complete Set Up to Test a Pulser Using an External Power Supply.
7. Turn on the external power supply and quickly observe the control valve stem. The
control valve stem should actuate one time in the Pulser sounding off a single click
sound. Once the control valve stem has actuated, shut off the power to the external
HEL FI0006 Rev. A
power supply. Do not leave the power on for more than 5 seconds because it may
cause the coils in the Pulser to overheat resulting in a possible failure.
Observe the control

valve stem actuate
Figure 7. Observe Sound of Control Valve Actuate Through Slotted Screen in Pulser.
8. If the Pulser does not actuate, try to increase the voltage and amperage settings on the
external power supply. Repeat step 8 until you are able to observe the valve stem
actuate. Remember not to set the voltage and amperage settings over 30 Vdc and 5
amps respectively.
9. Once the control valve stem actuation is observed, the Pulser has passed the test and
is ready to be installed into the tool.
10. If the control valve stem actuation is not observed, shut off the power and verify that all
wires and connections are attached correctly. Verify that the alligator clips are only
touching the kemlon connections. Repeat step 8.
12. If problems or discrepancies are found, contact the local technical advisor for more
support.
15. Installing the Orifice into the Pulser
9 The following steps should be implemented in the shop and in the field for proper installation of
an orifice into the pulser.
Step-By-Step procedures used for Orifice Installation:
1. Secure the Pulser Assembly into a vise.

HEL FI0006 Rev. A
2. You will need the following components:
Part 4 ¾” 6 ¾”
Retaining Ring L-AA002429 L-AA002518
O-Ring L-AA002430 L-AA002207
Orifice
Retaining Ring
O-Ring
Figure 5
3. Place the appropriate O-Ring on the selected Orifice and then grease the body of the
Orifice using Metalube (green grease) as shown in Figure 6.
MetaLube
O-Ring
Figure 6
4. Insert the Orifice in the Main Valve as shown below:

HEL FI0006 Rev. A
Main Valve
Orifice
Figure 7
5. You will need a torque wrench and fitted HEX socket.
Tool Size 4 ¾” 6 ¾” & 8”

Socket Size 1 7/16 inch 2 3/16 inch
6. Connect the wrench to the appropriate socket and then install the orifice. The torque
requirement is 50 ft-lbs and should NOT be exceeded as this could damage the carbide
orfice.
Figure 8
7. Install the appropriate retaining ring between the Main Value and the Orifice as shown
in Figure 9.

HEL FI0006 Rev. A
Figure 9
Note: Do NOT use metal to manipulate O-Rings or retaining rings. This can damage
the seal, resulting in washing or invasion.
16. Pulser Installaion

9 Record the Pulser and Pulser Flow Diverter serial number on the Tool Build Sheet.
9 Install Pulser Flow Diverter O-Rings and backup rings, lubricating O-Rings with a thin
coat of DC-111 grease.
9 Install J-slot O-Rings and backup rings, lubricating O-Rings with a thin coat of DC-111
grease.
9 Record the Orifice size on the Tool Build Sheet.
9 Thoroughly clean the mud and debris from the Pulser. Pay particular attention to all of
the Arlon bands.
9 Using Metalub (green grease), generously cover each Arlon band as shown:

HEL FI0006 Rev. A
Note: The Pulser should be removed from the tool and greased after each job prior to
tool shipment to facilitate its extraction back in the shop. This is especially
important when the HEL tool has been exposed to an OBM environment.
9 Place the orifice end of the insert into the collar with the latch key hishside. Push the
insert far enough into the Collar so as to allow for the insertion tool’s thread into the box
end of the Collar.
9 Using the short insertion tool, push the Pulser in until the latch key engages in the
Driver’s J-Slot. A dull “POP” will be heard as the two inserts latch together.
CAUTION: DO NOT rotate the Pulser latch key on the face of the Drive as this will
damage and potentially break the latch key.
9 Release the tension from the insertion tool and disengage the ears from the J-slot of the
insert. Remove the installation tools from the collar.
17. HEL Verification Test

9 Test each sensor installed in the HEL tool string with Spectrum’s Tool Comms as
described in the individual sensor sections.
18. Flow Ring Installation

9 Place the appropriate O-Ring on the Flow Ring and then lubricate the O-Ring with a thin
coating of DC-111 grease.
9 Measure the distance from the top of the Pulser to the box end of the Collar. Subtract the
length of the Flow Ring to determine the amount of remaining gap after the Flow Ring is
fully installed.
9 Using a slide hammer and Flow Ring Extractor, tap the Flow Ring into place. Verify that
the actual remaining gap equals what was calculated in the previous step.
19. Installing the Buffer Stack
The buffer stack consists of a series of round Teflon spacers of various thicknesses. The buffer
stack is installed on top of the flow ring/diverter, regardless of tool configuration (real-time or
recorded only). When the tool joint is made up there should be 0.0625 inch (1/16 inch) of
compression of the Teflon spacers.
The height of the buffer stack is adjusted by selecting spacers of the correct dimensions to
equal the calculated height. Spacers come in the following sizes 1-inch, 0.5-inch, 0.25-inch,
0.125-inch,and 0.0625-inch.
1. Measure and record the dimensions L and P.
2. Calculate the buffer stack height required to provide 0.0625-inch compression after the
tool joint is made up.
Buffer Stack Height = P - L + 0.0625
3. Calculate the installation reference dimension.

Reference Dimension = L - 0.0625

HEL FI0006 Rev. A
4. Select the correct Teflon spacers to make up the required height.
“L”
“P”
I
Measurements Required to Calculate Buffer Stack Height
19. Interconnects
9 Grease and clean all o-rings and threads prior to installation.
9 Clean electrical connections on male/female interconnects and pack the female kemlon with
DC-lll.
9 Once installed, verify proper lengths and proper resistance with a voltmeter. When not
connected, protect the interconnects with caps.
Interconnect Make-Up Length Calculation:

1. Using the Tape Measure to the 6” vernier depth gage with 10” base, measure the drill
collar tool joint pin length M3 and record on the worksheet. Do not measure along the
tool joint taper if using a Tape Measure.
2. Using the depth gage measure the distance from the end of the collar to the face of the
interconnect sonde assembly connector piston M4 and record on the worksheet. Do
not push so hard as to deflect the spring behind the piston.
3. Using the worksheet calculate C1. The equation to calculate this is C1 = M3 – M4.

HEL FI0006 Rev. A
Connector Make-Up Calculations

4. Using the worksheet calculate the connector make-up. Input the calculated values for
C1 and C2 into the following equation, Connector Make-Up = C1 – C2.
5. The connector make-up value must be between 0.500 inches and 1.875 inches. If this
value is less than 0.500 inches select a longer connector extension assembly and
recalculate C2. If the value is greater than 1.875 inches select a shorter connector
extension assembly and recalculate C2.
CAUTION: Do not assemble a tool with less than 0.50 inches of connector make-up or
electrical continuity may be lost when downhole pressure is applied to the
tool.
WARNING: Do not exceed 1.94 inches (1.875 inches max recommended) of connector
make-up or the interconnect will go solid and be crushed with the tool joint is made up.
Measure the assembly for verification of calculations and measurements.

HEL FI0006 Rev. A
CAUTION: Verify all calculations and double check before threading the two mating drill
collars together.
20. External Data Port
EDP Plug
Verify that the port has remained moisture free and the o-ring and backup rings orientation is as shown
above. Do not re-install bad retaining rings and do not over torque plugs. The maximum allowable
torque is 75 ft-lbs.
Note: NEVER install or pull inserts with the communication probe connected to the
external data port. This will cause damage to the probe threads.

HEL FI0006 Rev. A
10-Pin Box Mount

EDP End View Recepticle
Tool View
2 7 H A B
7 2
1
1 3 6 G K J C
6 3
4 5
5 4
F E D
10-Pin Box Mount

Tool Contacts
Recepticle
1 Red (Power Bus) A
2 Blue (Bi-Phase Bus) B
3 Violet (Private Bus) C

Orange (High Speed
4 Twisted Pair #1)
D
5 Yellow (High Speed E

Twisted Pair #1)
Green (High Speed

6 Twisted Pair #2)
F
Gray (High Speed
7 Twisted Pair #2) G
EDP Black (Comms Return) H

Ground
Lug Black (Power Return) J
No Connect K
21. Wear Band

9 Verify that it is in good condition.
9.0 Software
9.1 Cabling Setup
To communicate with the HEL tool using Spectrum you will need the following:
• EDP Probe (Part #000287)
• Comm Bullet (Part #004793)
• 10 Pin Cable Assembly (Part #003281)
• Universal Com Bridge/Biphase Box (RS232-to-Biphase) (Part #003798)
• 25 Volt AC/DC Power Supply (Part #004274)
• Standard M/F DB-9 Serial Cable
• MDM 15 Pin Wiring Harness to 10 Pin Amphenol Connector Assembly

HEL FI0006 Rev. A
1. Connect EDP Probe on to EDP port

Hold the silver part Rotate ONLY the
while screwing the brass part when
EDP probe screwing the EDP
probe
Be sure to align
the EDP probe
key with the EDP
port slot.
2. Connect the Comm Bullet on to EDP Probe, and then connect the 250 ft 10 Pin Cable to the
Comm Bullet.
EDP Probe Comm Bullet
10 Pin cable

HEL FI0006 Rev. A
3. In the unit, connect the other end of the 250 ft 10 Pin Cable to the Biphase Box using the
MDM Amphenol Adaptor, then power it using the DC power supply. The red light “ Logic
Power” should blink with a regular rhythm. If the rhythm is not constant or if it’s not blinking,
the Biphase Box is damaged. A failure report has to be written and the Biphase Box has to be
sent back for repair. For a temporary fix, the Biphase box can be powered through the USB
connector. But with this option, the Bus Power cannot be activated.
MDM to
250 ft 10 Pin Amphenol
Cable Adaptor
DB9 Com cable Biphase Box 24 V AC/DC

Power supply
The MDM to Amphenol Adaptor has the Pins J, H & K connected (on the Amphenol side).

HEL FI0006 Rev. A
Pin A: Power
Pin B: Biphase Comms
Pin J, H & K : Ground

(Connected together)
Remark: When the Biphase box is powered by the DC power supply, current can be supplied to
the MWD Tool via the Tool I/O (Bus Power).
4. Check that the EDP probe ohms-out at < 0.5 ohms. See the diagram below for the pin out
assignments.
10-Pin Box Mount

EDP End View Recepticle
Tool View
B A H
2 7 7 2
1 1 C J K G
3 6 6 3
4 5 5 4
D E F
Tool/Kemlon 10-Pin Box Mount

Contacts Recepticle
1 Red (Power Bus) A
2 Blue (Bi-Phase Bus) B
3 Violet (Private Bus) C

Orange (High Speed
4 Twisted Pair #1)
D
5 Yellow (High Speed E

Twisted Pair #1)
Green (High Speed

6 Twisted Pair #2)
F
Gray (High Speed
7 Twisted Pair #2) G
EDP Black (Comms Return) H

Ground
Lug Black (Power Return) J
No Connect K
5. Check the EDP “pogo” pin contacts in the end of the probe. They should be sharp to touch
and the ends should be in the same contact plane.

HEL FI0006 Rev. A
6. Check that the Com bullet ohms-out at < 0.5 ohms. See the diagram below for the pin outs
assignments.
EDP Side of the Cable Side of the

Com Bullet Com Bullet
A Red (Power Bus) A
B Blue (Bi-Phase Bus) B
C C
D D
E E
F F
G G
Black (Comms
H H
Return)
Black (Power
J J
Return)
Braided Shields and Drain K
K
Wires
7. Check the 250 ft 10 Pin Cable:

Pins A and J (18 AWG) gauge should ohm-out to 1.6 ohms.
Pins B, C, D, E, F, G, and H (24 AWG) gauge should ohm-out to 6.42 ohms.
Since K is a combination of the drain wires and the overall shield, it should ohm-out to
0.8 ohms.

HEL FI0006 Rev. A
AES Cable Schematic

Amphenol Pin Out
Red (Power Bus) A
Blue (Bi-Phase Bus) B
Violet (Private Bus) C
Orange (High Speed Twisted Pair #1) D
Yellow (High Speed Twisted Pair #1) E
Green (High Speed Twisted Pair #2) F
Gray (High Speed Twisted Pair #2) G
Black (Comms Return) H
Black (Power Return) J
Drain Wire 1
Drain Wire 2
K
Braided Shield
Terminate both drain wires to the braided shield and connect them to Pin
"K" on both ends of the cable
Cross Section of the 250 ft 10 Pin Cable

HEL FI0006 Rev. A
8. Check the MDM-to-Amphenol Adaptor ohms-out at < 0.5 ohms.
Amphenol Connector
Red Wire A
B
MDM 9 Pin
Connector C
1 2 3 4 5 D
6 7 8 9 E
F
Blue Wire
G
Black Wire H
K
9.2 PCI Serial I/O Card Settings
Recently, we have discovered that some PCI serial I/O cards have a default state that could cause
some problems when interfacing with the serial-to-Biphase communication box. Below are the steps to
correctly change the settings.
1. Go to System Properties by either right mouse clicking Properties on My Computer Icon on the
Desktop or via Control Panel System icon.
Click on Device
Manager

HEL FI0006 Rev. A
2. Open the PCI serial port as shown below.
Double click on PCI

Serial Port
3. Go to the Port Settings tab and set the change the Flow Control to None. Then save the
change.

HEL FI0006 Rev. A
4. Click the Advanced… button and uncheck the Enable Auto CTS/RTS Flow Control and then
click OK. Save your changes.
Uncheck
option “Enable
Auto
CTS/RTS
Perform this action on each PCI serial I/O port. The motherboard I/Os do not have these
settings; therefore they do not need to be modified.
9.3 TOOL I/O
Tool I/O is used to assign a COM Port for the communication between the computer and the MWD
Tool.
Due to sporadic electrical rig noise on the Biphase communication bus, the threshold of the receive
voltage may need to be increased gradually to 0.5 Volt; 0.8 Volt and 1.0 Volt. The limit for the Receive
Threshold decreases when additional sensors (BAP, MFR, HAGR, Neutron, Density) are added to the
MWD string. The maximum for the Receive Threshold is around 1.0 Volt.
9.3.1 Raising the Receive Threshold Voltage
1. When the Tool I/O application is opened, the receive threshold can be increased to reduce the
perturbation coming from the electrical noise.

HEL FI0006 Rev. A
Receive
Threshold
voltage
For example, to adjust the voltage to 1 Volt, type 207 into the box next to the receive voltage.
Enter in the box:

105 to get 0.5 Volt
146 to get 0.7 Volt
166 to get 0.8 Volt
207 to get 1.0 Volt

HEL FI0006 Rev. A
2. Next click the Control -> Set PWMs.
Select “Set PWMs”

To validate the
modification
9.3.2 Quality Check of the Communication
In order to detect if the Biphase communication bus is getting sporadic electrical noise from the rig, the
short test described below can be run:
1. Open Tool I/O

2. Type the command 01000B to check if the Controller Com Pic is answering at each order.
3. Check Continuous, do not check Snoop and press Send

HEL FI0006 Rev. A
Check
“Continuous”
Number of Number of
Type the command
commands sent Time Outs
“01000B”
The number of commands sent and Time Outs are displayed on the bottom right corner of the
Tool I/O window.
Wait until 5000 commands sent. The number of Time Outs should be 0.
Number of Commands Sent Number of Time Outs Biphase Bus Comm.

5,000 0 OK
5,000 0 to 10 OK, but try to reduce the
noise
5,000 > 10 Not OK, too much noise
9.3.3 High Temperature Battery
Warning: With this setup, the power brought through the 250 ft 10 Pin Cable can initiate a spark on the
tool side. So this option can ONLY be used if the MWD tool is in a non-hazardous area.
Do NOT use the High Temperature batteries in ambient temperature to energize pulser or perform IDS
Surveys. Otherwise it will damage cells and shorten the battery.
For a MWD tool with High Temperature batteries, the Biphase Box has to supply the current during the
surface test. This can be done with Tool I/O as described below:
Click on Control and select Bus Power.

HEL FI0006 Rev. A
When Bus Power

is activated, Bus
Voltage is set
around 22.75 V
At the surface, if you need to energize the pulser or activate the IDS longer than 30 minutes,
you have to hook up an external power supply set at 30 Volts DC. Use the bus power and the
ground wire of the MDM to Amphenol Adaptor to apply the 30 Volt directly to the MWD Tool.
Note: Power cannot be sent if the Biphase Box is powered through the USB.
9.3 HEL Surface Initialization
Surface communication with the HEL tool and all it’s sensors is achieved using the Tool Communication
utility.
The operational steps are as follows:
1. Establish Communication
• Launch Tool Comms. Check that all the sensors are out of logging mode before any
testing or initialization has started.
Note: By design, when any sensor goes through a POR, that sensor will automatically
come up in logging mode. Therefore, during tool assembly the sensors will be logging
once the batteries are installed. Be sure to take the sensors out of logging mode
during transportation or after each bit run.

HEL FI0006 Rev. A
2. Sensor Diagnostics
• A notes section for all biphase sensors (CM, GAM, BAP, IDS, ect.) is visible on the
General tab for each sensor. The notes section is also referred to as the scratch pad
memory that resides with each sensor. Use the scratch pad to write specific tests
performed to the sensor, especially during troubleshooting. First click the time stamp
and then add your comments and name.
• If the HEL has been equipped with a GAM sensor. Refer to section 7 for programming
instruction.
• If the HEL has been equipped with a BAP sensor. Refer to section 8 for programming
instruction.
3. Establish IDS Communication

• Select the “General” tab under IDS, if you are properly connected and communicating
with the IDS sensor, the processor versions and various inputs will display as shown.
9 Verify the processor versions and asset codes with those recorded on the
tool’s build sheet.
9 Sync the sensor clock with that of the surface computer by selecting “Sync
ELS”.
9 Verify the sensor time by selecting “Fetch RTC”.
4. IDS O-Par
• The IDS does not have a “logging mode”. It receives instructions (take toolface or
survey) from the CM. However a parameter table, as shown below, is downloaded to
the IDS. After the table is loaded, the Sync ELS command should be re-executed.
HEL FI0006 Rev. A
9 The parameter table should be populated with the local magnetic and gravity
values for the well.
9 Set the toolface switch over angle according to the directional needs.
9 Set toolface samples to 3 unless otherwise instructed.
9 Set ADC scans to 128.
9 Select “Apply” to write the parameters to the HEL.
9 Select “Read” to verify that the parameters in the HEL are per requirements.
5. Function Test the IDS

• Before the HEL is picked up, perform a horizontal roll test as shown below. If possible,
try to raise the pulser end of the collar and repeat the roll test. Ideally, a 45 degree
inclination would be preferred. Once the HEL has been placed in the BHA, the IDS roll
test should be repeated. Another good test once the string has been made up with the
mud motor is to raise the bit out of the hole and swing the string over the V-door. Align
the mud motor scribe line to high side and repeat the test. This allows you to verify the
mud motor-to-MWD offset that you had measured.
9 As you roll the HEL, observe the individual accelerometer and magnetometer
values. These should change accordingly.
9 It will be difficult to qualify magnetometer readings considering the surrounding
magnetic material. However, pay particular attention that they are not railed
out or that an axis is not locked while performing the vertical roll test.

HEL FI0006 Rev. A
6. IDS Calibration
• The IDS Calibration and be viewed under the Calibration tab.
7. Establish CM Communication
• Currently this is no diagnostic test for the CM. The versions should be verified.
9 Verify the processor versions and asset codes with those recorded on the
tool’s build sheet.
9 Sync the sensor clock with that of the surface computer by selecting “Sync
ELS”.
9 Verify the sensor time by selecting “Fetch RTC”.

HEL FI0006 Rev. A
9 Before the driver controller insert is to be pulled out of the HEL collar for an
extended period of time, the real time clock (RTC) should be placed in sleep
mode. This is done by clicking the RTC sleeping box. After the CM is in sleep
mode, the driver can be removed from the collar.
8. CM O-Par
• The O-Par tab is the main Real Time set up screen. Since this screen is so detailed,
each button shown below will be defined.

HEL FI0006 Rev. A
9 Initialize – Click this button to start the initialization sequence.

9 Defaults – Click this button to restore all predetermined parameters.
9 PreTrip Tab – This grid (mode) is used to create a custom data sequence that
will be displayed after the tool has been successfully initialized. The PreTrip
mode is the last chance to see that the tool is working properly. A PreTrip test
file is automatically saved to the installation directory (C:\Program Files\AES
Test). The sequence will end once the PreTrip Duration timer expires.
9 Mode 1 Tab – This grid is used to create a custom pulsing sequence for Mode
1. The maximum number of train IDs is 16 with a maximum of 10 data items in
each train ID. Any train ID created can be defined as an Initial or Loop. By
design all Initial train IDs are automatically moved to the top of the grid with the
Loops to fill out the rest of the grid. Initial is defined as a pulse sequence that
will only be pulsed up once per pump cycle. Loop is defined as a pulse
sequence that will continually pulse after all Initial train IDs have been pulsed.
From the following example the pulse sequence is TID 0, TID 1, TID 2, TID 3,
TID 4, TID 5, TID 6, TID 7, TID 8, TID 9, and the start over at TID 3 and so
on… The actual list construct can be accomplished two ways. First define the
cycle (Initial or Loop) and then double click into the adjacent cell. A combo list
box of all the Real Time data identifiers will be exposed for selection. Currently
there is no “Smarts” in the construction, so be sure to use data items.

HEL FI0006 Rev. A
9 Mode 2 Tab – This grid is used to create a custom pulsing sequence for Mode
2. Use the same set up principles as for Mode 1.

HEL FI0006 Rev. A
9 Library – Click this button to reveal a list of predefined train IDs. This does not
include every possible combination of sensors. Often users will have to build
their own train IDs based on services provided and data density requirements.

HEL FI0006 Rev. A
9 Stats – Click this button to show the data update rate based on the setup
parameters.

HEL FI0006 Rev. A
9 Filter – Click this button to filter the site definable tool combo list. Data items
associated with the selected sensor(s) will be available for inclusion.
9 Real Time Mode Box – Eventually there will be three selections that can be
downloaded to the CM.
9 Pre-Trip Duration – Set this timer (120 to 300 seconds) to view the data
defined in the pre-trip mode.
9 Last Initialization – The date/time that the CM was last initialized. The CM
stores the timestamp on each initialization.
9 Temperature ON – The CM has an internal temperature sensor that monitors
the electronic temperature of the board assembly. Once the Temperature ON
criteria is satisfied, the CM will start its mission as determined by the two
modes. Since there are two types of battery cells [a low temperature (-20 deg
C to 162 deg C) and a high temperature (75 deg C to 205 deg C) type], this
parameter is required to prevent the operation of high temperature batteries
below the normal range. If a constant draw (as in pulsing) is on, the cells will
be damaged and could explode. Note: When running with the low
temperature batteries, always set this parameter to 0 deg C.
9 Temperature ON Hysteresis – Set this parameter to turn off the CM once the
temperature falls below the Temperature ON parameter.
9 Temperature OFF – As with the Temperature ON limit, there is a Temperature
Turn OFF limit as well. When the temperature exceeds this limit, the CM will
shut down and not pulse anymore until the temperature falls below the
Temperature OFF – Hysteresis.

HEL FI0006 Rev. A
9 Temperature OFF Hysteresis – Set this parameter to turn on the CM once the
temperature falls below the Temperature OFF parameter.
9 POPO Source – There are three sources that can determine a pump ON/OFF
condition. The first is the external POPO which is the same board that we
have used since beginning, except that a port pin is now wired directly to the
CM. The CM monitors this line (hi or low) to determine is the pumps are on or
off. The second is the internal POPO. All the POPO functionality has been
coded into the CM firmware. However, at this time it has not been fully tested.
Once tested and released, a ECN will be submitted to remove all the external
POPO boards from the Driver-Controller inserts. The third type is an on-board
accelerometer that can sense the mud flow and/or string rotation.
9 Freq 1 – Set the pulse on time, minimum pulse off time and the decision time
width to control the mud pulse transmission speed. Click the check box to set
Freq 1 as the startup transmission rate.
9 Freq 2 - Set the pulse on time, minimum pulse off time and the decision time
width to control the mud pulse transmission speed. Click the check box to set
Freq 2 as the startup transmission rate.
9 Primary Mode – This combo box allows the user to select which mode (1 or 2)
the CM will first pulse up.
9 Mode Switch – Set this timer to define the mode change window starting from
the first pulse. Set the timer to “0” to lock in the selected mode.
9 Freq Switch – Set this timer to define the frequency toggle window starting
from the mode switch window. Set the time to “0” to lock in the frequency rate.
Note: It is recommended that you always have 2 different frequencies to chose
from when downhole. This is very beneficial when signal problems are
encountered.
9 Xmit Delay – Set this time to define when pulsing will start once the pumps are
determined to be ON.
9 Survey Delay – Set this timer to define when the survey acquisition starts once
pumps off are determined.
9 Restore Defaults – Click this button to restore the O-Par back to default (IDS-
GAM) set up.
9 Write to Detection – Click this button to transfer the Train IDs, frequency rates,
Xmit delay, ect. from the CM O-Par to the AESI Run UI application.
9 Read from Detection. Click this button to restore the Train IDs, frequency
rates, Xmit delay, ect. from the AESI Run UI application to the CM O-Par.
9 Cancel – Click this button to halt the CM initialization sequence.
Note: In the status bar, various messages are displayed during the initialization sequence.
Pay close attention to these messages when you are having any problems during the
download.

HEL FI0006 Rev. A
9.3 Troubleshooting Comms
If you experience difficulties communicating with any of the sensors, try enabling the Snoop option of
the Tool I/O utility.
The operational steps are as follows:
1. Open Tool I/O. Select the “Snoop” check box. Then try to re-establish communications.
• If the communication problem is a function of the computer speed, this often remedies
the problem. If the problem persists, contact the LWD coordinator on call.
• Do no leave Snoop enabled unless absolutely necessary. The Snoop option will slow
the communication speed down by at least a factor of 5!!!!!


Section 06 - HEL 091003

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Field Instruction

Hostile Environment Logging

Revision ECN Number Change Description

Prepared by: Christine Guerrero Date: April 1, 2003

Changed By: Date:

© 2002 Contents of this document are proprietary to Page 2 of 63

2.0 HEL Insert Assembly 5

4.0 Collar Configuration 10

6.0 Applications and Benefits 12

© 2002 Contents of this document are proprietary to Page 3 of 63

16.0 Pulser Installation ………………………………………………………………………. 35

© 2002 Contents of this document are proprietary to Page 4 of 63

2.0 HEL Insert Assembly

© 2002 Contents of this document are proprietary to Page 5 of 63

© 2002 Contents of this document are proprietary to Page 6 of 63

1. NO Flow – Control Valve Closed – Main Valve Closed

2. Pulse OFF – Flow ON – Control Valve Closed – Main Valve Open

3. Pulse ON – Flow ON – Control Valve Open – Main Valve Closed

© 2002 Contents of this document are proprietary to Page 7 of 63

1. NO FLOW - Control Value CLOSED - Main Valve CLOSED

© 2002 Contents of this document are proprietary to Page 8 of 63

2. Pulse OFF 3. Pulse ON

© 2002 Contents of this document are proprietary to Page 9 of 63

For more information on data decoding, see Section 3 – Spectrum (FI0003).

4.0 Collar Configuration

PMT Driver BAT BAT Flow Diverter IDS

© 2002 Contents of this document are proprietary to Page 10 of 63

PMT Driver BAT BAT GAM Flow Diverter IDS

PMT Driver BAT BAT BAP Flow Diverter IDS

PMT Driver BAT BAT GAM BAP Flow Diverter IDS

Pulser Monel Flex Directional Monel

© 2002 Contents of this document are proprietary to Page 11 of 63

6.0 Applications and Benefits

© 2002 Contents of this document are proprietary to Page 12 of 63

Nominal Tool OD 4 ¾ in. 6 ¾ in. 8 in.

Maximum OD 5 ¼ in. 7 3/8 in. 8 5/8 in.

Weight 1400 lbs 2850 lbs 4100 lbs

Top Connection 3 ½ IF Box 4 ½ IF Box 6 5/8 Reg Box

Bottom Connection 3 ½ IF Pin 4 ½ IF Pin 6 5/8 Reg Pin

9,900 – 10,900 28,000 – 32,000 52,000 – 56,000

Max Torque 16,700 ft-lbs 48,200 ft-lbs 77,250 ft-lbs

Max Tension 750,000 lbs 1,800,000 lbs 2,850,000 lbs

Bending Strength Ratio 2.10 2.53 2.70

Equivalent Bending Stiffness

356 °F 356 °F 356 °F

392 °F 392 °F 392 °F

Max Operating Pressure 30,000 psi 30,000 psi 30,000 psi

Max Flow Rate 400 gpm 1200 gpm 1200 gpm

Max LCM 80 lb/bbl 80 lb/bbl 80 lbs/bbl

Max Sand Content 3% 3% 3%

© 2002 Contents of this document are proprietary to Page 13 of 63

MTF to GTF Switching 1 – 25 Degrees of Inclination

Toolface Update Period 3 seconds

Survey Update 30 seconds

Toolface Accuracy +/- 1.5 °

Azimuth Accuracy +/- 0.5 °

Inclination Accuracy +/- 0.1 °

Temperature +/- 0.5 °Celsius

Gamma Accuracy See Section 7

Bore and Annulus Pressure Accuracy See Section 8

8.1 HEL Tool Build Procedure

Service Non Cut-Back Length – ALL Tool Sizes

© 2002 Contents of this document are proprietary to Page 14 of 63

2. IDS Centralizer Preparation