Manual D00125190 1 PDF

Geo-Pilot Field Operations Manual
Contents
GEO-PILOT®
ROTARY
STEERABLE
SYSTEM
…………………………………………….
FIELD OPERATIONS MANUAL

REVISION 1.4
DOCUMENT NO D00125190
7600 & 9600 SERIES SYSTEMS
PLEASE NOTE
This document contains information that was believed correct at the date of issue.
There may be a more up to date document on the Sperry-Sun web site.
This operation manual covers the Sperry-Sun Geo-Pilot Rotary Steerable System 7600 system
(6-3/4"/171mm nominal OD) and 9600 series (9 5/8"244mm) tools.
Manual Version 1 2003 © 30/11/03 Sperry-Sun Drilling Services Downhole Tool Development
Group, Nisku, Alberta, Canada
THIS WORK CONTAINS THE CONFIDENTIAL AND PROPRIETARY INFORMATION OF SPERRY-SUN. NEITHER
THIS DOCUMENT NOR ANY INFORMATION DISCLOSED HEREIN SHALL BE REPRODUCED IN ANY FORM OR
USED, OR DISCLOSED, TO OTHERS FOR ANY PURPOSE, INCLUDING MANUFACTURING, WITHOUT THE
EXPRESS WRITTEN PERMISSION OF SPERRY-SUN.
THIS HANDBOOK IS PROVIDED FOR INFORMATIONAL AND ILLUSTRATION PURPOSES ONLY. ACTUAL FIELD
CONDITIONS MAY VARY THE RESULTS OF SPERRY-SUN SERVICES AND PRODUCTS, AND NO INFORMATION,
RESULT OR STATEMENT CONTAINED HEREIN SHALL BE CONSTRUED AS ANY TYPE OF REPRESENTATION,
WARRANTY OR GUARANTEE BY SPERRY-SUN. THE OBLIGATION OF SPERRY-SUN FOR AND WITH
RESPECT TO ITS SERVICES AND PRODUCTS ARE ENTIRELY SUBJECT TO INDEPENDENT, WRITTEN
AGREEMENTS NEGOTIATED WITH INDIVIDUAL CLIENTS. CONSEQUENTLY, SPERRY-SUN SHALL HAVE NO
LIABILITY FOR ANYTHING CONTAINED HEREIN.
SPERRY DRILL, GEO-PILOT, GEO-SPAN DOWNLINK SYSTEM, INSITE, ABI, AGS, and DDS
are trademarks of Halliburton Energy Services Inc.
All other trademarks are the property of their respective owners.

Contents
CONTENTS
1 SAFETY .................................................................................................................................................1
1.1 OPERATOR SAFETY ...........................................................................................................................1
1.1.1 Lithium hazard .........................................................................................................................1
1.1.2 Pressurized fluids ....................................................................................................................1
1.1.3 Weight of tool...........................................................................................................................1
1.1.4 Sharp threads...........................................................................................................................1
1.2 TOOL SAFETY ...................................................................................................................................1
1.2.1 Clamp ......................................................................................................................................1
1.2.2 Lithium battery pack ................................................................................................................1
1.2.3 Seal failure...............................................................................................................................2
1.2.4 Temperature ............................................................................................................................2
1.2.5 Vibration ..................................................................................................................................2
1.2.6 Length of use............................................................................................................................2
1.2.7 Damage and wear to the outside of the tool ............................................................................2
1.2.8 Thread damage ........................................................................................................................2
1.2.9 Electronic connection ..............................................................................................................2
1.2.10 Tong damage ...........................................................................................................................2
1.2.11 Fishing requirements ...............................................................................................................3
2 DESCRIPTION OF THE GEO-PILOT ..............................................................................................4
2.1 THE SYSTEM’S ADVANTAGES ...........................................................................................................4
2.2 HOW THE GEO-PILOT STEERS ...........................................................................................................4
2.3 HOW THE GEO-PILOT’S TOOLFACE IS CONTROLLED .........................................................................5
2.4 THE COMPLETE DRILLING PACKAGE ................................................................................................5
3 RIG SET UP...........................................................................................................................................6
3.1 SHIPPED GOODS ...............................................................................................................................6
3.2 THE LITHIUM BATTERY PACK LOG ....................................................................................................6
3.2.1 Checking the battery log ..........................................................................................................6
3.2.2 Battery pack failure .................................................................................................................6
3.3 PHYSICAL CONDITION OF THE TOOL ................................................................................................6
3.3.1 Measure oil level .....................................................................................................................6
3.3.2 Check rollers & Avoiding Damage ..........................................................................................6
4 SETTING UP TO RUN IN HOLE .......................................................................................................8
4.1 SOFTWARE COMPATIBILITY ..............................................................................................................8
4.1.1 Surface and Downhole Software Compatibility table ..............................................................8
4.2 GEO-PILOT CONFIGURATION ............................................................................................................9
4.2.1 Scope of the following set-up procedures ................................................................................9
4.2.2 Bottom hole assembly configuration........................................................................................9
4.2.3 Rig Floor Offset .....................................................................................................................10
4.3 CONFIDENCE TEST .........................................................................................................................11
4.3.1 Electronics Confidence Test Available in INSITE. ................................................................11
4.4 DOWNLOAD SCREEN SETUP ...........................................................................................................13
4.4.1 Tdelay ....................................................................................................................................13
4.4.2 Temperature Sample Period ..................................................................................................13
4.4.3 Toolface/Azimuthal Gamma Sample Period ..........................................................................13
4.4.4 Brake/Clutch Slip Rate Sample Period).................................................................................14
4.4.5 Housing Slip Rate Sample Period ..........................................................................................14
4.4.6 Threshold for RPM ON ..........................................................................................................14
Contents
4.4.7 Resume Previous Toolface Timeout .......................................................................................14
4.4.8 Percent Deflection Steering Mode .........................................................................................14
4.4.9 Max ABI G total error ..............................................................................................................14
4.4.10 Bit Toolface Sample Rate.......................................................................................................15
4.4.11 Sample Rate for Diagnostic Values .......................................................................................15
4.4.12 DM Toolface Age ...................................................................................................................15
4.4.13 Mode B Gamma Off Delay ....................................................................................................15
4.5 REAL -TIME DATA TRANSMISSION .................................................................................................15
4.5.1 DS – Deflection Setting..........................................................................................................17
4.5.2 TT - Toolface setting ..............................................................................................................17
4.5.3 RI - GP inclination ................................................................................................................17
4.5.4 RD - GP deflection ................................................................................................................17
4.5.5 RR - GP rpm ..........................................................................................................................17
4.5.6 RG - GP G total ........................................................................................................................18
4.5.7 RB - GP battery current.........................................................................................................18
4.5.8 RT - GP battery voltage .........................................................................................................18
4.5.9 RS - GP status ........................................................................................................................18
4.5.10 DF – DM/GP toolface/“The Smart Toolface”.......................................................................19
4.5.11 DDS Download Thresholds ...................................................................................................20
4.6 SAMPLE VDF DEFINITIONS DOWNLOAD SCREEN ...........................................................................21
4.7 A TYPICAL VDF DOWNLOAD LIST.................................................................................................22
5 MONITORING GEO-PILOT PERFORMANCE ............................................................................23
5.1 CUSTOMER PRESENTATIONS ..........................................................................................................23
5.2 EOW LOG REQUIREMENTS ............................................................................................................23
5.3 RECOMMENDED REAL TIME LOG SET-UP .......................................................................................24
5.4 RECOMMENDED RECORDED LOG SET-UP .......................................................................................25
5.5 REAL TIME DISPLAY ......................................................................................................................26
5.6 OIL STATUS ....................................................................................................................................27
5.7 DDU ..............................................................................................................................................28
6 CONTROLLING THE GEO-PILOT ................................................................................................29
6.1 DOWNLINK CONTROL.....................................................................................................................29
6.2 CRUISE CONTROL ...........................................................................................................................29
6.2.1 Inclination within Tolerance..................................................................................................29
6.2.2 Inclination ouside Tolerance .................................................................................................30
6.2.3 Starting, Stopping and Running the Cruise Algorithm ..........................................................30
6.3 MANUAL CONTROL ........................................................................................................................31
6.3.1 Deflection Off ........................................................................................................................31
6.3.2 Alignment Toolface and turn Deflection On ..........................................................................31
6.3.3 Deflection On To Previous Setting ........................................................................................32
6.4 TOOL CONTROL FLOW-CHART .......................................................................................................33
6.5 FINDING THE “HOME” POSITION ...................................................................................................34
6.6 VERTICAL KICK-OFF ......................................................................................................................34
6.7 ADDITIONAL NOTES .......................................................................................................................34
6.7.1 Software locking up – Reading the tool standalone...............................................................34
7 RECOMMENDED RUNNING PROCEDURES ..............................................................................36
7.1 PICKING UP TOOL............................................................................................................................36
7.1.1 Brace......................................................................................................................................36
7.1.2 Flex collar .............................................................................................................................36
7.2 TRIPPING IN ....................................................................................................................................36
7.2.1 Setting deflection ...................................................................................................................36
7.2.2 Seal lubrication......................................................................................................................36
7.3 DISPLACING FLUIDS: ......................................................................................................................37
7.4 INSIDE THE CASING: .......................................................................................................................37
Contents
7.4.1 Before starting to drill ...........................................................................................................37
7.4.2 Drilling cement, float and shoe track ....................................................................................37
7.5 RATHOLE:.......................................................................................................................................37
7.6 TRIPPING AND REAMING IN & OUT OF OPEN HOLE ..........................................................................38
7.6.1 Tight hole conditions .............................................................................................................38
7.7 REAMING IN HOLE (EXPECTING TIGHT HOLE)..................................................................................38
7.7.1 Tight hole ...............................................................................................................................38
7.8 OPEN HOLE DRILLING: ....................................................................................................................38
7.8.1 Good drilling procedures ......................................................................................................38
7.8.2 Backreaming, or an interruption to drilling in an open hole-hole ........................................39
7.9 OPEN HOLE SIDETRACKS ................................................................................................................39
7.10 GENERAL INFORMATION: ...............................................................................................................39
7.10.1 Superior hole quality .............................................................................................................39
7.10.2 Entering sections with FullDrift systems ...............................................................................39
8 TROUBLESHOOTING & POST RUN ANALYSIS........................................................................40
8.1 DOWNHOLE SIGNS OF A BAD TOOL ................................................................................................40
8.2 REALTIME ERROR CODES ...............................................................................................................41
8.3 PHYSICAL SURFACE CHECKS OOH ................................................................................................41
8.4 GEO-PILOT PARAMETER REPORT ...................................................................................................42
8.4.1 Sample Geo-Pilot Parameter Report .....................................................................................42
8.4.2 Definitions for the Geo-Pilot Parameter Report Terms .........................................................46
8.5 OTHER DIAGNOSTIC INFORMATION IN MEMORY ............................................................................51
8.6 TROUBLE SHOOTING GUIDE ...........................................................................................................52
9 DEMOBILISATION ...........................................................................................................................55
9.1 CLEANING/PREPARATIONS BEFORE SHIPPING .................................................................................55
9.1.1 Compensator cavity ...............................................................................................................55
9.1.2 Mud Invaded Tools ................................................................................................................55
9.1.3 Acidised Tools........................................................................................................................55
9.1.4 Threads ..................................................................................................................................55
9.1.5 Coloured tape ........................................................................................................................55
9.1.6 Battery log sheet ....................................................................................................................55
9.1.7 Geo-Pilot Perceived Problem & Peformance Report ............................................................56
9.1.8 Memory Data / Images ..........................................................................................................56
9.2 TRANSPORTATION ..........................................................................................................................56
9.3 SHIPPING DOCUMENTATION............................................................................................................56
9.3.1 Documentation for Geo-Pilot shipment .................................................................................56
9.3.2 Shipping by air.......................................................................................................................57
9.3.3 Documentation Installation and Labeling .............................................................................57
10 FIELD SERVICING .......................................................................................................................58
10.1 OIL REFILL PROCEDURE ..................................................................................................................58
10.1.1 Geo-Pilot Compensator piston measuring device .................................................................59
10.1.2 To measure the compensator piston position.........................................................................59
10.1.3 Before refilling with oil past the three inch mark ..................................................................59
10.1.4 Refilling a tool after use ........................................................................................................59
10.1.5 Tools that have sent a low or no oil status.............................................................................61
10.1.6 Blocked relief valve ...............................................................................................................61
10.2 ROLLER CHANGE PROCEDURE ........................................................................................................62
10.2.1 Removal of the Carriages ......................................................................................................62
10.2.2 Preparation and Installation of Carriage Assemblies ...........................................................63
11 APPENDICES..................................................................................................................................70
Contents
TABLE OF FIGURES
Figure 1 The point the bit concept ....................................................................................................4
Figure 2 Geo-Pilot INSITE Confidence Test ................................................................................. 11
Figure 3 Geo-Pilot Download Screen ............................................................................................ 13
Figure 4 Geo-Pilot RPM Sensor .................................................................................................... 17
Figure 5 DF TF Logic ..................................................................................................................... 20
Figure 6 Sample VDF Definitions Screen ...................................................................................... 21
Figure 7 VDF Download Example ................................................................................................. 22
Figure 8 Recommended RT Log Display ...................................................................................... 24
Figure 9 Recommended Recorded Log Display ........................................................................... 25
Figure 10 Real Time Display ......................................................................................................... 26
Figure 11 DDU Display .................................................................................................................. 28
Figure 12 Geo-Pilot Downhole Manual Control Flow Chart .......................................................... 33
Figure 13 Double Hits on Clutch.................................................................................................... 51
Figure 14Tool repsonse with only one eccentric working.............................................................. 54
Figure 15 Measuring the Oil Level................................................................................................. 58
Figure 16 Oil Level Dipstick ........................................................................................................... 59
Figure 17 7600 Series Reference Stabilizer Roller assembly ....................................................... 62
LIST OF TABLES
Table 1 Software Compatability........................................................................................................8
Table 2 Uplink Items ...................................................................................................................... 16
Table 3 Recommended Set up for DDS Limits ............................................................................. 20
Table 4 Recommended RT Plot Set-up ........................................................................................ 24
Table 5 Recommended Recorded Plot Set-up .............................................................................. 25
Table 6 Determining Oil Status from INSITE ................................................................................. 27
Table 7 Downlinkable Commands ................................................................................................. 29
Table 8 Cruise Control Commands ............................................................................................... 30
Table 9 Trouble Shooting Guide.................................................................................................... 53
APPENDICES
Appendix A Tool Specifications Sheet ........................................................................................ 71
Appendix B Geo-Pilot Performance / Perceived Problem Report ................................................ 73
Appendix C Geo-Pilot Battery Log................................................................................................ 75
Appendix D Standard Field Toolkits ............................................................................................. 76
Appendix E Standard BHA Configurations ................................................................................... 77
Appendix F SPE 74458: Robotic Controlled Drilling: A New Rotary Steerable Drilling System
for the Oil and Gas Industry ................................................................................................... 94
Chapter 1-Safety
1 Safety
1.1 Operator safety
 Ensure that relevant PPE equipment is worn at all times to avoid any injury.
1.1.1 Lithium hazard

The Geo-Pilot contains a lithium battery pack. This pack can develop explosive and/or high
temperature conditions that must be handled with the correct procedure. In addition the correct
safety materials must be available. If the Geo-Pilot fails in use a lithium battery pack failure must
be prepared for before the tool is brought out of the hole. Follow District guidelines, or check the
web site for the correct procedures. Due to the design of the tool, the discharge of the battery will
also be mixed with lubricating oil from the tool.
1.1.2 Pressurized fluids
There is chance oil, drilling fluids or gases could be contained under pressure inside the tool. It is
recommended that suitable PPE be used whenever there is the slightest possibility oil or fluids
could spray from the tool.
1.1.3 Weight of tool
The Geo-Pilot is a heavy tool. Follow approved techniques for personal safety while handling the
Geo-Pilot while shipping, lifting and assembling into a string. See Tool safety for additional
caution (Clamp) while handling the Geo-Pilot.
1.1.4 Sharp threads
The Geo-Pilot may have sharp burrs around threads. Protect your hands with gloves whenever
handling the tool to prevent serious damage to fingers.
1.2 Tool safety
1.2.1 Clamp
The Geo-Pilot has a bearing at the top of the tool that is susceptible to damage if overstressed
sideways. There are only three times the clamp should be removed;
• During servicing when the bearing is supported on both sides horizontally.
• During shipping, if the bearing is supported by the shipping container
• Just before the tool enters the hole
The tool is delivered to the rig with the clamp attached. If the tool is sent without a clamp, the flex
collar should be sent separate to the Geo-Pilot, and made up on location in the rotary table.
Never use the clamp to lift the Geo-Pilot. The clamp is aluminium and not

designed to take the weight of the whole Geo-Pilot. Any attachment points on the
clamp are only to be used to lift the clamp alone.
1.2.2 Lithium battery pack

The Geo-Pilot has a lithium battery pack. These packs can fail, producing considerable hazards.
The tool could be potentially dangerous if;
• There is a failure to communicate with the tool while it is downhole
Page 1 of 114
Chapter 1-Safety
• The battery section is hot to the touch
• Gases are venting from the tool
• There are signs of heat damage specifically in the battery pack area
• The battery has low or no voltage
Water is particularly dangerous when brought into contact with a failing battery pack. Follow
district guidelines for handling a failed lithium battery pack, or contact the document centre on the
Sperry-Sun web site for the correct procedure.
The tool cannot be airfreighted while the battery is discharged, although surface transportation is
allowed.
Note: A new series of tools with field replaceable/removable batteries will alter these guidelines.
1.2.3 Seal failure

The internal mechanical parts of the Geo-Pilot operate in an oil bath and depend on seals to
prevent mud solids damaging the tool. A sudden change in pressure can rupture these seals. The
Geo-Pilot requires specific care while changing fluids in the well, or working in hole likely to pack
off. The tool is more sensitive to such events than conventional motor assemblies, so caution
must be exercised. Failure to handle the tool correctly can result in increased service charges.
(Refer to sections 5.6 and 7).
1.2.4 Temperature
The Geo-Pilot is configured to specific temperature operating ranges.
If the temperature is too low the oil will be too viscous to perform its job properly, and tool
performance may suffer.
If the temperature is too high the seals could fail, the electronic boards could fail, the oil could
escape and the lithium battery pack could explode. See the tool specifications in the appendix for
the recommended Geo-Pilot operating conditions.
1.2.5 Vibration
The Geo-Pilot is an electro-mechanical tool, and has a large amount of precision components
inside. Whilst extended gauge bits normally produce smoother drilling conditions, there is a finite
amount of vibration that the tool will withstand. It is recommended that where ever possible, the
tool is run together with a DDS sensor in the MWD string. Standard pre run modelling for critical
rpm string frequencies always should be done. (Refer to section 4.5.11)
1.2.6 Length of use
The Geo-Pilot uses the energy stored in the lithium battery pack to operate its communications
and sensors. The battery pack also supplies the power to the Geo-Pilot’s clutches. Keeping track
of the service life left in the battery pack by using a battery log is the main control the operator
has of the useful service life remaining in the tool.
1.2.7 Damage and wear to the outside of the tool
If the tool shows signs of wear, denting or is gouged, consult with the technical supervisor
concerning the removal of the tool from service.
1.2.8 Thread damage
Follow district practices concerning inspection and damage to the threads at the top and bottom
of the Geo-Pilot and Flex assemblies.
1.2.9 Electronic connection
Ensure that the proper spacing is used for the electronic kemlon connection. Incorrect spacing
can lead to communication failure. Damage to the tool can result from failure of the connection
seal.
1.2.10 Tong damage
The Geo-Pilot has some sections that will crush if gripped in power tongs or rig tongs. Observe
the tool markings for warnings concerning where tongs should not grip. The Geo-Pilot leaves the
shop with all connections tightened to their specified make up torques. Under NO
Page 2 of 114
Chapter 1-Safety
circumstances are the connections on the tool to be torqued or checked at the rigsite.
This may upset the internal tolerances in the tool, and result in tool malfunction, and/or damage.
There should be no need to grip the tool with tongs on any places other than the lower pin end of
the driveshaft and the repeater sub, and the top/bottom of the flex joint.
1.2.11 Fishing requirements
Always measure the tool before making up the string. The length and relative position of the sub
components of the tool will vary slightly over time as cut backs are made.
.
Page 3 of 114
Chapter 2-Description of the Geo-Pilot
2 Description of the Geo-Pilot

2.1 The system’s advantages
The Geo-Pilot System introduces many advantages over conventional steerable drilling systems.
With the ever increasing complexity of well profiles being required, some wells are simply not
economic or possible to drill with conventional technology.
• The Geo-Pilot is a rotary steerable tool. As such it is not dependent upon sliding to produce a
deviated hole. In extended reach and horizontal applications where weight transfer to the bit
is a problem, steering can be achieved more effectively.
• Hole cleaning is improved as the pipe is rotated both while steering the well and drilling
straight. ECD will be kept consistent, rather than fluctuating as the hole is loaded with
cuttings while sliding and then cuttings beds agitated and unloaded while rotating.
• Hole quality using the extended gauge bits matched to the Geo-Pilot is much improved, with
lower micro tortuosity, lower friction factors, easier casing runs, and larger maximum collar
pass through diameter. Geo-Pilot is currently the only commercial rotary Steerable tool using
extended gauge bits.
• Higher string rpm can be used, as there is no bend in the mud motor to limit rpm.
• Downhole vibration is reduced using extended gauge bit technology, increasing the reliability of
the MWD tools and the Geo-Pilot.
• It is possible to steer the well with a much higher degree of control due to the presence of
accurate near-bit measurements, and features such as cruise control. Continuous profiles
are possible.
• The Geo-Pilot direction can be remotely programmed or manually controlled. Using an INSITE
surface control unit the Geo-Pilot’s direction can be changed in a matter of minutes.
• Time spent to orient the toolface prior to conventional sliding is eliminated.
2.2 How the Geo-Pilot steers
Figure 1 The point the bit concept
The Geo-Pilot is designed with the concept of bending a shaft to point the bit in the direction that
the hole should be steered. The bendable shaft runs inside a slowly-rotating control housing. A
reference stabilizer with friction carriages prevents the control housing from freely rotating with
the drillstring and provides a stable reference from which the tool can work.
Page 4 of 114
Chapter 2-Description of the Geo-Pilot
The heart of the tool is the bias unit that resides inside the lower part of the housing. The bias unit
is made up of two eccentric rings that bend the shaft that runs through the tool. An upper
cantilever bearing and a lower focal bearing support the shaft section that runs through the bias
unit. When the shaft is bent the cantilever bearing acts as fixed point not allowing the shaft to
bend above it. The focal bearing allows the bit box on the end of the shaft to be tilted in the
opposite direction to the eccentrics. This gives the operator 360° of positional control for the
toolface selection. By positioning the eccentric rings appropriately any bend magnitude from zero
to full deflection can be attained.
2.3 How the Geo-Pilot’s Toolface is controlled
To control the toolface the Geo-Pilot utilises a tri-axial accelerometer stack located inside the
At-Bit-Inclination (ABI) insert. The ABI tracks the Geo-Pilot housing toolface relative to the high
side of the hole. The downhole software inside the Geo-Pilot monitors the relative position of the
housing, and also the position of the eccentric rings relative to this highside and thus controls the
tool. When the Geo-Pilot calculates that either the toolface or percentage deflection has drifted
out of the target range; the Geo-Pilot will automatically rotate one or both of the eccentric rings to
bring the actual value back into the target range.
In order to maintain the position of the eccentric rings each eccentric has a home sensor and two
quad counters. At the home position, the tool knows the precise location of the eccentric ring
relative to the ABI and can re-calibrate its position tracked by the algorithm. The quad counters
are used to monitor how far the rings have been moved, and thus the tool can calculate the
relative position of the eccentric rings at all times.
2.4 The Complete Drilling Package
The Geo-Pilot is part of an integrated drilling package consisting of the Geo-Pilot, a Geo-Span
Downlink system, a Sperry-Sun MWD system, INSITE and a SDBS Extended Gauge Bit.
The MWD pulser is used to transmit information back to the surface from the Geo-Pilot through
the normal VDF data lists. Either MPT negative pulse telemetry or P4M positive pulse telemetry
can be used. As a minimum, the MWD tools must contain a DM directional probe, an HCIM and
for operations using downlink, a PWD sensor.
The Geo-Span Downlink system (or Downlink skid) creates a brief negative pressure pulse in the
drilling mud without interrupting the drilling process. Advantages of the Geo-Span Downlink
System include:
• the signal transmission time is significantly shortened. (Max approx 90 seconds)
• drilling is not interrupted. – on the fly transmission on bottom is possible
• uplink communication is not interrupted. – no gaps in the real time logs
Approximately 15 per cent of the drilling fluids pass through the Geo-Span Downlink skid. By
controlling a valve a brief pressure drop in the downstream drill fluid is generated. The pressure
drop generates a low frequency pulse that is transmitted through the drilling fluid and is detected
by the PWD bore pressure transducer. The pulses encode signals using pulse position
modulation.
The operation of the Geo-Span system is outside the scope of this manual, and addressed in a
separate field operations manual. (SSDS p/n 074336)
Integral to the performance of the system is also an extended gauge bit, either PDC or Roller
Cone. If a roller cone bit is used, then a sleeve must be used to convert the bit to give an
equivalent long gauge performance. The point the bit Geo-Pilot concept will not work with a short
gauge bit.
A more comprehensive description of the tool can be found in “SPE 74458: Robotic Controlled
Drilling: A New Rotary Steerable Drilling System for the Oil and Gas Industry” located in the
appendices.
Page 5 of 114
Chapter 3-Rig Set Up
3 Rig Set Up
3.1 Shipped Goods
On arrival at the rig-site ensure that you have all the necessary items required for the job. This
will include suitably configured MWD strings, bits, a Geo-Span skid, surface plumbing gear and
field support kits. With additional connections to make offshore, the FE kit should be expanded to
include and increased number of CIM hanger adapter tips, Teflon spacers and test cables.
3.2 The lithium battery pack log

3.2.1 Checking the battery log
The Geo-Pilot is shipped with its battery pack sealed inside the body of the tool. You must check
the battery log to see how much power is left in the battery pack to check that the Geo-Pilot has
enough battery life for the proposed work.
Note: A new Geo-Pilot battery holds 48 to 60 amp-hours of capacity, depending

on the size of tool. The typical drain on capacity is about 0.12 amp-hours, if the
tool is powered and not firing the clutches. Since the tool will almost always fire its
clutches, the battery log should always error on the side of having enough reserve
to cover the job.
A new battery will typically be sufficient for 200 hours of steering.
This drain will go up if the Gamma ABI is installed in the tool. These numbers apply to ABI only
Geo-Pilots.
When testing the Geo-Pilot, confirm that the battery pack voltage is correct. (20Vdc)
Note: See the next section for the procedure if-
• The voltage is not correct.
• The battery compartment is venting or there are signs of heat.
• The Geo-Pilot suddenly fails in the hole.
3.2.2 Battery pack failure
If a Geo-Pilot fails in the hole or on surface, if its voltage is too low or if there are signs of heat or
venting, or have any other reason to suspect a battery problem, you should -
• Have a hazardous lithium battery kit ready before lifting the Geo-Pilot above the rotary table.
• Clear the area and proceed as per standard MWD procedure.
3.3 Physical Condition of the Tool

3.3.1 Measure oil level
The Geo-Pilot will arrive at the site pre-charged with oil. Check the oil level and recharge if
necessary. See the appendix for procedures. If the oil level is suspiciously low, check around the
tool for any visible leakage. Also check the transport basket/container for oil. The procedures for
refilling and checking the oil level in the tool are in section 10.1 Oil refill procedure.
3.3.2 Check rollers & Avoiding Damage
Examine the rollers for any transport damage. The rollers are made of tungsten carbide and can
liable to being chipped if impacted. If necessary the rollers can be serviced in the field; refer to
section 10.2 Roller change procedure.
Page 6 of 114
Chapter 3-Rig Set Up
The tool should be transported in such a manner that the rollers are protected from damage –
e.g. shipping basket or cradle. Also when laid on the deck the Geo-Pilot should be supported on
timber or tool racks so that the tool is not resting on the roller assemblies.
There are 2 different roller profiles available; standard and salt. The salt rollers have a sharper
profile, and give more rotational resistance. They are however more liable to chipping. Ensure
that the tool is dressed with rollers suitable style to the proposed application.
Page 7 of 114
Chapter 4-Setting Up to Run in Hole
4 Setting Up to Run In-Hole

4.1 Software compatibility
4.1.1 Surface and Downhole Software Compatibility table
The following table shows the current software that is compatible for the Geo-Pilot system. For
the latest versions release subsequent to the manual, please refer to Sperryweb software
compatibility pages. The Geo-Pilot can be configured to run with either negative (MPT) or
positive (P4M) pulse telemetry systems. Both systems can be run together with the Geo-Span
downlink.
Compatible
Minimum version
Software Versions
Geo-Pilot 3.10
PWD 3.70
HCIM 66.37
DM 3.10 (pic 0.13)
SDC 1.28
TM 6.02 (pic 0.43)
INSITE 5.3.5+
Table 1 Software Compatability

• The Geo-Pilot must currently be run in conjunction with a DM directional
probe.
• To run the Geo-Span downlink, a PWD with correct software must be
present in the string
Page 8 of 114
4.2 Geo-Pilot Configuration
4.2.1 Scope of the following set-up procedures
The following section concerns the Geo-Pilot and the INSITE surface system. There are
references specific to INSITE release version 5.3.5. This manual assumes the user is familiar
with the basic operation of INSITE FEWD, downloading, reading, log generation / setup and
FEWD surface systems.
This section does not address the Geo-Span Downlink System.
4.2.2 Bottom hole assembly configuration

The Geo-Pilot and the MWD string must be set up so that there is a suitable stabilizer set-up
above the Geo-Pilot. The objective of the stabilisation is to reduce the load being put onto the
upper radial bearings of the Geo-Pilot and give consistent dog leg capability. In addition they will
give a relatively neutral performance when drilling non-deflected.
Warning:

Failing to properly stabilize the Configure the BHA will result in poor or
unpredictable dogleg performance, damage to the upper bearings, and eventually
lead to a tool failure.
All RLLs must be configured with a hard connect at bottom to connect into the Geo-Pilot flex
collar for bus communications. This generally requires a Box down connection on the RLL. For
non-box down configurations – e.g. directional-PWD and directional-PWD-DGR – an annular
connector conversion sub can be used to cross over to a box down configuration suitable for a
hard connect at bottom.
In addition, for assemblies where stabilisation would be problematic to place “in line stabilizers”
are available.
Refer to Appendix E Standard BHA Configurations for examples of approved GP/MWD

configurations.
4.2.2.1 7600 Series Geo-Pilot GP/MWD Configuration
The Geo-Pilot has a reference stabilizer on the tool body and no other stabilization features.
The first stabilizer in the string should be immediately above the flex collar and have a gauge of
8.405” (for 8 ½” hole). This will generally be a long pin/pin stabilizer with a hard connect through.
The next stabilizer should then be placed with a spacing of 20 to 35 feet (6.1 to 10.6metres) away
from this first stabilizer. In the case of triple combo strings this is generally the SLD stabilizer.
For non-triple combo, it will either be a pin/pin stab between the MPT and DM/PM sub, or a
stabilizer on top of the MPT/HOC, dependent upon the sensor configuration being run.
Page 9 of 114
4.2.2.2 9600 Series Geo-Pilot GP/MWD Configuration

3
The 9600 series Geo-Pilot has in addition to the reference stabilizer, a / 16 ” undergauge stabilizer
on the repeater sub. This acts as the first stabilizer in the string, and replaces the stabilizer at the
bottom of the RLL used on the 7600 series configuration. A slick pin/pin stab with hard connect
should be used at the bottom of the RLL.
The second stabilizer should again be placed 30 to 45 feet (9.1 to 13.7m) above this repeater sub
stab. Again pin/pin stabs in the pulser, and SLD stabilizer are possible stabilizers to use in this
position, dependent upon the sensor configuration.
4.2.2.3 General BHA Configuration

In general, the amount of Drill Collars, Heavy weight DP, jar placement etc. should not be
significantly different from what would be run for the same hole drilled with a conventional
assembly.
It is recommended that a reaming device such as a full gauge stabilizer or roller reamer should be
placed above the MWD to aid in reaming out through any tight hole.
4.2.2.4 Simultaneous Use of Hole Openers/Underreamers

It is possible to run the Geo-Pilot in conjunction with a hole opener or undereamer. Jetting of the
reamer will not affect the downlink, providing the bit hydraulics allow a suitable pressure drop. It
is advisable to have a stabilizer immediately below the reamer to centralize it, and one possibly
higher up in the string to limit whirl problems.
4.2.2.5 Running Geo-Pilot together with a mud motor.

It is possible to run the Geo-Pilot together with a mud motor. There are several issues to be
addressed before doing this, and the DTDG technical support group must be consulted prior to
proposing this. Downlinking through the motor is not a problem, but manual control mode is no
longer available.
4.2.3 Rig Floor Offset
 Warning:
The Rig Floor Directional Offset must be set to zero in the MWD Tool Parameters
The “Rig Floor Toolface Offset” must always be set to 0° in the Directional Info in MWD Tool
Parameters screen prior to your run. There is no rig floor offset to measure when picking up the
Geo-Pilot. If you enter any number here, INSITE will add the offset to the Smart Toolface value
coming up, but the Geo-Pilot assumes the value is always zero.
The software will not allow you to download the string with a non-zero rig floor offset.
Any value entered in here would result, in the case of manual steering cause the Geo-Pilot to drill
off in the wrong direction.
For downlinked commands, the Geo-Pilot toolface would not appear to have gone to the
downlinked value but be offset.
Page 10 of 114
The Geo-Pilot’s ABI highside is decoupled from the rest of the drill string. It calculates its own
gravity toolface constantly so there is no need for an offset and there is no need to perform a rig
floor toolface offset measurement with the Geo-Pilot in the string.
4.3 Confidence Test
For a true confidence test, because the Geo-Pilot is an electronic and mechanical device, the tool
must be run on a beam so the performance of the mechanical parts can be assessed. This is not
currently possible outside of a level 1 repair and maintenance facility. An electronics and
communications test is available from within INSITE.
GP has been detected.

GP HC11 VERSION NUMBER: 3.10
GP PIC VERSION NUMBER: 0.00
GP FPGA VERSION NUMBER: 93
GP confidence test will take approximately 60 seconds.
GP CONFIDENCE TEST
28-Feb-02 14:35:55
-----------------------------------------------------------------------------
GP UNITS LOW ACTUAL HIGH
LIMIT READING LIMIT
-----------------------------------------------------------------------------
GP HC11 VERSION [] 3.10
GP PIC VERSION(Hex) [] A1D
GP FPGA VERSION(Hex) [] 93
GP ABI VERSION [] N/A
BATTERY VOLTAGE [V] 18.000 20.000 22.000
CAPACITOR VOLTAGE [V] 18.000 21.021 22.000
QUIESCENT CURRENT [mA] 15.000 104.790 50.000 H
CLUTCHES ON CURRENT [mA] 800.000 1112.770 1200.000
SURVEY CURRENT [mA] 90.000 59.880 140.000 L
+14 VOLTAGE [V] 13.500 14.539 15.000
-14 VOLTAGE [V] -15.000 -15.040 -13.000 L
HOUSING TOOLFACE [] -180.000 -159.662 180.000
HOUSING INCLINATION [] 0.000 90.567 180.000
GTOTAL [] 0.980 1.001 1.020
UPPER CAM POSITION [] 0.000 0.000 360.000
LOWER CAM POSITION [] 0.000 0.000 360.000
BIT DEFLECTION [] 0.000 0.000 100.000
GP confidence test completed successfully.
Figure 2 Geo-Pilot INSITE Confidence Test
4.3.1 Electronics Confidence Test Available in INSITE.

There are current draws on the confidence test that may well appear out of limits. This is due to
timing issues between the Geo-Pilot and the INSITE confidence test. In the example above the
quiescent current has been measured while taking an ABI survey and the survey current has
been taken without the ABI powered up.
Page 11 of 114
In addition be aware that the 9600 series tools draw significantly less power with clutches on
(300mA per clutch) compared to the 7600 series tools. The limits in the confidence test do not
change to cope with the different limits between the different tool sizes.
The ABI response can be verified for highside, inclination and G total . There is a highside scribe
line on the top of the lower housing of the Geo-Pilot. (approximately two meters from the bottom
of the control housing).
Page 12 of 114
4.4 Download Screen Setup
Figure 3 Geo-Pilot Download Screen
The screen above shows a typical download set up.

This is the recommended setup for the Geo-Pilot download screen. Each parameter is described
below along with recommended settings.
4.4.1 Tdelay
Trip In Time Delay in minutes for Geo-Pilot. The Geo-Pilot remains powered down for the number
of minutes entered, beginning after a successful download to the string. It is suggested that the
time expire prior to the estimated start of the shallow pulse test. There are currently no real
constraints on memory capacity, or major implications for battery usage, so a short Tdelay is no
problem.
4.4.2 Temperature Sample Period
Amount of time in seconds between recording the temperature measured in the Geo-Pilot
electronics’ housing. One measurement every 5 minutes (300 seconds) is the recommended
default.
4.4.3 Toolface/Azimuthal Gamma Sample Period
Amount of time in seconds between every time the Geo-Pilot samples the ABI for toolface and
gamma ray. A default of 15 seconds is recommended. 30 seconds is the minimum interval time
to ensure that downhole toolface corrections due to housing roll are done in a timely manner, and
for assessing tool performance during and after a run. This sample rate also has implications for
the cruise control algorithm. Refer to section 6.2 Cruise Control.
Page 13 of 114
 Note:
On Geo-Pilots with Gamma at Bit Inclination sensors, this will also be the Gamma
Sample Period.
4.4.4 Brake/Clutch Slip Rate Sample Period)

Amount of time in seconds between recording the status of any brake slippage or clutch slippage.
Every 60 seconds is the minimum interval time required for assessing tool performance after a
run. No faster than every 15 seconds is recommended. This is a recorded parameter only, used
for post run diagnostics.
4.4.5 Housing Slip Rate Sample Period
Amount of time in seconds for the recording the rate of slippage of the control housing. Every 60
seconds is the minimum interval time required for assessing tool performance after a run. No
faster than every 15 seconds is recommended. This is a recorded parameter only, used for post
run diagnostics.
4.4.6 Threshold for RPM ON
The minimum threshold RPM required for the Geo-Pilot to sense that the RPM is on. Refer to the
tool command flowchart. Also unless the tool senses rotation, it will not attempt to engage the
clutches to correct toolface.
Note that this is the difference in RPM between the Geo-Pilot shaft/drillstring and the control
housing. If the control housing is slipping the RPM measured by the Geo-Pilot RPM sensor will
be less than the drillstring RPM. Values in the 5-15 RPM range are typically. Note also that the
Geo-Pilot averages the RPM over a 15-second moving window period.
4.4.7 Resume Previous Toolface Timeout
This parameter is used in the manual shortcut method to allow the previous toolface setting to be
used again without the need to re-orient the MWD or resend a downlink command. Refer to the
tool command flowchart in section 6.3. It is the time window in which the rotary must be brought
back on after pumps on in order to return to the last setting.
If pumps have to be brought up slowly, it may be prudent to set this to a larger number depending
on the pumps on time needed. Default settings of 60 seconds for MPT and 120 seconds for P4M
are recommended.
4.4.8 Percent Deflection Steering Mode
The percent deflection the Geo-Pilot will use when deflection is turned on in manual use (i.e. not
commanded with the Geo-Span downlink). 100% is recommended for 7600 and 80% for 9600
under normal circumstances but the number is largely dependent on steering and dogleg
requirements for the well. If the downlink fails to operate or is not available for the job this is the
percent deflection you will be steering with. If a percentage of less than 100% is downloaded, the
downlink will still be able to send deflection settings in excess of this downloaded value.
 Warning:
Limit the 9600 tool deflection to 80% under normal circumstances. Only downlink
to exceed this when required to meet the wellplan.
4.4.9 Max ABI Gtotal error

This value acts as a downhole quality control on the ABI readings. It is the maximum error
tolerated when taking toolface measurements from the At-Bit-Inclination (ABI) tool in the Geo-
Page 14 of 114
Pilot housing. Measurements made with G total errors above this threshold are discarded and a
new measurement is attempted only after another toolface sample interval. A value of 50 milli-g
is recommended as default. Note that G total is not normalized for any local gravity variations.
Warning:
 • Too high of a value and the Geo-Pilot could start accepting bad toolface
measurements when vibration occurs.
• Too low a value could render the Geo-Pilot inoperable in a high vibration
environment as there will be no valid ABI readings on which to base the
current highside reference of the housing.
4.4.10 Bit Toolface Sample Rate

Amount of time in seconds between the recording of the current Geo-Pilot bit toolface and actual
deflection in memory. A default of 15 seconds is recommended. Every 30 seconds is the
minimum interval time required for assessing tool performance after a run. As a rule this should
be identical to the Toolface Sample Period. This is a recorded parameter only, used for post run
diagnostics.
4.4.11 Sample Rate for Diagnostic Values
Amount of time, in seconds, between the recording of the current diagnostic values in memory.
This 30-second period of time is not adjustable by the operator.
4.4.12 DM Toolface Age
Age of the toolface in seconds. This value is used by the Geo-Pilot when accepting a new
toolface command from surface in manual steering mode. This period of time is not adjustable by
the operator. The toolface accepted for steering with, by the Geo-Pilot is 30 seconds old prior to
the start of rotation guaranteeing that the toolface held for 60 seconds on surface is selected by
the tool when using the manual command. Refer to section 6.3.
4.4.13 Mode B Gamma Off Delay
The Geo-Pilot versions with azimuthal Gamma will normally on VDF Mode A power off the
gamma insert to preserve battery power 60 seconds after the pumps are turned off. In VDF
Mode B, the gamma sensor can be configured to remain powered on if desired to perform for
instance a wipe when pulling out of hole. In addition, the Gamma sensor can be downlinked to
override the power status to always on or always off. Such a downlink will be cancelled into the
respective VDF-A or VDF-B power down on pumps off mode by a mode switch of the MWD tool.
4.5 Real -Time Data Transmission

It is important to consider-
• How much bandwidth it will take for the Geo-Pilot to transmit steering and diagnostic data
• The impact of data transmission on the pulser battery life for MPT
• The balance between FEWD data density and the rate of penetration
There is additional information that the directional driller requires from the Geo-Pilot that has not
been required from a mud motor, which complicates the demand for uplink bandwidth. Inevitably
under most circumstances a trade-off will be required between the conflicting demands.
Page 15 of 114
The following table lists all the active variables important to the Geo-Pilot.
Note: For Geo-Span Downlink related variables see the Geo-Span Operations manual.
VDF Definition Description Lists Min / Max Seconds Recommended

Between Updates Time Between
Updates
DS – Deflection setting % Deflection Setting Initial, Periodic 120 / 600 240
TT - Toolface setting Toolface Setting Initial, Periodic 120 / 600 240
RD - GP deflection Actual % Deflection Initial, Continuous 45 / 120 60
Smart Toolface (Sends

Actual DM or GP
DF – DM/GP toolface toolfaces automatically Initial, Continuous 45/120 60
depending on
rotation state)
RI - GP inclination ABI Inclination Initial, Periodic 60 / 300 120
ABI Gtotal Value Initial, Periodic 60 / 300 120

RG - GP G-total
Ideally should be sent together with an RI VDF item, to reference it to an inclination.
RS - GP status Geo-Pilot Status Flags Initial, Periodic 60 / 300 240
RR - GP rpm Geo-Pilot Shaft RPM Periodic 120 / 600 300
Geo-Pilot Battery
RB - GP battery current Current Consumed Periodic if at all 900 900
since download
Voltage of Geo-Pilot
RT - GP battery voltage Periodic if at all 900 900
Battery Insert
Very Slow Periodic if planning to use Cruise Control. Could have just
Inclination Setting Used
IS – Inclination Setting in start-up format and then track differences using Geo-Span
by Cruise Control
verification when changes are transmitted to Geo-Pilot
Cruise Control
Z3 ** Slow Periodic e.g 600s - Data Dependent upon cruise being active
Configuration Settings
Geo-Pilot Gamma At
GGA As FE Dictates if Gamma Sensor in Geo-Pilot
Bit Bank A
Geo-Pilot Gamma At
GGB As FE Dictates if Gamma Sensor in Geo-Pilot
Bit Bank B
Geo-Pilot Gamma At
GGC As FE Dictates if Gamma Sensor in Geo-Pilot
Bit Bank C
Geo-Pilot Gamma
GGT Must be sent with GGA, GGB, GGC Triad
Highside Toolface
Table 2 Uplink Items

** Z3 – Note this is found in the PWD section of mneumonics
Page 16 of 114
4.5.1 DS – Deflection Setting

This is the value of the current target percent deflection the Geo-Pilot is trying to maintain.
4.5.2 TT - Toolface setting
This is the Target (bit) Toolface that the Geo-Pilot is trying to maintain with deflection turned on.
4.5.3 RI - GP inclination
This is the current inclination from the ABI inside the Geo-Pilot housing. It is different than the
standard ABI variable (AI) and RI should always be used when using the Geo-Pilot and not the
regular AI value. The inclination is updated every time the toolface is sampled by the Geo-Pilot.
 NOTE - An ABI receiver may be present in the FEWD string. It will not interfere
with the Geo-Pilot ABI, as these respond at different addresses on the bus
4.5.4 RD - GP deflection
This is the current actual percent deflection of the Geo-Pilot bit tilt.
4.5.5 RR - GP rpm
This is the 15-second rolling averaged RPM value of the Geo-Pilot shaft. This is the differential
RPM of the shaft relative to the control housing.
Figure 4 Geo-Pilot RPM Sensor
Page 17 of 114
4.5.6 RG - GP Gtotal
This is the G total for the Geo-Pilot ABI accelerometers. RG should ideally be sent together with
an RI transmission to ensure that the G total is related to an inclination measurement. Inclination
measurements and G total are updated every time the toolface is sampled within the Geo-Pilot.
4.5.7 RB - GP battery current
This is the Amp Hours Consumed by the Geo-Pilot battery and not the actual Geo-Pilot current.
The variable counts in two Amp-hour increments. An 8-1/2” Hole Geo-Pilot has a 48 Amp-hour
battery. A 12-1/4” hole Geo-Pilot has a 60 Amp-hour battery.
A mode switch of the HCIM will not reset the Geo-Pilot as it operates on its own power. The Geo-
Pilot will power down 30 minutes after there has ceased to be HCIM comms on the bus.
4.5.8 RT - GP battery voltage
This is the present battery voltage of the Geo-Pilot battery insert. The nominal battery voltage of
the Geo-Pilot is 20 Volts.
4.5.9 RS - GP status
This variable consists of eight “dummy lights” or status bits, with the logic described below. It is
worth noting that the Status Flags are summed using an “OR” function over the period between
transmissions of the list, such that several lights may light simultaneously, although the individual
events have been at different times.
4.5.9.1 Oil reservoir status

Contains a 2 status bits describing the position of the Oil Piston
False False =>OK
True False =>Low Level = Piston Position 1
True True =>No oil = Piston Position 2
False True =>N/A = Position Switch Failure
Refer to section 5.4.
4.5.9.2 Bit Position status/Toolface Tracking

False =>No errors detected
True =>Set if any of the other status flags is reported (including "ABI No Comm") with
the exception of the "Brake Slip" flag. If no other status flag is set and the "Toolface
Tracking" is indicated, it means that the GP encountered communication errors while
talking to the Clever board (which controls the clutches).
4.5.9.3 Housing slip rate

False =>OK
True => Indicates that the control housing is moving and is set under a variety of
different conditions The housing roll is calculated as an average over the last four ABI
samples. The maximum rate at which the tool can correct the toolface is calculated as
a function of the differential rpm between the housing and the shaft.
• If the housing roll is more that 50% of the absolute maximum correction rate the
Housing Slip flag will be set but not the TF Tracking Error flag and the tool will
continue its correction attempts.
• If the housing roll exceeds 75% of the maximum correction rate the Housing Slip
and the TF Tracking Error flags will be set and the tool will stop correcting the
toolface.
• There are two fixed thresholds for housing roll. If the housing roll exceeds 20 rolls
per hour the Housing Slip flag will be set regardless of the maximum correction rate
calculations. This is because at the maximum ABI sample rate of 10 seconds the
housing will roll more than 20 degrees between samples causing the toolface to be
within a window of 20 to 35 degrees instead of the desired 14 to 15 degrees.
• The other fixed threshold will be at 45 rolls per hour. This roll would cause the
toolface to be within a window of 45 to 60 degrees, making the toolface tracking to
Page 18 of 114
be barely within a quadrant. If the housing roll exceeds this 45 rolls per hour
threshold the Housing Roll and TF Tracking Error flags will be set and the tool will
abandon its attempts at TF correction (regardless of the maximum correction rate).
45 rolls per hour equates to 75% of maximum corrections rate at 180rpm on the
drillstring.
4.5.9.4 Clutch slip

False =>OK
True => This flag is set if after eight seconds, from the clutch engage time, the clutch
is rotating slower than half of the input RPM rate. In such conditions, the clutch will try
to re-engage after the initial 4 seconds.
4.5.9.5 Brake slip rate

False =>OK
True => If the clutches for some reason are slow to stop (e.g. viscosity or mechanical
problems), they will run past their target position. When this occurs the downhole
software will release the clutch earlier than its target to compensate.
In order to accomplish this efficiently, the range of acceptable toolface will be widened.
The Brake Slip error flag is used to indicate overrun greater than 10 degrees. Once the
Brake Slip (overrun) is indicated the toolface will be tracked within a window that is
greater than ± 10degrees.
Overrun greater than 30 degrees or duration longer than 7seconds causes Brake Slip
and Toolface Tracking error. This indicates that the toolface window is now more than ±
22 degrees or cannot be determined. At this point the tool will no longer be able to
maintain toolface tracking.
N.B. Unlike early versions of firmware, the brake slip light is not reason to stop drilling
and POOH. It is however a clear indication that the tool is not performing 100%, and
diagnostics should be examined carefully at the next trip out of hole before deciding to
rerun.
4.5.9.6 Adjust time exceeded
False =>OK
True => This error is indicated if the toolface adjustment takes longer than 5 minutes.
It can be reported for low RPM (but above RPM threshold). After the "Adjust Time
Exceeded" is reported the tool will wait for 15 seconds before it powers the clutches
again.
4.5.9.7 G total error

False =>OK
True = Downloaded ABI Gtotal threshold is exceeded, and ABI values are not being
used for toolface control
4.5.10 DF – DM/GP toolface/“The Smart Toolface”

The DF variable is the “smart toolface”. The HCIM is designed to automatically switch between
sending DM toolfaces when rotation is off and Geo-Pilot toolfaces when rotation is on. This
variable is therefore dependent on differential string rotation between the Geo-Pilot housing and
the drillstring. If the RPM is picked up by the Geo-Pilot RPM sensor then the HCIM reads this
from the Geo-Pilot and starts sending Geo-Pilot toolfaces to the pulser assembly (Telemetry
Module or Smart Driver Controller) for transmission to the surface whenever it is time to transmit
a DF variable.
The different cases for the DF toolface are outlined in the flowchart below.
Page 19 of 114
DF TF
RPM > GP RPM On Yes
Threshold
No
Deflection On/Off
Off On
DF Sends DM toolface Geo-Pilot ABI Housing Geo-Pilot Bit Toolface

(Use for Manual Steering) Highside Toolface (Steering Direction)
Figure 5 DF TF Logic
4.5.11 DDS Download Thresholds
The DDS should be set up in accordance to the OPTEC advisory limits. VC, AY and PY should
all be sent realtime. This will also pick up strong vibrations in the Y axis only, which would not be
seen in the VC item. All three items are data dependent pulsing parameters.
For 9600 Series tools the DDS thresholds should be set up as if running a 9 ½” LWD tool, even if
running an 8” MWD string. Refer to table below.
Realtime Download Parameter 7600 series 9600 series

Average X 3 2
Average Y 3 2
Average Z 2 2
Delta Average X-Y 1 0.5
Peak X 30 30
Peak Y 30 30
Peak Z 15 15
Delta Peak X-Y 15 15
Table 3 Recommended Set up for DDS Limits
It is important that the vibration be actively monitored and where persistent vibration occurs,
parameters are adjusted to try to eliminate the downhole vibrations.
Further information regarding vibration tools and dealing with downhole vibration is available in
the DDS manual.
Page 20 of 114
4.6 Sample VDF Definitions Download Screen
Figure 6 Sample VDF Definitions Screen
This screen shows a typical VDF definition table for a Geo-Pilot run, with triple combo, PWD,
downlink, and cruise control.
Make sure all relevant Geo-Pilot variables in Section 4.5 can be found in the definition table on
the left before proceeding with list creation.
Notes:
• In the list V0, the actual deflection RD is as relevant as DF (smart toolface) when running the
Geo-Pilot since there is not a fixed bend and the deflection does vary in real-time downhole.
• Ensuring that both PW and BP are transmitted is the most accurate method to get the actual
pressure drop across the PWD for purposes of sizing the bypass jet in the Geo-Span
downlink skid
Page 21 of 114
4.7 A Typical VDF Download List
Figure 7 VDF Download Example
VDF list definitions are as per Figure 6 Sample VDF Definitions Screen.
In general, the most practical way to configure the list transmission is to keep all the Geo-Pilot
parameters as periodic transmissions, and FE as continuous format.
Page 22 of 114
Chapter 5- Monitoring Geo-Pilot Performance
5 Monitoring Geo-Pilot Performance

The performance of the Geo-Pilot is fed back to surface via uplinked data from the MWD pulser.
To monitor the performance of the tool, data must be presented using a combination of realtime
plots, realtime displays, and tables. All this data is obtainable through INSITE.
A DDU is normally sufficient for display of information on the rigfloor. However in contrast to
regular directional drilling operations with mud motors, other data presentations should be readily
available for viewing.
Since in addition, the directional driller will still have to run standard directional software such as
Compass or Drillquest, as a minimum an extra workstation should be provided, preferably with a
dual video capability.
In addition, it is strongly recommended that the PC for the direction driller be equipped with a
network card and INSITE, such that downlink control of the Geo-Pilot can be done from the
directional driller’s computer.
5.1 Customer Presentations

No logs of the Geo-Pilot performance should be given to the customer. All reporting should be
done through standard Sperry-Sun directional reporting software (e.g. Planit). Should there be
any requirement for customers to have copies of either Realtime of Recorded Parameter logs,
these must be cleared with the district’s Geo-Pilot coordinator first.
5.2 EOW Log Requirements

An “emf” or “pdf” copy of the Geo-Pilot Realtime and Recorded Logs against time should be
made and backed up together with the rest of the ADI data sent to town at the end of the well.
Page 23 of 114
5.3 Recommended Real Time Log Set-up
Track Parameter Record Variable Scale

1 Geo-Pilot At Bit Inclination GP RT Inclination 10º range, scale as reqd
1 Geo-Pilot ABI G total GP RT G total 0.95 to 1.05g
1 Block Height Time/Depth Block Position 0 to 150ft / 0 to 50m
2 Independent Variable Time 1 in : 30 minutes
3 Toolface Target GP Config TF Setting (1) -180 to +180
3 Actual Steered Toolface GP Toolface Toolface Gravity -180 to +180
4 Deflection Setting GP Config Bit Deflection (1) 0 to 100
4 Actual Steered Deflection GP RT Bit Deflection 0 to 100
5 (2) Geo-Pilot RPM GP RT RPM To Match Surface RPM
5 (3) Surface RPM Time SDL Fast RPM Surface Avg Scale to suit
5 (3) Flow in Time SDL Fast Flow In Pum Avg Scale to suit
5 (3) Torque Time SDL Fast Torque Abd Avg Scale to suit
(1) Smooth with 1 minute intervals and Smoothing Option “Last”
(2) Plot as discrete point data
(3) If mudlogging or 3rd party realtime data available. Alternatively possible to use MWD Pump Stat for Flow in and
MWD Surf Pres data for Standpipe pressure
Table 4 Recommended RT Plot Set-up
Figure 8 Recommended RT Log Display
Page 24 of 114
5.4 Recommended Recorded Log Set-up
Track Parameter Record Variable Scale

1 (1) Geo-Pilot At Bit Inclination GP Toolface Inclination 10º range, scale as reqd
1 (1) Geo-Pilot ABI G total GP Toolface G total 0.95 to 1.05g
1 Block Height Time/Depth Block Position 0 to 150ft / 0 to 50m
2 Independent Variable 1 in : 30 minutes
3 (2) Toolface Target GP Config TF Setting -180 to +180
3 (1) Actual Steered Toolface GP Bit Toolface Bit Toolface -180 to +180
3 (1) Housing Toolface GP Toolface Toolface Gravity -180 to +180
4 Deflection Setting 0 to 100
4 (1) Actual Steered Deflection GP Deflection GP Deflection 0 to 100
5 (1) Geo-Pilot RPM GP RPM RPM To Match Surface RPM
5 (3) Surface RPM Time SDL Fast RPM Surface Avg Scale to suit
5 (3) Flow in Time SDL Fast Flow In Pum Avg Scale to suit
5 (3) Torque Time SDL Fast Torque Abd Avg Scale to suit
(1) Record Type Only available or relevant in this context as “Insite Read” record processed from GP image.
(2) Smooth with 1 minute intervals and Smoothing Option “Last”
(3) If mudlogging or 3rd party realtime data available. Alternatively possible to use MWD Pump Stat for Flow in and
MWD Surf Pres data for Standpipe pressure
Table 5 Recommended Recorded Plot Set-up
Figure 9 Recommended Recorded Log Display
Page 25 of 114
The Geo-Pilot image contains more detailed information. A plot of these can be used to identify
problems encountered, and assess the general operating performance of the tool. Suggested
plot set-up is shown below. Much data is processed out into specific records, rather than being
grouped into the GP RT record. In addition it should be noted that the contents of some
record/variables has a completely different meaning between the realtime and recorded data,
such as the toolface in the GP toolface record.
5.5 Real Time Display
There is a default real time display installed together with INSITE as shown below. This shows
most of the relevant parameters required to monitor the tool and drilling performance.
Figure 10 Real Time Display
Page 26 of 114
5.6 Oil Status
The tool’s internal piston displacement transducer reflects the level of the oil reservoir inside the
tool. The oil in the tool is used to lubricate and protect all the mechanical parts. The transducer’s
position will be sent up in the Geo-Pilot status (RS) list.
Note: the Geo-Pilot status list must always be included in the download items,

transmitted in all modes
If the tool begins to report “Low Oil” or “Piston Position 1” status, then the tool has lost 90% of the
oil from its oil reservoir. If the “No Oil” or “Piston Position 2” status is achieved, then the positive
oil pressure within the tool has been lost, and it will be possible for mud to easily invade the tool.
Mud solids will damage the internal components, and result in escalated repair costs at best.
The unknown status definition “No Oil*” or “Position Unknown” will result when the No oil switch is
enabled without the Low Oil; a situation which should not be possible. This would indicate a
problem with either the switch or the circuitry. Before deciding on a course of action, the general
situation should be considered; namely whether there have been any pressure surges or pack-
offs that could have compromised the seal integrity. As a general rule of thumb one should pull
the tool out of hole if the unknown status light is sustained.
There is a bug in INSITE 5.3 in reporting of the transducer position, but the true status can be
established by examining the GP Status record using Data Manager.
Reported on Session log GP Status Record True Status

OK OK Oil level good
Position 1 Position 1 Oil reservoir low
Position 2 Position 2 No oil left in reservoir
Position 2 N/A Position switch failure
Table 6 Determining Oil Status from INSITE
It is considered acceptable to continue operations for the same period of time after first "no oil"
status as it took for the tool to go from first "low oil" occurrence to first "no oil" occurrence
provided there has been no pack off indications in the period between low and no occurrences.·
All low, no and N/A statuses are to be confirmed by checking the data

base and reported in to the DD/Geo-Pilot coordinator as soon as
possible. Failure to do so and continuing operations without the
acceptance of district management can result in disciplinary action. If
one is unable to contact the appropriate person, then preparations
should be started to POOH rather than continuing operations.
A note of caution, the oil status light only indicates the switch position. In the case where there
is a no seal integrity after a “No Oil” light, it may be possible for the tool to have well bore fluid
invasion thus potentially moving the switch back to the “Low Oil” or “OK Oil” switch positions.
Page 27 of 114
If a customer wishes to continue drilling against Sperry-Sun advice to pull the tool out of hole,
they should be informed of the scale of possible repair charges before they decide to continue
drilling with a tool with no oil. A repair charge of up to $100,000US is possible if drilling is
resumed and mud enters the Geo-Pilot.
5.7 DDU
The standard Sperry-Sun DDU application and rig floor

display can be used to run the Geo-Pilot. By setting up
multiple levels, it is possible to gauge how the tool is
performing. While steering, toolface corrections will be seen
as adjustments to the left
When Geo-Pilot is non-deflected, the Geo-Pilot will send

the Housing highside toolface (assuming rpm is greater than
rpm on threshold). This will be seen on the DDU as the
toolface progressing clockwise. The degree of housing roll
can be inferred from this.
When steering as the toolface rolls to the right with the roll of
the tool, every correction of the eccentric rings will be seen
as an adjustment to the left.
In addition one should also add ABI inclination, Toolface

Setting, Deflection % Setting and Actual % Deflection to the
text field on the DDU. Include AGE ON for all values so that
there is a measure of the validity of each parameter.
Figure 11 DDU Display
Page 28 of 114
Chapter 6- Controlling the Geo-Pilot
6 Controlling the Geo-Pilot

6.1 Downlink Control
The toolface and deflection settings of the Geo-Pilot can be controlled using the Geo-Span
Downlink system. The operation of this system is fully described in a separate manual. The
prime benefit of the using the downlink to control the tool is that all adjustments can be made on
the fly while drilling ahead. Also it is possible to adjust the deflection setting as required, rather
than just having on/off settings allowable with the manual control algorithm.
Currently the following commands are available, and must be included as active commands on
the DL tab on the MWD Download if they are to be used.
Command Parameters
Toolface Setting & Deflection Setting 0 – 360 Highside (3degree steps)
0 to 100% Deflection (8% and 5% steps)
Toolface Correction ±20º (5º increments) Applies toolface
correction to current TF setting
Deflection Correction ±20% (5% increments) Applies Deflection
setting to current deflection setting
Toolface and Deflection Correction ±20º & ±20% Applies both above
corrections simultaneously
Special Command Home – Will send eccentrics to home
position
Special Command Reset – Will restart downhole code.
Inclination Cruise Refer to Section below
Azi GR Power Control Turn the Gamma Sensor on or off at all
times. Mode switch will reset to
downloaded VDFA/VDFB settings.
Table 7 Downlinkable Commands
The Correction commands are shorter commands to send, requiring fewer downlink pulses, and
are faster to send, and easier to detect if there are any downhole detection issues.
6.2 Cruise Control

The current 3.10 software release supports the downhole cruise control algorithm. The algorithm
works off a target inclination, combined with a set of configuration parameters (tolerance, max
deflection, aggressiveness, turn setting). In essence the algorithm is two-sided, and responds
differently according to whether the current inclination is within the set tolerance or not.
As the algorithm assesses performance of the tool by looking at 12 ABI samples, the
responsiveness of the algorithm will depend upon the toolface sample period. It is recommended
to use 15seconds.
6.2.1 Inclination within Tolerance
If the trend of the last 12 ABI samples is steady (i.e. not building or dropping), then providing the
inclination is within the inclination setting ± tolerance, then the tool will continue at its current
toolface and deflection settings.
If the tool identifies a build/drop trend in the ABI, it will begin to automatically adjust the deflection
and toolface to counter this trend. The amount that it increases the deflection by will be
dependent upon the aggressiveness setting.
Page 29 of 114
6.2.2 Inclination Outside Tolerance
If the average of the last 12 ABI samples is outside of the target inclination ±tolerance, then the
tool will steer with maximum allowed deflection in the appropriate direction to come back within its
desired inclination setting. Once within this setting, it will continue to steer, and adjust deflection
to achieve a steady inclination, as per described in the previous section.
6.2.3 Starting, Stopping and Running the Cruise Algorithm

There are various ways in which to start the cruise control algorithm. Generally in order to start, a
downlink command will be sent, to the Geo-Pilot to acquire the current ABI inclination, and use
this as the target inclination. This target inclination can be transmitted to surface in the IS VDF
mnemonic. All commands for the Cruise Control are solely downlinkable. The following
commands are available:
Command Function
Cruise Off Will leave the Cruise Control function, and the tool will continue
steering at the current TF and Deflection settings being used by the
Cruise Algorithm
Cruise On Will Engage the Cruise algorithm using the last Inclination Setting, and
Configuration settings
Use ABI Inc Will Engage the Cruise Control, and set the Inclination Setting to the
Current ABI Inclination
Inclination Setting Adjust the Inclination setting. Adjustable in 0.1º increments by ±12.7º
This command will also engage the Cruise Control.
Turn Setting Set the amount of LH/RH turn applied. Downlinkable in 10% steps
from 100%L to 100%R. Current default value on initialisation of tool is
20%L. This command will also engage the Cruise Control.
Configuration This will downlink 3 different parameters.
The tolerance on the inclination, which is how wide the window around
the inclination setting is. 0.3º to 1.0º in 0.1º steps. Default value on
initialization is 0.5deg.
The maximum deflection from 10% to 100% that it will allow the cruise
control routine to apply up or down when controlling the tool. This can
be used to limit the amount of dogleg that the tool is allowed to
generate, and therefore also the wellbore tortuosity. Default value on
initialization is 60%. The tool may steer larger deflections if combined
with turn.
The Factor is a measure of how aggressively the tool will respond to
changes in inclination. Default value on initialization is 7. As a
general rule for faster drilling, use a lower factor, and for slow drilling
use a higher factor. The range is 0 to 15 in steps of 1.
This command will change settings but will neither engage or
disengage the Cruise Control.
Table 8 Cruise Control Commands
Any regular downlink command – e.g. TF/Def, TF Corr, Def Corr, TF & Def Corr or Special Home
will take the Geo-Pilot out of Cruise Control Mode. TF or Deflection Corrections will be applied to
the current settings with which the Geo-pilot is steering in Cruise mode.
Similarly, cycling the pumps and performing a manual setting will take disable the Cruise Control.
If the tool was in Cruise Control prior to a connection, a manual shortcut will return the tool to
Cruise mode.
Page 30 of 114
With INSITE 5.3, the cruise must be run using files Z3.txt, Z3.clc and ICDL.EXE. Z3 will contain
the tolerance, max deflection, aggressiveness, and turn settings. In addition, the standalone
program ICDL.EXE must be used to convert commands into data values for downlink
transmission. Refer to Techfax 000375 for details on how to operate the cruise control using
INSITE 5.3.
6.3 Manual Control

When downhole the Geo-Pilot's deflection can be turned on and off using the flow chart below.
(Figure 12 Geo-Pilot Downhole Manual Control Flow Chart) It essentially works by using a
combination of the pumps and RPM. Manual control is a fall back to be used in cases where the
downlink has failed or is having some other difficulty. In some situations, such as backreaming, it
is easier and more efficient to control the deflection solely by manual control.
Note:
When using these algorithms it is important to remember that the “pumps on” refers to the time at
which the MWD registers pumps on. For SDC negative pulsers this will be after 3 consecutive
pressure samples greater than Delta P. For P4M systems this will be related to the impellor rpm.
The emulation of the pressure transducer goes to pressure up 8 seconds after the impellor speed
is over circa 800rpm. The HCIM will still require 3 pressure samples (potentially an additional 12
seconds), before it registers pumps on status.
Similarly the RPM is the differential rpm between the Geo-Pilot’s housing and the shaft. If there is
no differential rpm, due to the housing slipping, it will not be possible to adjust the Geo-Pilot’s
settings manually. Similarly to the pumps algorithms, the Geo-Pilot uses a rolling 15 second
average of the RPM
6.3.1 Deflection Off

To turn off the deflection follow these directions:
• Start with the pumps off and rotation off for at least 60 seconds.
• Begin rotating for at least 20 seconds.
• Turn on pumps. % Deflection will now go to zero.
The manual deflection off command is very useful for situations such as backreaming out of hole,
where you wish to maintain zero deflection, but it is impractical to continuously downlink.
6.3.2 Alignment Toolface and turn Deflection On
To turn on the deflection to a specific toolface follow these directions:
• Have pumps off and rotation off for at least 60 seconds.
• Turn on pumps
• Wait to see DM toolfaces being transmitted
• Orientate the DM from surface by turning the drillpipe until the desired toolface from the DM is
being pulsed up.
• Wait 60 seconds at that toolface value (and ensure that the “resume previous toolface
timeout” period has expired)
• Begin rotating well above your threshold RPM value setting. Preferably at your drilling RPM if
possible. The tool will take the toolface that the DM had 30 seconds previously as its new
target.
• The Geo-Pilot has now recorded that toolface value and will turn on the deflection to this
toolface. Watch for the Actual % Deflection, Deflection Setting, Actual Toolface and Toolface
Setting values to come up to confirm the Geo-Pilot has accepted the command.
Page 31 of 114
6.3.3 Deflection On To Previous Setting
In order make rig operations more efficient, a pumps and rpm command is available to return to
the last toolface/deflection or cruise control setting the tool was using. This enables you to return
to previous settings even after a period of non-deflected activity.
• Start with the pumps off and the rotation off for 60 seconds.
• Turn on the pumps.
• Wait minimum 20 seconds for the HCIM to recognize that the pumps are on. You can wait up
to the time specified in the “Resume Previous Toolface Timeout” parameter in the download.
• Turn on the RPM above the RPM On Threshold, preferably at your standard drilling RPM.
• Return to drilling and watch the session log/displays to verify the Geo-Pilot has accepted the
command and has turned on the deflection and set the toolface to the last setting.
Page 32 of 114
6.4 Tool Control Flow-Chart
No
Deflection Rotation Deflection
Pumps Off
ON For 60s OFF
Pumps On Start Rotating

Above RPM
ON Threshold
Wait 20 Seconds Wait more than

resume previous Wait 20s
Max wait TF timeout (can
depends on adjust toolface
downloaded during this time
value but no rotating)
Turn Pumps
On
Get
Start Toolfaces
Rotating From DM
above RPM
ON GP Goes To
Work String to Get Zero
Desired Toolface % Deflection
Last
Toolface
Target Wait 60
Setting Is Seconds
Now Active
Start Rotating
above RPM
ON Threshold
GP sets
Target Toolface
to a 30-sec old
toolface from DM
Figure 12 Geo-Pilot Downhole Manual Control Flow Chart
Page 33 of 114
6.5 Finding the “HOME” Position
In the Geo-Pilot tool there are a set of position sensors that monitor the position of the eccentric
rings which ultimately control which way the shaft is bent inside the tool. When a tool is sent out
from an R&M facility it should already be in the home position.
After downloading to run in hole, the tool checks to see if the home sensors are engaged. If they
are not engaged, then the tool will need to find home in order to know the orientation of the
eccentric rings. Locating the home sensors will take priority over all other tool activities.
In order to do this the tool will engage the clutches and rotate the eccentrics until the home
position is achieved on each eccentric ring. The home position always has a deflection of 0%.
Until the home postion is found, the Geo-Pilot will not be able to accept any toolface or deflection
commands. It may take up to 180 rotations of the drillpipe before the Geo-Pilot has found home
position due to the gearing ratios inside the tool that control the movement of the eccentric rings.
In general, a tool will find the home position without this even being noticed at surface; either
while breaking in the seals, or just when setting up to start drilling. The only time that the tool
may otherwise need to find home is if it has had a downhole reset, and needs to re-establish the
locations of the eccentric rings.
As a general procedure and good practice, wherever possible, the tool should be downlinked a
home command before pulling out of hole, to ensure it is ready to re-run.
6.6 Vertical Kick-Off

The Geo-Pilot is a tool that uses gravity toolface to steer. At low inclinations the toolface will
become more erratic, despite being located in the control housing which provides a much more
stable platform for measurement. It is recommended that where possible, deliberate well plans
with angles of less than 5 degrees are avoided. Particular care should be taken in planning drop-
turn-build sections to ensure that there is some inclination retained at all times during the turn. If
desired, at inclinations below 1º, the Geo-Pilot can be manipulated to build angle.
When the inclination is below 1 degree, the deflected toolface will remain constant relative to the
ABI highside, rather than gravity highside. Since the tool will have a larger tendency to roll with
motion in and out of the hole, it may be necessary to time drill to control the roll of the housing. A
command of 100% deflection, 0 deg TF must be sent to the tool while in kick off mode, such that
when it comes over 1 degree it will continue to build when it starts gravity steering. Azimuth can
then be spiraled round at low inclination. The mode has 0.3 degrees hysteresis. Once the
inclination is above 1.0 degrees it has to drop below 0.7 degrees to engage the "Kick Off" mode
again. It then has to increase to above 1.0 degrees to disengage the "Kick Off" mode.
If the tool has a zero deflection setting, then it will not auto-deflect while under 1 degrees.
If the tool is in cruise control mode, and drops below 1 degree, the cruise control algorithm will not
disengage.
6.7 Additional Notes

6.7.1 Software locking up – Reading the tool standalone
There is a possibility that the Geo-Pilot may lock-up if communications occur on the sub-bus as it
is trying to power down. This is possible when communications between INSITE and the HCIM
last for more than 30minutes, without any comms to the Geo-Pilot. This would typically be during
a tool read situation. Although the chances of this have been mitigated through software
modifications, there are methods to eliminate the danger.
If a toolstring has been laid down to be read, then it is recommended to read the Geo-Pilot
separate to the RLL string. This will eliminate any chance of a software lock-up.
There should be a cross-over from SWRO probe to female kemlon in the field kit. Connect the
CIM I/O channel up to the Geo-Pilot, and poll the toolstring for sensors. Select “Other
Configuration” or No Busmaster and then read as per normal. It should not be necessary to use
a booster box.
Page 34 of 114
With a string that will take a long time to read (i.e. 2 hrs plus), consider the feasibility of removing
the Geo-Pilot from the string, and reading the MWD and Geo-pilot separately. Every 30 minutes
while reading the RLL tool, there will be a risk of a Geo-Pilot lock up.
In tools with external batteries, such tools can be reset by pulling and reseating the battery.
Page 35 of 114
Chapter 7-Recommended Running Procedures
7 Recommended Running Procedures

7.1 Picking up tool
7.1.1 Brace
Keep the brace on the drive-sub neck when handling the Geo-Pilot. The clamp should only be
removed immediately prior to running the Geo-Pilot below rotary, and put back on when coming
above rotary, if the tool is to be racked or laid out.
 Never use the brace to pick up the Geo-Pilot.
7.1.2 Flex collar

The flex collar can be installed on top of the Geo-Pilot on the drill floor, or installed before
shipping to the rig. The resulting length of the assembly is approximately 33 feet (10.65 meters).
If the flex is to be made up at the rigsite, normal CIM hanger compression applies to the kemlon
connections.
• For a Repeater with NO TAPERLOCK FITTED you should attain a

final Teflon COMPRESSION of between 0.031” and 0.063”.
• If the Repeater is FITTED WITH A TAPERLOCK there should be
ZERO Teflon compression. The GAP should be between 0.00” to
0.030”.
Compression will have the effect of unloading the taperlock ring, negating it’s
benefit.
7.2 Tripping In
7.2.1 Setting deflection
The deflection should always be set at zero per cent while tripping in and out of the hole.
After downloading the tool, the Geo-Pilot will want to find home first. Allow the Geo-Pilot to do this
before sending the tool a command. The Geo-Pilot will show zero deflection when it is at the
home position.
There is a danger of accidental sidetracking if the tool is deflected when reaming/washing down
to bottom.
7.2.2 Seal lubrication
To lubricate the seals, rotate the drill string at five RPM for the first three minutes. Then gradually
increase the string RPM to the maximum speed over the next five minutes.
Page 36 of 114
7.3 Displacing Fluids:
 Sudden pressure spikes and differentials could damage sensors and seals in
the Geo-Pilot, resulting in a failure.
The Geo-Pilot tool should not be downhole while displacing from fluids such as brine to fully
weighted mud systems unless there is a controlled discharge route.
If displacement operations are undertaken then care must be taken to ensure that system
volumes and pressures are controlled throughout the procedure. Suggested precautions should
include the venting off of displaced fluids through a restriction to prevent “U-tubing”. This can be
achieved in most cases by closing the Annular Preventer and discharging through a choke, thus
providing an annular backpressure of 200 – 500 psi.
Consideration should also be given to introducing a semi-weighted spacer in order to reduce the
effective pressure/shock differential.
During normal mud displacement programs, pump rates should be reduced to a minimum-to
minimise any sudden pressure spikes or shock waves damaging the seals as the heavier mud
hits the bit also causing unequal pressure balances around the rotary seals or pressure
compensator piston area. Once certain that the new weighted mud system is circulating around
the Geo-Pilot tool downhole, gradually increase the pump rates again to full rate.
7.4 Inside the Casing:

7.4.1 Before starting to drill
Fill the pipe and establish the circulating parameters, wash down with good flow one stand before
tagging the cement or rubber plug. Ensure that the Geo-Pilot is set in the “Zero” deflection
position. If the seals have not been broken in, do this before starting to drill. (ref 7.2.2 above).
7.4.2 Drilling cement, float and shoe track
Drill cement, float and shoe track with up to 4 tons weight on bit, 30-60 rpm and maximum flow.
Once completely satisfied that the plugs have been drilled, the weight-on-bit may be increased to
facilitate timely drill-out.
After drilling out the shoetrack, pull back up, stop rotating and push the bit back and forth across
the plug several times to chew it up and potentially prevent it from sealing around the Geo-Pilot’s
housing.
Continue to drill to 6 meters below the shoe. Pull the Geo-Pilot back into the shoe to ensure that
the tool is free from debris. Check that float etc. has not doughnutted around the reference
stabilizer, lower tool body, or around the bit (creating potential “pack-off” situations). When certain
that the Geo-Pilot is free of any junk or debris, proceed to the next step with caution.
If at any time during the operation there is a pack off, or the control housing becomes static (use
smart toolface with no deflection to check), then pull off bottom to ensure that the tool is free from
debris.
If a “reaming shoe” is used, then drill out with caution. Problems have been experienced by the
excessive amount of aluminum in such shoes and trepanning whereby the nose is cored out of
the reaming shoe, consequently leaving a section intact and in the way. – I.e. bit spins on top of
it.
7.5 Rat-hole:
Clean out the rat-hole using recommended good drilling practices.
Page 37 of 114
Be especially vigilant, when there are stabilizers in the BHA, with the transition from rat-hole to
newly drilled hole.
If an extended rat hole or any overgauged section (hole section larger than the bit OD) is to be
drilled/reamed etc., Firstly suggest running a dedicated drill out assembly prior to running the
Geo-Pilot in hole.
Failing this, ensure that the concerns with the rat hole (overgauged hole) are clearly
communicated to all. Proceed with extreme caution, 0% deflection, minimum RPM and gently
guide through the rat hole section and continue drilling new formation until the upper LWD
stabilizer/Roller Reamer is in contact with the new hole of the same OD as the bit.
7.6 Tripping and Reaming in & out of open hole

Keep the Geo-Pilot’s deflection at zero.
If the Geo-Pilot is to be run through a section of poor quality hole drilled by a short gauge bit, the
customer should be made aware that a certain amount of reaming may be required to straighten
up the hole. If possible a dedicated clean up run should be made in such circumstances with a
long gauge bit to condition the hole.
7.6.1 Tight hole conditions

If encountering tight hole conditions do not use excessive force to try and work through it. If it is
not possible to work through it, then pull back to above the problem area and work the pipe in
order to remove packed cuttings from the BHA. Cuttings could cause pack-off when the pumps
are switched on.
Start pumps carefully and bring up to 50 per cent of drilling flow. Start the Geo-Pilot’s rotation.
Establish pressure. Keep a person on the pump throttle. Turn the pumps off quickly should the
hole pack off, to avoid stressing the rotary seals. Ream through a tight hole with 100 rpm and
very little weight-on-bit. Pick up and back ream every three to four meters.
Before tripping out of a hole, a “Home” command should be sent with the Geo-Span™ Downlink
unit.
7.7 Reaming in hole (expecting tight hole)
7.7.1 Tight hole
If a tight hole is expected, e.g. unstable clay stringers, then the BHA should be reamed/washed
pre-emptively from the before the expected problem zone and past it wherever possible. Keep the
deflection at zero. This is easiest done using manual control.
Wash in the hole when there is no resistance; ream when there is resistance. Be extra careful
when entering the interval where the expected tight hole is. Ream through the tight hole.
Bring up the pumps to 50 per cent of drilling flow while inside casing. Establish steady pressure.
Record the pressure and the up / down weights. Keep one man on the pump throttle to turn the
pumps off quickly should the hole pack off. A pack-off pressure of more than 500 psi will probably
blow the Geo-Pilot seals.
7.8 Open hole drilling:
7.8.1 Good drilling procedures
Initiate and maintain good recommended drilling procedures.
• Ensure proper communications at all times: keep everyone informed.
• If hard stringers are encountered, and the inclination is deflected off track, initiate “time-
drilling” practices and procedures.
• Ensure that you pull off bottom gently, while rotating whenever practical.
Page 38 of 114
7.8.2 Backreaming, or an interruption to drilling in an open hole-hole
Ensure that the Geo-Pilot is set to the “Zero” deflection position. This will prevent the tool trying to
orient while circulating, using battery unnecessarily, and adding wear onto the internal
mechanical componentry.
In addition for Geo-Pilots with Gamma Sensors, consider turning off the Gamma Sensor by
downlinking GP Azi GR Power Control to “OFF” to conserve battery.
Rotate and reciprocate the drill-string as normal. Regard the BHA as a normal rotary assembly.
7.9 Open hole sidetracks
Open hole sidetracks are achievable and have been performed in horizontal hole. Determine the
sidetrack point based first on drillability and then on hole geometry. If it is in a section previously
drilled using the Geo-Pilot, use a plot of the ABI against depth to find the best location.
Time the drill at a setting between 150 left and 150 right of highside. Monitor the ABI and
determine the ROP for the time drilling. If digging a ledge at lowside, then remember that the
housing will roll more at higher running rates. As the ledge develops, more weight can gradually
be applied. If the bit “jumps” into the old hole, then this will be seen quickly on the ABI, and the
bit should be pulled back up 1 ft, and time drilled down onto the ledge again.
Remember that a Geo-Pilot/Long gauge bit is not an aggressively sidecutting combination, and
the sidetrack will take time. Previous open hole sidetracks have taken from two and a half to
eight hours.
7.10 General Information:
7.10.1 Superior hole quality
Previous experience with Geo-Pilot has demonstrated that reaming each stand can be limited to
a minimum. There is substantial evidence to prove superior hole quality when using long gauge
bits. It is however recommended to ream through any stringers after drilling them, as per normal
good drilling practice to ensure that any ledges or unconformities are reamed out.
Ensure that the directional driller on site is consulted about any abnormal drilling performance, or
other non-standard operations that may impact the tool.
It is also recommended that when coming off bottom, the string be pulled in a slow and controlled
manner through fresh hole. This is to ensure that if the hole has come in behind the bit, that this
will be reamed in a controlled manner, rather than pulling the bit hard into this tight formation.
7.10.2 Entering sections with FullDrift systems

Entering wells with sections that have been drilled with non Fullgauge systems, has proved to be
difficult. Due to inferior hole quality with features such as micro doglegs, hole spiralling etc., it
may be necessary to ream through these entire sections to get to bottom. Before going into such
wells, consideration should be given to a dedicated clean out run, with a long gauge bit/full gauge
stabilizer assembly. If this is not possible, the customer should be made aware that extended
amounts of reaming may be required. In addition, the Geo-Pilot assembly is not an ideal reaming
assembly, and such reaming will be more prone to pack off situations.
Page 39 of 114
Chapter 8 Troubleshooting and Post Run Analysis
8 Troubleshooting & Post Run Analysis
Download issues during cold weather

ABG might fail during confidence test or Download on the Surface if temperature is lower than 5
°C. However the same ABG will pass confidence test and download if temperature rises higher
than 5-10 °C.
Possible symptoms when this issue occurs:
- Incorrect housing inclination & G Totals readings in the confidence test

- download Pre-Trip it gives “Data Not Read” and “No Response” errors
-
An interim solution to this if this issue is encountered It is recommended that the tools be heated
prior to use.
The decision to rerun a tool is based primarily upon it’s downhole performance on the previous
run, the physical condition of the tool at surface, and diagnostics obtained from the memory.
It is important not to speculate about cause of failure on location, as full root cause analysis can
only be completed using a rotation beam to aid in full mechanical performance analysis.
8.1 Downhole Signs of a Bad Tool
There are a limited number of signs that could indicate a bad tool downhole. These include, but
are not limited to:
• Oil Warnings.
The tool must be pulled to prevent significant internal damage. Refer to section 5.4
• Failure to track toolface/deflection
There may be cases where partially effective steering is possible, with poor toolface and/or
deflection control. Instances such as where there is excessive rotation of the control housing
would lead to impaired steering ability. An assessment of the housing roll rate is possible by
sending zero deflection, and observing the rate at which the housing toolface rolls.
Instances where one clutch is failing to perform will typically be seen as a “roller-coaster”
pattern in actual deflection, together with poor toolface control. This is caused as the other
clutch continues to adjust for housing roll. It is possible to continue with impaired steering
control, and reduced dogleg performance. It may be possible to enhance the steering
Page 40 of 114
performance of such a tool by pulling periodically a small distance off bottom to roll the
control housing.
• Repetitive Clutch Slip statuses
• Clutch overrun corrections being applied (Indicated by the brake slip light – refer to 4.5.9.5)
8.2 Realtime Error Codes
Geo-Pilot Gamma Error Codes

251. reserved for future use (should never show up with 3.10 software)
252. Gamma Detectors Powered Down (No counts)
253. Gamma Detectors Not Present (Inclination Only Insert in tool)
254. reserved for future use (should never show up with 3.10 software)
255. Used by HCIM for No Response code
8.3 Physical Surface Checks OOH

• Oil consumption during run.
The amount of oil consumed during a run will vary considerably, dependent upon hydrostatic
pressure, temperature and duration of run. If a suspiciously large quantity of oil has been
consumed, then the tool’s seals should ideally be pressure tested before re-running. The tool
should be refilled to the 3” mark on the dipstick before rerunning. Refer to section 10.1 Oil
refill procedure for full procedure.
• Housing Rotation
If a problem is suspected with excessive housing roll, or housing locked onto the shaft, then
while the tool is hanging in the rotary, a chain tong can be put on the housing, and this
checked to see if it is decoupled from the shaft. It should require approximately 50 ftlbs to
rotate the housing on the shaft. Rotation of the shaft should be smooth.
• Physical Damage to outside of the tool
The roller assembly of the reference stabilizer should be examined for wear. Particular areas
to check are the slots in the sub for the bushings, and the rollers themselves. Chipped or
damaged rollers can be replaced in the field. Normally due to rig time constraints it would be
advisable to lay the tool out, and perform this on deck. Refer to section 10.2 for procedure.
• Permisible Wear on RLL Stabilizers
The stabilizer on the bottom of the RLL, may be required to backream with, ahead of the
reference stabilizer on the Geo-Pilot. As such the absolute minimum OD of this stabilizer
should be the same OD as the reference stabilizer.
Page 41 of 114
8.4 Geo-Pilot Parameter Report
INSITE stores the Geo-Pilot parameter report as an ASCII file in the INSITE>Data>Tool Read
Reports folder. Open this file with any text editor (Wordpad, MicroSoft Word, Notepad, etc.) to
view the contents or to print a copy.
8.4.1 Sample Geo-Pilot Parameter Report
GP SENSOR PARAMETER REPORT
RUN NUMBER - 100

CUSTOMER: Example Customer
RIG NAME: Example Rig
WELL NAME: Example Well
FIELD: Example Field
JOB NUMBER: XX-XX-12345
GP SENSOR ID NUMBER .............. 1

GP SOFTWARE VERSION .............. 310
GP PIC VERSION .................. 0xa1d
SENSOR LOAD TIME (GP) .............. 29-Oct-03 21:51:09
TIME OF FIRST SAMPLE (GP).......... 29-Oct-03 23:20:32
SENSOR READ TIME (GP) .............. 03-Nov-03 11:56:37
SENSOR READ TIME (SURFACE).......... 03-Nov-03 11:57:04
MEMORY USED (KILOBYTES)............. 941
MEMORY READ (KILOBYTES) ............ 941.00
MEMORY USED (%).................... 46.68
TOOL ON HOURS...................... 110.08
MEMORY FILLED (DATE & TIME) ............. N/A
TOTAL RESETS........................ 1
ILLEGAL OPCODE RESETS............... 0
MAX ANN TEMPERATURE................. 0
NUM PRESS SAMPLES................... 0
MAX ANN PRESS....................... 0
PRESS SAMPLE PERIOD(Sec)............ 0
SUBBUS LV ERROR..................... 0
NUM UNIV COMMANDS................... 36578
FLASH ERROR.................. NO
TIME SYNCS COMPLETED(BUS MASTER) 1361

TIME SYNCS ATTEMPTED(BUS MASTER) 1361
TIME SYNCS ERRORS 0
-------------------------------------------------------------------------
DOWNLOAD PARAMETERS
-------------------------------------------------------------------------
TIME DELAY ....................... 29-Oct-03 23:20:32

TEMPERATURE SAMPLE RATE .......... 300 seconds
TOOLFACE SAMPLE RATE ............. 15 seconds
BRAKE SLIP RATE SAMPLE RATE ...... 60 seconds
HOUSING SLIP RATE SAMPLE RATE .... 60 seconds
RPM ON THRESHHOLD ................ 10 rpm
RESUME PREVIOUS TOOLFACE TIMEOUT . 60 seconds
PERCENT DEFLECTION STEERING MODE . 100 percent
MAX ABI GTOTAL ERROR ............. 50 milli g
DIAGNOSTIC SAMPLE RATE ........... 30 seconds
VSS ENABLED ...................... YES
BIT TOOLFACE SAMPLE RATE ......... 15 seconds
DOWNLINK ENABLED ................. YES
RPM AVERAGE TIME ................. 60 seconds
Page 42 of 114
-------------------------------------------------------------------------
TEMPERATURE BINS (Min)
-------------------------------------------------------------------------
0-5 6-10 11-15 16-20 21-25

deg C deg C deg C deg C deg C
0 10 95 50 35
26-30 31-35 36-40 41-45 46-50
90 80 70 400 210
51-55 56-60 61-65 66-70 71-75
510 295 800 770 715
76-80 81-85 86-90 91-95 96-100
680 830 590 370 0
101-105 106-110 111-115 116-120 121-125
0 0 0 0 0
126-130 131-135 136-140 141-145 146-150
0 0 0 0 0
151-155 156-160 161-165 166-170 171-175
0 0 0 0 0
176-180 181-185 186-190 191-195 196-200
0 0 0 0 0
-------------------------------------------------------------------------
HOLE CONTROL
-------------------------------------------------------------------------
Average Bit TF Error 0.00 degrees
Average Deflection Error 0.00
-------------------------------------------------------------------------
TOOL DIAGNOSTICS
-------------------------------------------------------------------------
Low Oil First Occurence 31-Oct-03 17:54:33
No Oil First Occurence 31-Oct-03 18:40:01
Oil Level Sensor Error Yes
Upper Brake Slip Error No
Lower Brake Slip Error No
Upper Missed Targets 0
Lower Missed Targets 2
Upper Found Home Yes
Lower Found Home Yes
Rotating Hours 73.7 hours
Downhole Hours 110.0 hours
-------------------------------------------------------------------------
CURRENT CONSUMPTION
-------------------------------------------------------------------------
Amp Hours Used 9.91 Amp-Hrs
Maximum Current 1.34 Amps
Average Current 0.09 Amps
-------------------------------------------------------------------------
RPM
-------------------------------------------------------------------------
Average RPM 99.1 RPM
Maximum RPM 6451.7 RPM
-------------------------------------------------------------------------
ABI
-------------------------------------------------------------------------
Average Roll Rate 11.1 revs/hour
Maximum Roll Rate 655.3 revs/hour
Percent Bad Surveys 0.1 percent
Average Gtotal Error 2 milliGs
Communication Errors 20
Page 43 of 114
-------------------------------------------------------------------------
CLEVER
-------------------------------------------------------------------------
Communication Errors 0
Turned Upper Cam OFF for Unknown Reason 0
Turned Upper Cam ON for Unknown Reason 0
Turned Lower Cam OFF for Unknown Reason 0
Turned Lower Cam ON for Unknown Reason 0
-------------------------------------------------------------------------
DOWNLINK
-------------------------------------------------------------------------
Downlink Commands Received 67
Invalid Downlink Commands 0
-------------------------------------------------------------------------
MANUAL SETTINGS
-------------------------------------------------------------------------
Settings Received 61
-------------------------------------------------------------------------
UPPER CAM
-------------------------------------------------------------------------
Percent Adjusting 15.9 percent
Average Overshoot 2.8 degrees
Average Error 654.16 degrees
Average Clutch Slip 0 ticks
Average Home Error 6547.6 ticks
Total Brake Slip 0.0 degrees
Timeout Finding Target 0
-------------------------------------------------------------------------
LOWER CAM
-------------------------------------------------------------------------
Percent Adjusting 18.7 percent
Average Overshoot 3.2 degrees
Average Error 654.60 degrees
Average Clutch Slip 0 ticks
Average Home Error 6547.8 ticks
Total Brake Slip 0.0 degrees
Timeout Finding Target 0
-------------------------------------------------------------------------
DOWNLINK MESSAGE BUFFER
-------------------------------------------------------------------------
Time Type Value1 Value2 Value3
01-Nov-03 21:36:50 3 10 10 0
02-Nov-03 02:37:08 1 20 226 0
02-Nov-03 03:08:23 2 246 251 0
01-Nov-03 05:52:19 1 10 50 7
01-Nov-03 06:43:26 2 236 206 0
Page 44 of 114
-------------------------------------------------------------------------
MANUAL MESSAGE BUFFER
-------------------------------------------------------------------------
Time Type Setting
03-Nov-03 02:36:49 1 52
03-Nov-03 02:38:45 1 0
03-Nov-03 04:10:41 1 106
03-Nov-03 04:59:05 1 15
RESET DATE AND TIME
04-Dec-93 03:12:00
TIME SYNC DIAGNOSTIC
SENSOR TIME SURFACE TIME DIFFERENCE(sec)

04-Dec-93 03:12:06 29-Oct-03 21:51:09 -280953543
02-Nov-03 13:56:47 02-Nov-03 13:57:05 -18
03-Nov-03 06:27:42 03-Nov-03 06:27:45 -3
03-Nov-03 08:34:58 03-Nov-03 08:35:00 -2
---------------------------------------------------------------------------------
GP TOOL STATUS
---------------------------------------------------------------------------------
TIME DEPTH TDACT PISTON BIT POS HOUSING CLUTCH BRAKE ON G TOT
POSITION SLIP SLIP SLIP SLIP TARGET ERROR
m
02-Nov-03
13:23:51 3550 Trip Out OK Slip Slip OK OK OK OK
13:24:46 3551 Trip Out OK Slip Slip OK OK OK OK
Page 45 of 114
8.4.2 Definitions for the Geo-Pilot Parameter Report Terms
GP SENSOR ID NUMBER
The ID Number in the Geo-Pilot’s EEPROM
GP SOFTWARE VERSION
The version of the downhole software used by the Geo-Pilot
GP PIC VERSION
The PIC version of the Geo-Pilot Tool
SENSOR LOAD TIME (GP)
The date and time at which the tool was initialized as reported by the Geo-Pilot
TIME OF FIRST SAMPLE (GP)
The time at which the Geo-Pilot stored the first ABI sample after initialization
SENSOR READ TIME (GP)
The tool time at which the Geo-Pilot was read.
SENSOR READ TIME (SURFACE)
The time at which the sensor was read on the INSITE surface computer. The difference in
time between the surface read time and sensor read time should equal the time taken to
read the HCIM
MEMORY USED (KILOBYTES)
The number of kilobytes of memory used during the run
MEMORY READ (KILOBYTES)
The number of kilobytes of memory read by INSITE. This should match the MEMORY
USED
MEMORY USED (%)
Percentage of the 2MB memory used
TOOL ON HOURS
Number of hours from tool initialization to tool read
MEMORY FILLED (DATE & TIME)
Date and Time at which the tool’s memory filled. The tool will continue to operate after this
time, but diagnostic and Gamma data will not be recorded.
TOTAL RESETS
Number of times the tool has reset during the run. The tool will always have at least 1
reset which occurs at the time of download. Other resets can be present but you should
check that these occur at the time of tool reads or tests from offshore otherwise there may
be a problem with the tool. There is a table of all the reset times at the bottom of the
parameter report.
ILLEGAL OPCODE RESETS
These are where the software has stopped running, and the tool tries to execute invalid
commands. There should never be any illegal opcode resets, if any are listed then there is
a problem with the tool and it should be investigated.
MAX ANN TEMPERATURE
NUM PRESS SAMPLES
MAX ANN PRESS
PRESS SAMPLE PERIOD(Sec)
These items are not used.
Page 46 of 114
SUBBUS LV ERROR
Number of Low voltage errors on the Sub Bus
NUM UNIV COMMANDS
Number of Universal Commands received by the Geo-Pilot
FLASH ERROR
Number of errors in the Flash memory
TIME SYNCS COMPLETED(BUS MASTER)
The number of Time synchronizations completed with the HCIM
TIME SYNCS ATTEMPTED(BUS MASTER)
The number of Time synchronizations attempted. This should match the number
completed
TIME SYNCS ERRORS
The number of Time synchronization errors
-------------------------------------------------------------------------
DOWNLOAD PARAMETERS
-------------------------------------------------------------------------
TIME DELAY
The time at which the downloaded time delay expired
TEMPERATURE SAMPLE RATE
The rate at which the Geo-Pilot is storing temperature samples
TOOLFACE SAMPLE RATE
The rate at which the Geo-Pilot is sampling toolface
BRAKE SLIP RATE SAMPLE RATE
The rate at which the Geo-Pilot is storing brake slip samples
HOUSING SLIP RATE SAMPLE RATE
The rate at which the Geo-Pilot is storing housing slip rates
RPM ON THRESHHOLD
The downloaded value of the RPM threshold
RESUME PREVIOUS TOOLFACE TIMEOUT
The downloaded value of resume previous toolface for the manual steering settings
PERCENT DEFLECTION STEERING MODE
The downloaded deflection setting to be used for manual steering
MAX ABI GTOTAL ERROR
The downloaded Gtotal error to be allowed for the ABI
DIAGNOSTIC SAMPLE RATE
The rate at which the Geo-Pilot is storing diagnositic samples
VSS ENABLED
Status of the Vibration severity sensor
BIT TOOLFACE SAMPLE RATE
The rate at which the Geo-Pilot is storing toolface and deflection positions
DOWNLINK ENABLED
The downloaded status of whether to enable the downlinkable commands
RPM AVERAGE TIME
The rate at which the Geo-Pilot stores the downhole RPM values
Page 47 of 114
TEMPERATURE BINS (Min)

Binned distribution of the temperatures at which the tool operated, showing minutes in
each range.
-------------------------------------------------------------------------
HOLE CONTROL
-------------------------------------------------------------------------
Average Bit TF Error
Average Deflection Error
This section of the parameter report is not in use, and these values are always listed as zero.
-------------------------------------------------------------------------
TOOL DIAGNOSTICS
-------------------------------------------------------------------------
LOW OIL FIRST OCCURRENCE
The time at which the tool first registered a low oil/position 1 status
NO OIL FIRST OCCURRENCE
The time at which the tool first registered a no oil/position 2 status
OIL LEVEL SENSOR ERROR
If the tool has seen a Low/No or N/A Oil status
UPPER BRAKE SLIP ERROR
This does not work at this time, and will always be “NO”
LOWER BRAKE SLIP ERROR
This does not work at this time, and will always be “NO”
UPPER MISSED TARGETS
This is an incremental counter registering every time the cam misses its target angle.
LOWER MISSED TARGETS
This is an incremental counter registering every time the cam misses its target angle.
UPPER FOUND HOME
This is always YES, even if the home sensor fails
LOWER FOUND HOME
This is always YES, even if the home sensor fails
ROTATING HOURS
Number of hours the tool has been operating with RPM greater than RPM on threshold
DOWNHOLE HOURS
Number of hours the tool has been downhole. This will be the same as the TOOL ON
HOURS
-------------------------------------------------------------------------
CURRENT CONSUMPTION
-------------------------------------------------------------------------
AMP HOURS USED
The number of Amp Hours of battery that were consumed during the run
Page 48 of 114
MAXIMUM CURRENT
The peak current draw during the run. This will typically be from a period where both
clutches have been powered simultaneously
AVERAGE CURRENT
The average current draw during the run
-------------------------------------------------------------------------
RPM
-------------------------------------------------------------------------
AVERAGE RPM
The average RPM seen while the tool is registering RPM greater than the RPM on
threshold
MAXIMUM RPM
The maximum RPM seen by the tool. This will typically be maxed out.
AVERAGE ROLL RATE
The average roll rate of the tool calculated from the ABI highside.
MAXIMUM ROLL RATE
The maximum roll rate of the tool calculated from ABI highside. This will typically be
maxed out from a point where the housing has spun.
PERCENT BAD SURVEYS
Percentage of ABI surveys outside the Gtotal error limits
AVERAGE GTOTAL ERROR
Average G total Error of all ABI Surveys
COMMUNICATION ERRORS
The number of communication errors between the Geo-Pilot electronics and the ABI.
Some errors can be expected here, but an abnormally high number indicates a problem in
the tool.
-------------------------------------------------------------------------
CLEVER
-------------------------------------------------------------------------
COMMUNICATION ERRORS
The number of communication errors with the Clever Board
TURNED UPPER CAM OFF FOR UNKNOWN REASON
TURNED UPPER CAM ON FOR UNKNOWN REASON
TURNED LOWER CAM OFF FOR UNKNOWN REASON
TURNED LOWER CAM ON FOR UNKNOWN REASON
The number of times the respective upper or lower cams turned on or off unexpectedly
-------------------------------------------------------------------------
DOWNLINK
-------------------------------------------------------------------------
DOWNLINK COMMANDS RECEIVED
The total number of downlink commands received by the Geo-Pilot
INVALID DOWNLINK COMMANDS
The number of downlink commands sent to the Geo-Pilot that were invalid
Page 49 of 114
-------------------------------------------------------------------------
MANUAL SETTINGS
-------------------------------------------------------------------------
SETTINGS RECEIVED
The number of manual command settings received by the Geo-Pilot
-------------------------------------------------------------------------
UPPER CAM & LOWER CAM
-------------------------------------------------------------------------
Percent Adjusting
Amount of time that the cam was active as a percentage of Tool rotating hours
Average Overshoot
Average amount of angle that the cam overshoots each time an adjustment is made.
Formula used is (turn off angle – end angle)/number of adjustments
Average Error
The average Cam error after overshoot corrections have been applied. This should be a
small number.
Average Clutch Slip
Average amount of slip per adjustment expressed in ticks. There are 64 ticks per revolution
of a clutch. Formula used is (cam counts – rpm counts during clutch engagement)/ number
of adjustments.
Average Home Error
This is the average amount of ticks that the cam is short of per revolution. The tick counter
is reset each time the cam passes the home sensor and there are 11520 ticks per
revolution of the cam
Total Brake Slip
This is the total amount of cam movement seen over the run where the clutches were not
activated. This does not include cam overshoot.
Timeout Finding Target
The number of times the cam exceeds 300 seconds during an adjustment. The cam will
stop its movement after this time and then resume again 8 seconds later if the target is still
not reached
-------------------------------------------------------------------------
DOWNLINK MESSAGE BUFFER & MANUAL MESSAGE BUFFER

These currently contain a buffer of the last commands received, but are in a compressed
format, and not readily readable.
RESET DATE AND TIME

This will contain a list of the date and time of any downhole resets the tool needed to
perform. There will typically be one dated 04-Dec-93 03:12:00 which is generated in
association with the tool initialization
Page 50 of 114
TIME SYNC DIAGNOSTIC
This will contain a list of the date and time of any time there has been a large shift in the
downhole clock’s time sync with the HCIM. There will typically be one dated to 04-Dec-93,
generated in association with the tool initialization
GP TOOL STATUS
This will contain an entry every time that there has been a change on one of the status
flags during the run.
8.5 Other Diagnostic Information in Memory

• Double Hits
If after 4 seconds the output rpm of the Clutch is less than half of the input rpm, then normally
the clutch would stop trying to engage. On the 3.10 software, the clutch will be re-engaged a
second time after 4 seconds (i.e. Double hit.) If after the second hit, the output is still less
than half the input, then the clutch will be de-energized, and the clutch slip error flag on the
RS status list enabled.
“Double Hit”
Figure 13 Double Hits on Clutch
There is currently no method of knowing this “Double Hit” is happening while the run is in
progress. The Clutch Adjustment records processed out of INSITE shows a blank in places
where the clutch has “double hit”.
If there is a high proportion of “Double Hits” on the clutch during a run, then laying out the tool
post run should be considered. A tool showing these double hits would on previous versions of
software would most likely have failed for clutch slip. Contact GP Coordinator or DTDG group for
advice.
As there is no possibility to know if this is happening while the tool is downhole, the GP Image
should be processed and the GP Upper Adjust and GP Lower Adjust records examined to assess
if the tool is re-runable.
Page 51 of 114
8.6 Trouble Shooting Guide
AdjustTime Exceded
ABI No Response
Toolface Traking
Piston Pos N/A
GP ABI Gtotal
Piston Pos 1
Piston Pos 2
TF Tracking
Gtotal Error
GP ABI Inc
Clutch Slip
Brake Slip
Deflection
GP RPM
Hsg Slip
Possible Cause of Problem, and Corrective action
Clutches are not disengaging properly

Tool starting to compensate with Overrun correction algorithm
Not as
 tight TF
control
Indicates overrun of greater than 10 degs TF will be tracked within a
window which is greater than +- 7degs
Continue drilling – monitor performance to ensure that dogleg
requirements are met, change out tool at next opportunity.
Clutches are not disengaging properly
  No
Control
Overrun correction algorithm not able to correct.
Continue if possible, change out at first opportunity
  OK OK
One or Both Clutches Slipping
Check for Double Hits, change out at next opportunity.
Possible that one clutch is slipping or not engaging properly
It may be possible to drill on with reduced dogleg capability
  Poor Undulating Tool may show better TF control while in ABI HS is in one 180º
section compared to the other
Check for Double Hits, change out at next opportunity
Housing is moving faster than the eccentrics can correct.
 Increase rpm to increase rpm output from clutches
If not successful reduce rpm to try to reduce housing rotation
Control Housing spinning.
Highly Not able Reduce RPM to decrease torque required to hold housing
 Zero Erratic
or Max
Max to
Control
Not able to
Control
If soft formation drill on to hard formation if possible and then catch
up on trajectory
If wash-outs are suspected, reduce flow rate and drill on.
 Comms trouble with clever board in Geo-Pilot
Higher ABI surveys are out of downloaded Gtotal limits, and not used for
 May be
erratic
or lower
than
usual
Poor Poor
toolface control.
If running DDS check for vibrations, and reduce as per DDS SOP
Downloaded Gtotal should be min 50mg.
Page 52 of 114
AdjustTime Exceded
ABI No Response
Toolface Traking
Piston Pos N/A
GP ABI Gtotal
Piston Pos 1
Piston Pos 2
TF Tracking
Gtotal Error
GP ABI Inc
Clutch Slip
Brake Slip
Deflection
GP RPM
Hsg Slip
Possible Cause of Problem, and Corrective action
 Not
Tracking
Adjustment is taking too long.
Increase the rpm
 Geo-Pilot has detected Low Oil

Continue with caution
 Geo-Pilot has detected No Oil

POOH
Geo-Pilot has an unable to determine Oil Status.
 Wait for next transmission to check, then consult with Coordinator to
decide course of action.
  Stays
Constant
Stays
Constant
Stays
Constant
Stays
Constant
ABI has lost comms with GP Electronics. Check to see if no
responses are constant . Consult with Co-Ordinator
Unable
Unable to
to
Zero OK OK Change Possible problem with RPM sensor.
Change
Deflection
TF
Tool has problem with rpm sensor inducing false clutch slip errors. If
Very
  High or
erratic
OK OK OK OK
TF and Deflection are OK then proceed with caution. Increasing
rpm may help to control toolface as all clutch actions may be limited
to 8seconds duration. If not consult with Town.
The above should be used as a guide only. Speculation about mode or cause of failure should be avoided.
The root cause may be complex, and the signs/symptoms may only be indications of a different problem.
Table 9 Trouble Shooting Guide
Page 53 of 114
Example - Clutch Slip
Figure 14Tool response with only one eccentric working
In this example, one of the eccentric rings is not moving due to clutch slip. The result is a
characteristic “roller coaster” pattern in the deflection. The toolface also is not properly controlled,
with the actual toolface progressing clockwise as only one eccentric is corrected back.
Page 54 of 114
Chapter 9 Demobilization
9 Demobilization
9.1 Cleaning/preparations before shipping
9.1.1 Compensator cavity
When returning a used tool from the rig use a wash gun to clean out the cavity while the tool is
lying down on its side. Drain excess water as best as reasonably possible. Pour approximately
three to four ounces of Mobil SHC6306, or spray WD-40 oil into the sand screen ports. Put three
to four wraps of packing tape over the sand screen ports to keep chamber sealed from salt-water
etc.
9.1.2 Mud Invaded Tools

If there have been indications of a seal failure, then the tool should be charged with oil, to try to
flush out some of the mud from inside the tool. It is a matter of common sense as to how much
oil should be attempted to be flushed through. If the oil leaking from the tool starts to clean up,
then this will help repair and maintenance of the tool significantly.
9.1.3 Acidized Tools

If a tool has been exposed to acid for any reason while downhole, wash with fresh water as much
as possible to dilute and flush any residue acid. Pay particular attention to the areas around the
upper and lower seals. The tool should be clearly marked on the body with chalk/paint as
“Acidized” so that additional PPE precautions can be taken at the R & M center.
9.1.4 Threads
Place thread protectors on all exposed threads.
9.1.5 Colored tape

All backloaded tools are marked with colored tape at top and bottom as per standard FEMWD
procedure.
Tape Colour Meaning
Red Failed tool
Yellow Used tool, no problems, reusable
Green Unused tool
9.1.6 Battery log sheet

Complete the battery log for the Geo-Pilot, and place it inside a plastic bag. Place it in the top end
of the tool, ready for the R&M facility. Without a completed battery log, the Geo-Pilot batteries will
have to be replaced before it is run again.
Page 55 of 114
9.1.7 Geo-Pilot Perceived Problem & Performance Report
A Geo-Pilot Performance report(s) should be completed, and returned together with the battery
log with each tool returned to the R&M facility. In addition an electronic copy should be forwarded
to the job co-ordinator whenever possible.
9.1.8 Memory Data / Images
The Geo-Pilot image should be sent in for all runs.
For any tool failures, the PWD image should also be included as a minimum and the DDS where
available.
9.2 Transportation
The Geo-Pilot must be shipped in a manner that will prevent excessive strain being placed on the
driver sub. There should be support both under the housing and the repeater areas of the tool.
In addition, the tool should not be strapped down with straps around the upper or lower seal
protectors. It is highly recommended that the Geo-Pilot be shipped in tool baskets to prevent
damage due to unsupervised handling at any point of transfer.
9.3 Shipping documentation
The Geo-Pilot contains a lithium battery insert inside the housing. This means that when the tool
is transported it must be declared as hazardous goods. A few things must be done when shipping
the tool to meet UN regulatory requirements, adopted by most countries as a minimum.
Each tool must have a “Hazardous Goods Declaration” and the proper labelling.
9.3.1 Documentation for Geo-Pilot shipment

Two types of documents need to be filled out when shipping the Geo-Pilot.
1. The first Geo-Pilot type of document is a shipping memo or waybill.
These types of documents must have, as a minimum, a description and quantity.
For example: Quantity: Three

Description: Geo-Pilot containing lithium battery
If you are shipping by land and sea you use either a bill of lading or a shipper’s declaration for
dangerous goods.
Note: If you are shipping by air you must use a shippers declaration for dangerous goods.
A bill of lading must contain the following information:
1. Type of Container: Collar
2. Proper Shipping Name: Lithium Batteries Contained in Equipment
3. Class Number: 9
4. UN Number: UN 3091
5. Packing Group: PG II
6. Indication of Hazardous Material: Containing
111.6 grams of lithium in the 7600 Geo-Pilot with internal battery
227 grams of lithium in the 7600 Geo-Pilot with “Battery on Top” configuration
139.5 grams in the 9600 Geo-Pilot with internal battery
Gross Weight of Container
The other type of document is a Dangerous Goods Declaration.
A Shipper’s Declaration of Dangerous Goods must contain the following information:
1. Shipment Type: Non-Radioactive
2. Proper Shipping Name: Lithium Battery Contained in Equipment
3. Class Number: 9
4. UN Number: UN 3091
Page 56 of 114
5. Quantity and Type of Packaging: 1 Collar x (actual weight of collar) with XXXX grams lithium.
(Refer to quantities above)
6. Packing Instructions: PG II
7. Additional Handling Information: “This shipment is made under the provisions of 49 CFR
171.11.”
8. Emergency Contact Name & Number: Follow Local District Rules – usually local Materials
Coordinator and the main office line phone number.
9.3.2 Shipping by air
Note: It is Sperry-Sun’s policy not to ship the Geo-Pilot tool on passenger aircraft.
By law you must declare whether it is legal to ship by passenger or cargo aircraft even if there is
no intention to fly the tool via passenger aircraft. On the shipping form, you must cross out
passenger aircraft.
There is presently no need for quoting the Competent Authority Approval Number as stated in the
CP01231 procedure. Nor do you have to include the letter showing the certification approval. This
is handled at border crossings etc. when specifically asked for, which is rare.
9.3.3 Documentation Installation and Labeling
When a Geo-Pilot tool is shipped the tool must have the UN required labels applied to the body of
the tool. If the tool is shipped in an enclosed container a separate declaration sticker must be
applied to the outer container.
Note: People who are handling the Geo-Pilot must be able to see a hazardous goods label to be
aware of the hazard.
1. Complete the Hazardous Goods declaration.
2. Place the declaration inside a clear plastic zip-lock bag obtained from your local district or use
P/N 074475 from Nisku Manufacturing.
3. Place inside the zip lock bag a copy of the Material Safety Data Sheet for lithium batteries.
4. Place the required labels on the front of the bag such that they do not obscure the name of
the shipper and consignee on the Hazardous Goods Declaration form inside.
Note: The shipper and consignee must be clearly visible at all times.
5. Affix “Miscellaneous Dangerous Goods Class 9” label (P/N 018536).
6. Affix “LITHIUM BATTERIES CONTAINED IN EQUIPMENT, UN 3091” label (P/N 028176)
7. Affix “Cargo Aircraft Only” labels (P/N 014423)
Note: You must attach this label even if the tool will not be flown while in transit.
8. Affix “The Inner Packages Comply with Prescribed Specifications” label (P/N 014426)
9. Tape the zip lock bag, containing the Hazardous Goods Declaration and the labels on the
front of it, just below the reference stabilizer (Use 3″ clear packing tape).
Page 57 of 114
Chapter 10 Field Servicing
10 Field Servicing
Both Pre and Post run, the oil level in the Geo-Pilot tool should be checked. In addition, it may be
necessary to top up the oil, or to test the integrity of the rotary seals. These issues are addressed
in this chapter.
10.1 Oil refill procedure
Figure 15 Measuring the Oil Level
Note: The compensator piston position should be measured and recorded prior to re-filling the
tool.
Page 58 of 114
10.1.1 Geo-Pilot Compensator piston measuring device
Figure 16 Oil Level Dipstick
Note: Dipstick – part number 078553– can

be used on both sizes of Geo-Pilots.
Should you lack a dipstick in the field kit, one can be made from a 3/8” wide stainless “Bandit”
strapping, or a thick cable tie approx. 13” long.
Referring to the photo (above) the left-hand end has a 3/8" length that is folded back and
flattened. This prevents the dipstick from getting stuck between the outside of the piston and the
inside of the housing. A hook is formed at the other end to help pull it out. The length of the
dipstick is formed at a 12" radius (to make insertion easier). A line is scribed at 3" from the left-
hand end. The number "3" is stamped at the right-hand side of this line. A second line is scribed
7-7/8" from the left-hand end. The letter "E" is stamped at the right-hand side of this line.
10.1.2 To measure the compensator piston position

Note: If refilling the Geo-Pilot, always measure and record the position of the compensator
piston. Monitoring the amount of oil being used is important to confirm the seals are still
functioning correctly.
The compensator piston cavity is pumped full of oil, then some is allowed to drain out to allow
the oil to expand in the warmer conditions of the hole. The piston position in the tool, measured
with the dipstick, should be at the “3” mark on the dipstick
• The 7-7/8" mark is the empty position.
• The 3" mark is the filled position.
Remove the retaining ring and filter screen from one of the three ports.
Insert the dipstick into the filter screen port towards the down hole end of the tool until it
contacts the compensator piston.
Note: The dip stick should pass over the outside diameter of the spring. If the tool is reasonably
full of oil the thickness of the spring coil and compressed nature of the spring would not allow
insertion of the dipstick into the wrong place. See the illustration on the page before to see where
the dipstick should be going.
10.1.3 Before refilling with oil past the three inch mark
Prior to charging a tool past the three-inch compensator piston position always check that oil
bleeds off through the charging tools drain valve.
10.1.4 Refilling a tool after use
When using any Oil Filling Equipment or Adapters every effort needs to be made

WARNING
NOT to introduce air into the hydraulics. Always purge the fill hoses and adapters
before connecting to the tool. DON’T fill the Simplex pump 5 minutes before you
need it. It can take several hours for the air to clear itself from the oil filling
equipment, BE PREPARED IN ADVANCE!
Connect the Charge Valve Filling Assembly (Pic 1) to the Simplex Hand Pump (Pic 2) and purge
any air that may be in the system by pumping oil through the Charge Valve Filling Assembly.
Page 59 of 114
Remove the Charge Valve Plug and screw the Charge Valve Filling Assembly into the Charge
Valve. Position the Charge Valve Filling Assembly Valve and the Simplex Hand Pump Valve
accordingly to recharge the Geo-Pilot. Pictures 1 and 2 show both valves in the filling position.
Page 60 of 114
Monitor the piston position using the dipstick around the compensator.
• Tools should be recharged until the pressure relief valve opens at between 500 and 550 psi.
• The pressure can go as high as 600 psi.
• The pump is a 2 stage pump. As the pressure increases, it will become easier to pump.
Then a quantity of oil should be drained out to reset the compensator piston at three inches from
the downhole edge of the filter screen port.
Re-install the filter screen and retaining ring.
10.1.5 Tools that have sent a low or no oil status.
The refill procedure is the same as any used tool, with one additional step.
Check to make sure the pressure remains steady once the excess oil has bled off through the
relief valve.
If the tool is losing pressure, check for approval from the onshore co-ordinator before using the
tool again.
10.1.6 Blocked relief valve
If the pressure increases to 600 psi and holds steady this would indicate that the relief valve is
blocked. In this case the tool should be slowly increased in pressure until a maximum of 750 psi
is reached. If the relief valve still does not open, or oil leaks from any other area, then the tool
should be replaced.
If a tool with this problem has to be used again the excess oil should be bled off and the
compensator piston set three inches from the Filter Screen Port.
Note: This should only be done with approval from the onshore co-ordinator.
Page 61 of 114
10.2 Roller change procedure
Figure 17 7600 Series Reference Stabilizer Roller assembly
10.2.1 Removal of the Carriages

1 Place the clamp over the Carrier Assembly and Stabilizer Housing.
2 Tighten the clamp until the Springs are compressed.
Page 62 of 114
3 Remove all 4 x Spring Tension Pins using hammer or air hammer and special punch. Note
the punch is not long enough to punch these pins all the way though; a short extra length is
required.
4 Carefully unscrew and remove the clamp.
5 Lift the carriage assembly out of the housing pocket.
10.2.2 Preparation and Installation of Carriage Assemblies
The components that go into making up the Carriage Assemblies are ARH size

WARNING
specific.
A lot of these parts look alike but if mixed can cause serious problems
downhole.
The spreadsheet at the end of this section lists which parts go with which reference Stabilizer.
The photographs are there as a guide. If the dimensions do not agree with what you have then
contact your Global Support representative for clarification.
1. Smear ample amounts of Unirex grease or equivalent to all components before assembly.
2. Insert the Roller Shaft/Bushing assemblies into each Carrier Plate.
3. Slide a Roller Discs onto each end of the shaft. Pay close attention to the orientation of the
discs. Looking downhole and from left to right the orientation for Standard Discs is 2/1/1/2 and
for Salt Discs 2/1/2/3. See attached graphic for clarification.
4. The Carrier Assemblies are now ready for installation.
5. Liberally coat Compression Springs with Unirex grease.
6. Place the correct springs into the round recess at the bottom of the ARH pockets. Note the
9600 series tool has a Spring Insert which needs to be installed first

Note
On 7600 series tools (except 10 5/8”) the Roller End Bushing must be oriented so
that the Chamfered leading edge is facing down towards the Anti-Rotation Housing.
7. Insert 2 x Spring Pads, one over each pair of Springs.

8. Carefully lower a Carrier Assembly over the Spring Pads. On 7600 series tools make sure all
six Roller End Bushings are aligned with their slots in the Housing Body. Make sure that the
Chamfered leading edge is still facing towards the Anti-Rotation Housing.
9. Coat two Carrier Retainers with Unirex grease and place one over each end of the Carrier
Assembly.
10. Place the clamp over the Carrier Assembly and Stabilizer Housing.
11. Tighten the clamp until the Springs are compressed and the spring tension pin holes in the
Carrier Retainers are aligned with the holes in the Stabilizer Body.
12. Coat 4 x Spring Tension Pins (089761) with Unirex grease.
13. Hammer 1 x Spring Tension Pin into each hole until they are an equal depth at both sides.
Remove the Clamping Fixture and repeat this process for the other two Carrier Assemblies.
If the tool is configured with “salt rollers”, these must be place into the tool with the correct
orientation. The flat edge should be to the right looking downhole, to present the most resistance
to the formation.
Page 63 of 114
Reference Stabilizer Carriage Assembly Procedure

Different
7600 Series 9600 Series Component
8 1/2" to 9 7/8" 10 5/8" 14 3/4" to 17 1/2" 12 1/4" Types
S.S SAP S.S SAP S.S SAP S.S SAP
Part Part Part Part Part Part Part Part
Roller Carrier Plate 089768 288450 602552 314937 602555 314932 602555 314932 3
Carrier Retainer 089755 288346 602561 314933 602559 314927 602560 330444 4
Spring 1 089760 288373 601880 314934 601862 293681 601862 293681 3
Spring 2 n/a n/a 077159 290758 n/a n/a n/a n/a 1
Spring Insert n/a n/a n/a n/a 601865 293680 601865 293680 1
Spring Pad 089767 288449 089767 288449 601856 293679 601856 293679 2
Disc 1 070871 288830 600339 293581 077154 290762 077154 290762 3
Disc 2 070872 288831 600347 293580 077155 290761 077155 290761 3
Salt Disc 1 602241 331775 602247 331923 601891 331918 601891 331918 4
Salt Disc 2 602242 331776 602248 332004 601892 331919 601892 331919 4
Salt Disc 3 602243 331777 602249 332005 601893 331920 601893 331920 4

WARNING
NOTE In addition to the items listed in the above table there are several obsolete versions of each item. Use the attached photographs as
a guide. If you are not sure ask. Getting these parts mixed up can cause serious problems downhole!
Page 64 of 114
Reference Stabilizer Assembly Procedure (Carrier Plates)
0.440”
9600 Series
Carrier Plate
12 ¼” to 17
1.425” 1.875” ½” Hole size.
Note the cutout for the Spring

0.440”
9600 Series
Carrier Plate
OBSOLETE
1.475”
0.540”
7600 Series
Carrier Plate
10 5/8” Hole
size.
1.475”
The middle Carrier Plate is for reference only to show how easily they can be mixed up.
Only two types of “two-hole” carrier plates should exist, one for all 9600 series tools and
one for the 7600 series 10 5/8” tool. WARNING ! there are another FIVE VERSIONS of
“two-hole” carrier plates that are OBSOLETE but may still be in stock. Double
check before using.
7600 Series
“3 hole”
Carrier
Plate. 8 ¼”
to 9 7/8”
Holes size.
Page 65 of 114
Reference Stabilizer Carriage Assembly Procedure (Carrier Retainers)
3.275” 3.275” 3.150”
.433” .500”
.500”
8 ¼” – 9 7/8”
1.500” 1.712” 1.500”
10 5/8”
14 ¾” – 17 ½” 12 ¼”
10 5/8” 12 ¼” 14 ¾” – 17 ½”
0.500" 0.375" 0.575"
1.250” 1.500” 1.300”
CURRENT
If the Carrier Retainers do not conform to these measurements or patterns do not use them.
Page 66 of 114
Reference Stabilizer Carriage Assembly Procedure (Springs & Pads)
Nominal Spring
height is 3.0”. Nominal Spring
Diameter 1.20” heights are 3.0”.
Outer spring
diameter 0.975”
inner spring 0.580
Nominal Spring
height is 2.550”.
Diameter 0.975”
Spring Insert
7600 Series 10 5/8” 7600 Series

9600 Series All Nested Spring Assembly 8 ¼” – 9 7/8"
1.00” 1.255”
7600 Series All 9600 Series All
Page 67 of 114
Reference Stabilzer Carriage Assembly Procedure (Roller Discs)
9600 Series Standard
3.050”
3.200” 2 1 1 2
Note the orientation of disc #1. The larger polished face goes towards the Carrier Plate
9600 Series Salt
3.189” 2 1 2 3 2.952” 3.130”
LOOKING DOWN-HOLE
Page 68 of 114
Reference Stabilizer Carriage Assembly Procedure (Roller Discs)
7600 Series 10 5/8” Standard
3.075” 2 1 1 2 2.925”
Note the orientation of disc #1. The larger polished face goes towards the Carrier Plate
7600 Series 10 5/8” Salt
3.075” 2 1 2 3 2.755” 2.970”
LOOKING DOWN-HOLE
Page 69 of 114
Appendices
11 Appendices
Appendix A Geo-Pilot™ Specifications Sheet
Appendix B Geo-Pilot Performance/ Perceived Problem Report
Appendix C Geo-Pilot Battery Log
Appendix D Standard Field Toolkits
Appendix E Standard BHA Configurations
BHA Component Description
BHA Component Part Numbers
7600 Series BHA Configurations w/ 6 ¾” MWD
8 3/8” BHA Configuration
8 ½” BHA Configuration
8 ¾” BHA Configuration
9600 Series BHA Configurations with 8” MWD
12 ¼” BHA Configuration w/ 8” MWD
12 ¼” BHA Configuration w/ 8” Hi Flow MWD
14 ¾” BHA Configuration w/ 8” Hi Flow MWD
9600 Series BHA Configurations with 9 ½” MWD
12 ¼” BHA Configuration w/ 9 ½” MWD
14 ¾” BHA Configuration w/ 9 ½” MWD
16” BHA Configuration w/ 9 ½” MWD
17 ½” BHA Configuration w/ 9 ½” MWD
Appendix F SPE 74458: Robotic Controlled Drilling: A New Rotary Steerable

Drilling System for the Oil and Gas Industry
Page 70 of 114
Appendices
Appendix A Tool Specifications Sheet
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Appendices
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Appendices
Appendix B Geo-Pilot Performance / Perceived Problem Report
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Appendices
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Appendices
Appendix C Geo-Pilot Battery Log
Geo-Pilot Battery log

Battery S/N: Battery configuration:
Minimum voltage: Light load_______ volts Heavy load____________________ volts
Starting Amp-Hours (round usage entries to hundredths of an Amp-Hour.)

Start date/time Serv. Stby H Rate AH Used Subtotal Cum Battery Test Stave Build date Tested ok
A-H Used AH used Total Assy.
Stop date,/time Op mode Oper H Lot Code AH Used Light Ld Built by Install date
DESCRIPTION OF USE AH Left
Heav
yLd
Customer
1
SOA Number
Bit run
Customer
2
SOA Number
Bit run
Customer
3
SOA Number
Bit run
Customer
4
SOA Number
Bit run
Customer
5
SOA Number
Bit run
Customer
6
SOA Number
Bit run
Customer
7
SOA Number
Bit run
Page 75 of 114
Appendices
Appendix D Standard Field Toolkits

Oil Fill and Charge Kit
Equipment Part number Quantity Check-off
Charging Pump assembly 073200 1
Fill adapter assembly 075997 1
0-1000 psi pressure gauge 076363 1
(spare)
Filler fitting (spare) 076352 1
O-ring 012 C90 .375 ID 014809 5
Charge valve plug 076354 1
Measuring stick Piston position 2
Tape, thread ¼” wide Roll 1
Filter plugs for Compensator 094306 3
Retaining rings (Filter plug) 095511 5
Mobil oil (SHC-630) x 20 liters 075450 (70-110˚C) 1
Reference Stabilizer Assembly Service Kit
Carrier plate assemblies 3
Roller shaft assemblies 9
Disc #1 (Inner) 070871 18
Disc #2 (Outer) 070872 18
Roller end bushings 089758 18
Compression springs 089760 12
Spring pad 089767 2
Carrier retainers 089755 2
Spring tension pins 089761 24
G clamps For roller repairs 2
Punch, pin ¼” long 2
Punch, starter ¼” 1
Other Supplies
Grease gun 1
Grease cartridge To fit grease gun 2
Grease DC-55 O-ring Tube 1
lubrication
Cross-Over SWRO to Kemlon 1
Boot
Page 76 of 114
Appendices
Appendix E Standard BHA Configurations
BHA Component Description

BHA Component Part Numbers
7600 Series BHA Configurations w/ 6 ¾” MWD
8 3/ 8 ” BHA Configuration
9600 Series BHA Configurations with 8” MWD
12 ¼” BHA Configuration w/ 8” MWD
12 ¼” BHA Configuration w/ 8” Hi Flow MWD
14 ¾” BHA Configuration w/ 8” Hi Flow MWD
9600 Series BHA Configurations with 9 ½” MWD
12 ¼” BHA Configuration w/ 9 ½” MWD
14 ¾” BHA Configuration w/ 9 ½” MWD
16” BHA Configuration w/ 9 ½” MWD
17 ½” BHA Configuration w/ 9 ½” MW D
The most up to date versions of these documents are to be found

on DTDG web. Please refer to the online version for latest part
number revisions prior to ordering any components.
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
Appendix F SPE 74458: Robotic Controlled Drilling: A

New Rotary Steerable Drilling System for the Oil and
Gas Industry
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Appendices
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Geo-Pilot Field Operations Manual

FIELD OPERATIONS MANUAL

All other trademarks are the property of their respective owners.

1.1.1 Lithium hazard

1.2.2 Lithium battery pack

1.2.3 Seal failure

2 Description of the Geo-Pilot

2.2 How the Geo-Pilot steers

Figure 1 The point the bit concept

3.2 The lithium battery pack log

Note: A new Geo-Pilot battery holds 48 to 60 amp-hours of capacity, depending

3.3 Physical Condition of the Tool

4 Setting Up to Run In-Hole

DM 3.10 (pic 0.13)

TM 6.02 (pic 0.43)

Table 1 Software Compatability

4.2.2 Bottom hole assembly configuration

Refer to Appendix E Standard BHA Configurations for examples of approved GP/MWD

4.2.2.1 7600 Series Geo-Pilot GP/MWD Configuration

4.2.2.2 9600 Series Geo-Pilot GP/MWD Configuration

4.2.2.3 General BHA Configuration

4.2.2.4 Simultaneous Use of Hole Openers/Underreamers

4.2.2.5 Running Geo-Pilot together with a mud motor.

4.2.3 Rig Floor Offset

4.3 Confidence Test

GP has been detected.

GP confidence test will take approximately 60 seconds.

Figure 2 Geo-Pilot INSITE Confidence Test

4.3.1 Electronics Confidence Test Available in INSITE.

4.4 Download Screen Setup

Figure 3 Geo-Pilot Download Screen

The screen above shows a typical download set up.

4.4.4 Brake/Clutch Slip Rate Sample Period)

4.4.9 Max ABI Gtotal error

4.4.10 Bit Toolface Sample Rate

4.5 Real -Time Data Transmission

VDF Definition Description Lists Min / Max Seconds Recommended

DS – Deflection setting % Deflection Setting Initial, Periodic 120 / 600 240

TT - Toolface setting Toolface Setting Initial, Periodic 120 / 600 240

RD - GP deflection Actual % Deflection Initial, Continuous 45 / 120 60

Smart Toolface (Sends

RI - GP inclination ABI Inclination Initial, Periodic 60 / 300 120

ABI Gtotal Value Initial, Periodic 60 / 300 120

RS - GP status Geo-Pilot Status Flags Initial, Periodic 60 / 300 240

RR - GP rpm Geo-Pilot Shaft RPM Periodic 120 / 600 300

Table 2 Uplink Items

4.5.1 DS – Deflection Setting

Figure 4 Geo-Pilot RPM Sensor

4.5.9.1 Oil reservoir status

4.5.9.2 Bit Position status/Toolface Tracking

4.5.9.3 Housing slip rate

4.5.9.4 Clutch slip

4.5.9.5 Brake slip rate

4.5.9.7 G total error

4.5.10 DF – DM/GP toolface/“The Smart Toolface”

DF Sends DM toolface Geo-Pilot ABI Housing Geo-Pilot Bit Toolface

4.5.11 DDS Download Thresholds

Realtime Download Parameter 7600 series 9600 series

4.6 Sample VDF Definitions Download Screen

Figure 6 Sample VDF Definitions Screen

Figure 7 VDF Download Example

5 Monitoring Geo-Pilot Performance

5.1 Customer Presentations