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AutoTrak

Operations Manual

Section 5
Troubleshooting

Troubleshooting
AutoTrak 3.0

ATK-20-70-0000-05-02
AutoTrak
Operations Manual
Troubleshooting
ATK-20-70-0000-05-02 Revision: B May, 2005

Confidential

Revision History
All revisions to the document should be listed here. At the minimum, entries should include the section
altered, the approver of the revision, and the date. All revisions to this document must have an associated
Document Change Request (DCR). Changes cannot be made to this document without an approved DCR.

REV DCR Amendment Detail Approval Date


A -- Initial release M. Menge 09/2004
B # 3712 Bieri Pump primary issues added G. Cawthorne 02.05.05

This manual is provided without any warranty of any kind, either expressed or implied. The
information in this document is believed to be accurate; however, Baker Hughes INTEQ will not
be liable for any damages, whether direct or indirect, which results from the use of any
information contained herein.

© 2005 Baker Hughes Incorporated. All rights reserved.

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Table of Contents
Troubleshooting ........................................................................................................................ 5-1
Troubleshooting AutoTrak 3.0.................................................................................................. 5-1
Introduction ........................................................................................................................... 5-1
Discussion of Failure Modes................................................................................................. 5-1
FTT (Failure to Transmit) ................................................................................................. 5-1
Desync............................................................................................................................... 5-1
Downlink Issues ................................................................................................................ 5-2
Problems with the Steering Unit ....................................................................................... 5-3
ASS Bieri Pump False Pressure Readings at Surface ....................................................... 5-3
Gamma .............................................................................................................................. 5-8
Flow-Off Pressure Data..................................................................................................... 5-9
Troubleshooting Procedures................................................................................................ 5-11
Trouble Shooting Failures from Memory Files................................................................... 5-22
OBE00000.m00............................................................................................................... 5-22
0BE10000.m00 ............................................................................................................... 5-26
0BE20000.m00 ............................................................................................................... 5-28
OBE30000.m00............................................................................................................... 5-29

List of Figures
Figure 5-1 Typical Desync Pattern ................................................................................... 5-2
Figure 5-2 Time Error Warning...................................................................................... 5-10
Figure 5-3 Memory File Selection in Memproc ............................................................. 5-22
Figure 5-4 Memory File OBE00000.m00....................................................................... 5-23
Figure 5-5 Export Memory File Screen .......................................................................... 5-24
Figure 5-6 Bus Communication Investigation Spreasheet.............................................. 5-24
Figure 5-7 Nodes Retry Graph, Normal Run.................................................................. 5-25
Figure 5-8 Nodes Retry Graph, Severe Communication Problems ................................ 5-25
Figure 5-9 Obe10000.m00 First Time Power Up ........................................................... 5-26
Figure 5-10 Obe10000.m00 Events .................................................................................. 5-27
Figure 5-11 Obe10000.m00 Reset and Breaker Trip........................................................ 5-28
Figure 5-12 Obe20000.m00 Node Status ......................................................................... 5-29

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List of Tables
Table 5-1 Surface Gear and Toolcom NT Troubleshooting 1....................................... 5-11
Table 5-2 Surface Gear and Toolcom NT Troubleshooting 2....................................... 5-12
Table 5-3 Pulsing Problems .......................................................................................... 5-13
Table 5-4 Pulsing Problems (continuation)................................................................... 5-14
Table 5-5 Steering Problems ......................................................................................... 5-15
Table 5-6 Steering Problems (continuation) ................................................................. 5-16
Table 5-7 Error Flags / Survey Problems...................................................................... 5-17
Table 5-8 Downlinking Problems ................................................................................. 5-18
Table 5-9 Downlinking Problems (continuation).......................................................... 5-19
Table 5-10 Downlinking Problems (continuation).......................................................... 5-20
Table 5-11 General Issues ............................................................................................... 5-21

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Section 5
Troubleshooting
Troubleshooting AutoTrak 3.0
Introduction
A number of failure modes have been identified with the AutoTrak G3.0 system since its
introduction at the beginning of 2001. Due to the modularity of the system rig trouble shooting
and failure investigations have been lengthy with some complete strings taken out of service due
to uncertainty over root cause of a particular failure.
This document is intended to improve the troubleshooting process so that failures can be traced to
a single sub and possibly to a board. This should allow the modularity of the AutoTrak G3.0
system to be more fully utilized.

Discussion of Failure Modes


A number of different failure modes have been identified during the deployments over the last
two years.

FTT (Failure to Transmit)


An FTT is the traditional MWD term for a silent pulser. No pressure pulses can be recognised at
surface either by the surface computer or on the manual gauges on the rig floor. In most cases an
FTT is caused in some way by the BCPM. Traditional troubleshooting techniques should be
utilized when confronted with an FTT.

Desync
This term is new to OnTrak and AutoTrak G3.0 services. It means that the BCPM is pulsing to
surface all data as being a series of zeros with a 1 in the least significant bit. See Figure 5-1.

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Figure 5-1 Typical Desync Pattern


In the AutoTrak G3.0 system the master and pulser are in different subs. The master resides in the
OnTrak and the BCPM contains the pulser. The two subs are connected via the M30 bus system
which limits communication down hole to 9600 baud using FSK Adam bus protocol. The master
and the BCPM assume they know the next word that needs to be sent (and received). The master
sends a message to the node which should supply the data. The returned data is scaled and passed
onto the BCPM. The BCPM checks whether the data is the piece that is expected, if yes it is put
into a buffer ready for sending. If the word received is not the one expected then the BCPM
replies with an error and identifies the next data item and the time at which it required. If the
BCPM has no data in its buffer to send then it sends a set of zeroes with a trailing 1 (i.e.
00000001) to indicate that there is a problem. Equally if the BCPM has no contact with the
master it will also have no data in the buffers so will continually send a desync pattern.
This issue is sometimes identified by the field engineer as “the tool is transmitting all zeroes and
all the status bits are set. On closer examination of the HSTDecode screen they will see that the
tool is actually sending trailing 1’s (i.e. 00000001 (binary 1))for all data items.

Downlink Issues
There are a number of different problems that can relate to down linking:
Being unable to down link:
The tool does not shut down after a down link start sequence or possibly starts up again half way
through the down link.
False downlinks being recognized:
The tool may valve off and come back 40 seconds later with a downlink recognition FID (13).
This is an indication that the flow pattern down hole was such that a down link start sequence was
recognized. This has been seen with all tool sizes but seems to be more prevalent with the small
tool sizes and with ultra low flow turbines (where small changes in flow produce large changes in
turbine RPM). Equally motor applications have been seen to produce flow changes that could be
interpreted as down link start sequences. The problem with the false down links has been
addressed by changing the start sequence for down link recognition to include more edges.

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The down link trap:


This was a situation that arose with the implementation of combinatorial into the AutoTrak tools.
The tool identified the data rate pulses and the beginning of pulsing as being the start of a down
link. The pulser switches off, as with a normal down link situation then starts up again when the
BCPM realises that it is not a real down link. The first pulses would be the data rate pulses so
once again a false down link would be recognised. This situation is corrected in the OnTrak-
BCPM configuration so it is not possible to have a down link trap with the G3.0 tools.

Problems with the Steering Unit


The AutoTrak steering unit has three ribs which when powered correctly work independently.
Any problems with the steering unit are generally identified initially by a loss in steering
performance. Increase in variation of near bit inclination when in hold mode in a tangent COULD
be an indication of a problem with the steering unit. If there is any concern regarding the
performance of the steering unit then a down link should be sent to get a diagnostic survey. This
contains data on a snap shot of the target pressures and actual pressures on each of the ribs. For
each of the ribs the actual pressure should approximately match the relevant target pressure. If
there is a significant variation this rib could be faulty.
It is possible for you to continue with one failed rib. With normal sleeve rotation of the steering
unit, it has been calculated the steering unit can maintain a build rate of 4.5 degrees/100ft.
If the steering unit looses traction on the well bore then it can start to spin. At surface this
generally seen in the sleeve rotation increasing then the sleeve position locking at ***degrees.
The inclination can also be erratic.
If the steering unit values are being sent as zeroes then it is possible that there is either a problem
in the power to the steering unit, a communications problem with the steering unit or a general
bus communication problem. If the problem is purely communication and the directional targets
are being achieved in hold mode, then it is possible to drill ahead monitoring the surveys from the
sensor sub. Whilst there is no communication to the steering head it will not be possible to change
the steering unit parameters; if the steering unit is not achieving directional targets then a trip will
be necessary.

ASS Bieri Pump False Pressure Readings at Surface


Currently there are two manufactures of hydraulic pumps that are used in the hydraulic units of a
6-3/4” or 9-1/2” G2.0 Steering Unit, LeDuc or Bieri. The Bieri pumps are prone to give false
‘failed rib’ indications (i.e. High Motor RPM, and low Actual Pressure) when conducting a
surface desk test. These situations emerge due to the lack of sufficient static hydraulic pressure,
causing the pump to improperly prime itself and spin without providing any pressure. This
phenomenon is only seen when the system is at atmospheric pressures, not when the system is
downhole, and usually there is no fault with the pump(s) (or rib hydraulic system). The FSE
should check the associated paperwork to verify what type of hydraulic units are installed
General Description Rev (old) Rev (new) Part Number Tool Size
UNIT,HYDRAULIC,TYPE 3,6.75ATK2 C C 10127589 6 3/4”
UNIT,HYDRAULIC,TYPE 2,SST,6.75ATK2 G G N919103235 6 3/4”
UNIT,HYDRAULIC,HP,6.75ATK2 B B 10109795 6 3/4”
UNIT,HYDRAULIC,9.50ATK2 E E 10078928 9 1/2”
UNIT,HYDRAULIC,HP,9.50ATK2 A A 10143862 9 1/2”

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and notify/verify your findings with your respective Technical Support/Operations Coordinator
when this situation arises.

Note: This is not applicable for 4 3/4” AutoTrak.

The example below was recreated with the AT2.exe program. The upgrade to this program is
ATSteer2.exe, and can perform this procedure in a similar way.
• Ensure that AT2.exe is started in expert mode.
o Browse to AT2.exe (D:\Inteq\advantage\mwdcomms\autotrak)

o Create a shortcut of AT2.exe and place it on the desktop


o On the Shortcut to AT2, right click, select “Properties”, select the “Shortcut” tab

o Change the target line to read “…\AT2.exe expert”

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• Click on the “Steering Unit Test” tab (this should already be selected when the program
starts).

• Ensure that you are getting >95% Communication Statistics (bottom right of screen) and
wait until a count of 200 or greater for TxD and RxD (possible communications errors could
occur if less than 200).

This is particularly important with the Steering Unit, where reprogramming with poor
Note: communications runs the risk of generating a checksum error in the EEPROM. This can
only be resolved in a suitably equipped workshop.

• Click on the “AT Main Ctl” tab

• Send the parameters as shown above (Steering Mode=Steer, Direction=0, Force=0%)

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• Click on the “Motor Ctl” tab

• Verify the Actual Pressures are matching the Target Pressures (Note: Pump #2 has not
started up properly in this example.) If the Pressures are matching then the pumps are
reacting properly; continue with the normal programming for running the tool in the hole.
• Set new PWM Cycles to 15%. For areas, or seasons, where the ambient temperature is
below 4.5°C (40°F) then set these to 10%, due to the viscosity of the hydraulic fluid.

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• Verify new PWM settings, and make note of the new “Actual Pressures”

• Click on the “AT Main Ctl” tab

• Re-Send the parameters as shown above (Steering Mode=Steer, Direction=0,


• At this point all of the pumps should be working, verify new Target Pressures and respective
Actual Pressures (for this example, Pump #2 is reacting properly)

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If there is still a pump (or pumps) that is not responding properly, contact the local Technical
Support for further troubleshooting avenues.
After this procedure has been completed and all of the pumps are responding properly, the
Steering Unit is ready for further downhole preparatory programming (i.e. TIP).
If no further programming is to be done, then ensure the Steering Unit is in Ribs Off prior to
running downhole (AT Main Ctl -> Steering Mode “Ribs Off” -> Send).

Gamma
There are two intermittent gamma problems that have shown up during early use of the OnTrak
sub. The first of these is a vibration related problem with some of the gamma detectors, resulting
in off-the-scale high counts. The second problem is a firmware issue that crops up when the
pressure-gamma battery is either dead or latched off. It results in one of the gamma sensors
occasionally broadcasting zero counts. Both of these problems are believed to be resolved,
through more rigorous screening and new firmware versions. However, they still may occur
occasionally. The zero counts problem is usually related to power cycles, and cycling the power
to the tool typically clears it. This problem always affects the same detector, so if a bypass
actuator is present, the FSE can downlink to the tool and transmit only from the other detector.
Any incidents of the high counts problem, or any other gamma problems affecting only one of the
detectors, can be dealt with the same way.
While programming the tool there might be a gamma status bit set due to a low gamma count
below the programmed range of values.

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Flow-Off Pressure Data


Flow-off pressure data is stored in the flash memory of the Pressure/ Gamma board until the tool
is powered up, either by the BCPM or a TCS box. At that point, it is transferred to the memory
node.
If power is not supplied to the tool for long enough to transfer all the memory from the pressure
gamma memory to the OnTrak memory the residual is transferred dumped during a normal
Toolcom NT memory dump. The resulting file is called PGAM.mem. With Advantage 1.4U1 and
later versions the PGAM.mem file is automatically merged into the normal memory. Earlier
versions of Advantage need to run pgmerge.exe program, which is part of Advantage, to merge
the Flow-off pressure data.
There are couples off issues outstanding with the flow off pressure:
1. Loss of minutes of data due to time drift – to date, this problem has only resulted in a
maximum loss of 7 minutes of flow off data and will ONLY occur when the transitioning
between blocks or sectors on the Pressure/ Gamma board. As stated previously, the
Pressure/ Gamma firmware does not have a real-time clock. When the Master/ Memory
powers up, it broadcasts the time on the 1039/M33 bus. The Pressure/ Gamma node
synchronizes its time with the Master/ Memory after receiving this broadcast. After
synchronization, the time for the Pressure/ Gamma board is determined by monitoring the
PITR (Programmable Interrupt Timer) on the P/G board main micro controller. As stated
previously, the Pressure/ Gamma node stores a full time stamp at the beginning of each
flow off cycle and at the beginning of each sector. This time may drift with respect to the
RTC (Real-Time Clock) on the Master/ Memory board. The Master/ Memory board
calculates and assigns the times to archived data by assuming the measurements are
equally spaced at 2 second intervals. If there is a full time stamp stored to the local
memory on the Pressure/ Gamma board, the Master/ Memory will archive this time. If
there is any drift between the two times (time offsets determined by the Master/ Memory
and time stamps stored to P/G flash), there will be a time gap in the flow off data. This
will only occur when reading the time stamp archived at the beginning of a new sector on
the Pressure/ Gamma flash – it will not occur with the full time stamps stored in the
Pressure/ Gamma flash at the beginning of a flow off event.
2. Loss of flow off data due to loss of power – as stated in the previous problem description,
the Pressure/ Gamma firmware monitors which data has been successfully transferred to
the Master/ Memory or Advantage by “flagging” this data with a marker. In the previous
versions of the Pressure/ Gamma firmware (All versions before Conventional
:77849TC210 and Azimuthal:00022FW00R), the marker is stored in volatile memory. If
the battery is latched off (downlink or manual command) or the battery is depleted, there
is a voltage sag or power glitch during operation, or if a hardware or firmware fault
triggers the watchdog timer resulting in a reset of the microprocessor, the markers (and
battery on time) will be lost. After power is restored, the makers will be set to the last
record archived to the local memory on the Pressure/ Gamma board (and not on the last
transferred file). Under these circumstances, all of the flow off data which has not been
successfully transferred but before power has been restored will not be automatically
available to the user. The data is not lost – it is just not recoverable using conventional
means. Please contact the local technical support or Technical Services in case this data
needs to be recovered.

In the current versions of the pressure/gamma firrmware (Conventional:77849TC210 and


Azimuthal: 00022FW00R), the flow-off pointers and markers are saved in non-volatile

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memory as well as volatile memory. If for any reason power is lost during flow-off data
transfer, the node will retrieve all its pointers and markers from the non-volatile memory.
Therefore, the pointers will point to the last transferred record in the file and the node will
resume its normal operations.

If for any reason the pointers can not be retrieved from the non-volatile memory (Bad
non-volatile memory) or if re-dumping the entire data in the P/G local flash memory is
required. The markers need to be moved to the start of the P/G Memory (not to be done
offshore). In this case the complete Pressure/ Gamma memory is transferred. This
solution is available for the azimuthal gamma firmware 00022FW00R and higher and
normal gamma firmware from 77849TC210. Please contact the local technical support or
Technical Services in case this data needs to be recovered.
3. In case a reset of the Pressure/ Gamma board happens while the tool is in flow off mode
the tool will not recover (and not record data) until the next power cycle. This is most of
the times a minor issue except when tripping out data is required.
4. Especially while testing the tool on the deck or when the tool is supposed to RIH with
battery on, a time stamp error can occur.
• P/G board does not have a realtime clock as master does. It replies on master for
date/time, which is broadcasted on the bus shortly after power up, as a starting point
in time for time keeping.
• When P/G battery is off, this date/time information will only remain valid when
whole tool is power up by turbine or external power like TCS. Once this power is
removed, the P/G board loses date/time until next time/date broadcast. In this case,
P/G uses the computer’s “0” date/time, which is 1970-01-01, 00:00, Greenwich
meantime. Then the P/G boards adds the local time offset (for example Houston
with -06:00, it becomes 1969-12-31, 18:00).
• When P/G battery is on (by downhole condition, downlink, or manually turned on),
P/G boards keeps correct date/time if it has received the date/time broadcast from
the master.
If tool has to be run with P/G battery on, it is crucial that after manually turned on
P/G battery, power to the tool should be cycled, i.e., cut off power to the tool, turn
on the power to the tool AND let tool run on its own for at least 3 minutes to make
sure P/G gets date/time from master, then switch off power to the tool, and run in
hole if so desired.
MemProc in Advantage 1.40U2 improved handling of this kind of problem. The
user will be prompted for possible time error in the file as below:

Figure 5-2 Time Error Warning

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Troubleshooting Procedures
Table 5-1 Surface Gear and Toolcom NT Troubleshooting 1

Surface Gear and ToolCom NT Problems

Problem When “Tool Line Power” is Voltage, but no current draw When attempting to Poll,
applied from TCS Box, the when “Tool Line Power” is no nodes are found, or
Voltage displays zero applied to tool. only the memory node is
found.
Most likely Bad connection or cable Loose connection on tool Loose tool cable
causes between TCS box and cable, bad tool cable, display connection, bad tool
breakout box, display or other problem with TCS cable, loose or bad RS
problem or other problem with box. 232 cable, ToolCom NT
TCS Box itself, bad breakout settings, bad Com port.
box.
Step 1 Check that the connections Turn off power to tool, check If RS 232 cable is
between the TCS and connections on tool cable to connected to Com 2,
breakout boxes are all clean, TCS box and to tool. Tighten ensure that “Use Com2” is
tight and aligned correctly. if necessary. Reapply power selected in ToolComNT
Apply Tool Line Power again and watch for current draw. Properties.
and check voltage.
Step 2 Use backup cables between Switch to backup tool cable. Switch RS 232 to the
TCS and breakout box. Apply power and watch for other Com port.
Apply Tool Line Power again current draw. (Ensuring Com2 is
and check voltage. enabled if necessary.)
Step 3 Use backup TCS box . Apply Switch to backup TCS box. Turn off power to tool, and
Tool Line Power again and Apply power and watch for check connections on tool
check voltage. current draw. cable to TCS Box and to
tool. Tighten if necessary.
Reapply power and poll
again.
Step 4 Use backup breakout box. Use backup tool cable.
Apply Tool Line Power again
and check voltage.
Step 5 Use backup RS 232
cable.
Step 6
Comments Voltage should be displayed on There have been occasions Memory can be polled
the TCS box when “Tool Line where dampness or cold have through the Ethernet cable
Power” is enabled, even when affected the displays on TCS from the breakout box, so if
the tool cable is not attached to boxes. In cold weather, it is a it is the only node polled,
a tool, assuming the cabling good idea to keep the TCS box the problem is probably
from the TCS box to the inside to prevent problems. with the RS232 or the
breakout box is attached and Additionally, condensation or, ToolCom NT settings.
working. This should be in extreme circumstances ice
verified before plugging into may form on the pins of cable
and applying power to a tool. connectors brought indoors
from low temperatures. Store
cables inside or allow them to
warm up at cold locations.
On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-2 Surface Gear and Toolcom NT Troubleshooting 2

Surface Gear and ToolCom NT Problems

Problem TCP/IP not available on Memory No simulated pulse for TCS Red light on Bypass
Dump screen. Decoding when power is Controller on hook up of
applied to tool. BPA and power up

Most likely Bad connection to tool, bad Daqio settings, breakout Cable not connected.
causes Ethernet cable, ToolCom NT box cable, Nidaq port, Electrical short or open
settings, network card settings. master not reset. circuit in equipment
transmit (BPA) cable.
Step 1 Turn off power to tool, and Reset the master by Check all cables are
ensure that tool dump cable is cycling power to the tool. connected. Break, clean
firmly seated on the tool. This The tool should begin and reconnect all
may require several attempts. pulsing 60 seconds later. connections.
Step 2 Ensure that Ethernet cable from Check that the Nidaq port Try backup cables.
breakout box is plugged into the into which the breakout
3Com network card. Change box is plugged is set as
Ethernet cable if necessary. “Active” in Daqio. This can
(Green LED on the network card be changed in the Settings
while plugged into the tool will option under Config.
indicate a good electric
connection.)
Step 3 In ToolCom NT Properties, Switch ports on the Nidaq Change out Bypass
ensure that “Use TCP/IP” is card. This must be done Controller. See AutoTrak
selected. Also, ensure that the with the computer powered G2.5/3.0 Operations
tool IP address in ToolCom NT down to avoid shorting the Manual, Chapter 2-7
Properties is 10.128.252.1. card. (ATK 3.0-20-70-0000-02-07)
Step 4 Through Network Neighborhood Switch to backup breakout Change out Bypass
Properties, check the TCP/IP box cable. Again, plugging Actuator.
Protocol properties of your 3Com into the Nidaq card must
network card. The IP address of be done with the computer
the card should be 10.128.1.1. powered down.
(Reboot required afterward.)
Step 5 Double-check the IP settings by
opening a DOS prompt and
typing IPCONFIG. Look for
Ethernet Adapter EL90x10, and
confirm the IP address is
10.128.1.1.
Step 6 In DOS prompt, type Ping
10.128.1.1. There should be 4
responses from the memory
node.
Comments If TCP/IP cannot be resolved, the To get a clean current Electrical connection
memory can be dumped through draw signal for TCS problem will also be
the RS 232 cable, at a speed of decoding, the Telemetry identified on Advantage
up to 56 KBPS. If this becomes Test function of the OnTrak software. Mark all
necessary, use the IO1039 program within ToolCom suspicious cables.
setting on the TCS box to allow NT must be run.
the fastest dump speeds.
On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-3 Pulsing Problems


Pulsing problems

Problem Tool is not pulsing after flow on time (default 1 Tool stops pulsing
min)

Most likely Low temperature near surface. Pulser Pulser blocked by foreign object. Turbine
causes blocked by foreign object. Turbine stalled stalled or jammed.Pulser or electrical
or jammed.Pulser or electrical failure. failure.

Step 1 Confirm signal is dead at standpipe, if not Note pressure changes (15-20 bar (218 -
find fault with surface system. Check pump 290 psi) drop or increase). Confirm signal
pressure versus expected pump pressure. is dead at standpipe, if not fault-find
If a blocked pulser is suspected , see the surface system.
column “Tool stops pulsing”
Step 2 Start up pumps with 600 l/min (160 gpm) Cycle pumps off for 5 mins for complete
circulate for 5 minutes and increase slowly reset of the tool and start pumps slowly
by 100l/min (25 gpm) over 30 seconds up back to operating flow rate and circulate for
to 1000 l/min 265 gpm), circulate for 2 10 minutes, repeat this cycle twice with
minutes and then increase slowly to minimum operating flow rate +10% and
operating flow (± 20% below maximum). then maximum flow rate +10%.
This should re-couple the clutch, and is
more relevant to v1.5 tools where the
tubine also drives a hydraulic pump.
Step 3 Repeat step 3 after a 5 minute break and Rotate pipe with maximum available rotary
rotate pipe with maximum available rotary (to a maximum of 200 rpm) with max flow
(to a maximum of 200 rpm) with max flow minus 10% and circulate for 10 minutes.
minus 10% and circulate for 10 minutes.. Stop and start rotary whilst circulating.
Step 4 Drill ahead with 60 rpm if close to bottom If permitted, surge pipe (pick up 30 ft /
and directional requirements allow (ie 10m, turn pumps off drain standpipe and
cement, float, shoe, etc.). leave open, drop pipe 10 ft / 3m) NB
Ensure ribs are retracted before surging
pipe.
Step 5 Evaluate the use of low viscosity pill, in Drill ahead with 60 rpm if directional
HTHP applications cold pill. requirements allow (ie cement, float, shoe,
etc.)

Step 6 Evaluate the use of low viscosity pill, or in


HTHP applications cold pill

Comments Check w/ mud engineer for add-on's. Check w/ mud engineer for add-on's.
Check drillpipe screen if run for LCM, etc. Check drillpipe screen if run for LCM, etc.
Note whether tool starts up with start of Note whether tool starts up with start of
Raw survey halfway through telemetry Raw survey halfway through telemetry
sequence. Keep active pit volume little. sequence. Check mud screen when tool
Dump memory and analyze if tool was back on surface. In case debris is found
powered up. Examine file obe10000 for inform c-man (report or customer warning).
further information. Dump memory and analyze if tool was
powered up!
On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-4 Pulsing Problems (continuation)


Pulsing problems
Problem Decoding / Pulsing problems

Most likely Signal attenuation, pump noise, torque noise or


causes downhole motor noise, foreign object at pulser,
pulser damage, surface gear problems, wrong
Tel./ Config. Files, air in mud system.

Step 1 HSTDecode:
Measure pulse height of data rate pulse. Check
out the FFT view to determine the frequency of
noises. Try different correlators and filters.
Check Decoding School manual/ HSTDecode
manual!
Step 2 Save configuration to the RD file and send the
RD file to the local technical support for further
analysation.

Step 3 Change data rate and repeat step 1 and 2!

Step 4 Check pulsation dampener setting. As a rule of


thumb it should be about 1/3 of standpipe
pressure.

Step 5 When drilling with motor reduce WOB / torque


on motor. Increase or decrease flow rate.

Step 6 Check/ change pressure transducer, check rest


of surface gear, mud plugs / airlocks in the
standpipe.

Comments Check Decoding School manual/ HSTDecode


manual!
The MWD engineer should always target for the
highest data rate possible!

On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-5 Steering Problems

Steering problems

Problem High sleeve rotation with erratic inclination Sleeve orientation trend normal but no steering
values. response.

Most likely Loss one or more ribs hydraulics. Strong formation trend - bit/rock
causes Formation wash out. Electronic lock up. interaction. Start of Hydraulics failure.
Step 1 Stop drilling and pick up off bottom Downlink to change to steer mode and
reducing rotary to less than 40 rpm. If stick apply full force in the direction to be
slip occurs, increase RPM until it is gone. steered. Resume drilling with reduced rpm
Observe if sleeve rotation and inclination of 40 and less then 50% of normal ROP if
are getting steady. appropriate.

Step 2 Cycle pumps off for 5 mins and back to Downlink to get a diagnostic survey. Check
operating flow rate. Resume drilling with the reading for target and actual rib
reduced parameters i.e. lower flow, rpm pressures. It is best to do this stationary if
and hold back ROP. possible. If the target and actual pressures
are significantly different then there is
probably a problem with the rib.
Step 3 Downlink to get a diagnostic survey. Check Turn off pumps and rotate for 2 minutes
the reading for target and actual rib with 40 RPM, (to get ribs retracted and
pressures. It is best to do this stationary if change out oil in the rib cylinders) turn on
possible. pumps, and drill ahead while monitoring
If the target and actual pressures are NBI values.
significantly different then there is probably
a problem with the rib.
Step 4 Turn off pumps and rotate for 2 minutes Downlink to steer on highside or lowside
with 40 RPM, turn on pumps and drill with full force and evaluate NBI trend for
ahead monitoring sleeve orientation. steering performance, with high rpm and
reduced ROP

Step 5 Downlink to change mode with completely Downlink to change mode with completely
new settings (I.e. Not only a mode new settings (I.e. not only mode change).
change.).

Step 6 Drill ahead with full force in direction Drill ahead with full force in direction
required evaluating how far you can drill required evaluating how far you can drill
without compromising the well path. without compromising the well path.

Comments May be wash out but formation being


drilled will determine whether this is likely.
Full force application will provide maximum
bending and thus maximum side force on
sleeve. Check caliper log if ORD is used
(poor real-time data).
On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-6 Steering Problems (continuation)

Steering problems

Problem Stepwise inclination build up dependent on


sleeve orientation

Most likely One or two ribs with reduced hydraulic


causes power.

Step 1 Downlink to get a diagnostic survey. Check


the reading for target and actual rib
pressures. It is best to do this stationary if
possible.
If the target and actual pressures are
significantly different then there is probably
a problem with the rib.
Step 2 Drill ahead if overall directional
requirements allow. Follow the TA of drilling
with a failed rib.

Step 3 Before sleeve gets into an unfavorable


position, work pipe up and down to let the
sleeve rotate into a more favorable
position.

Step 4

Step 5

Step 6

Comments

On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-7 Error Flags / Survey Problems

Error Flags/ Survey problems

Problem Suspicious NBI values

Most likely Downhole vibrations (lateral). Lock up of


causes NBI module.

Step 1 In the occurrence of vibrations change


parameters to reduce/eliminate vibrations.
Follow anti vibration practices.

Step 2 Evaluate build force setting while drilling


ahead in hold mode. Reduce build force -
as low as possible, see Technical Alert
AT01/029/JR.

Step 3 Rotate pipe up to 200 rpm on/off without


pumping - impact on sensor can release
lock up (This is assumed to be more
efficient than shocking/surging the pipe).

Step 4

Step 5

Step 6

Comments Suspicious NBI value could be real caused


by hitting a hard stringer with a certain
angle. In cases above 9°/30m DLS follow
the Troll Operations Guide from Norway.

On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-8 Downlinking Problems

Downlinking problems

Problem No pressure drop / flow bypass on Downlink not recognized with flow being
transmission of downlink. diverted.

Most likely Actuator is isolated from stand pipe. Air Inadequate flow diversion for recognition,
causes supply to actuator switched off. Bypass bad communication between BCPM and
Actuator failure. master. Wrong start sequence being
used.

Step 1 Check if BPC is operating by listening for Downlink cannot be sent during first 2
actuations; Comm line between surface minutes after power up or previous
computer and BPC might be broken or downlink when using Advantage
com port hang up. Combinatorial.

Step 2 Check that actuator is lined up with Check the version of the down link
standpipe in use and check low torque firmware being used in the tool. The
valve. standard firmware 77834C0136 has a
normal start sequence. Firmware ending
T*153 have a new start sequence which
should be used (16-12-8-12-8)
Step 3 Check air pressure gauge on air Increase TFA of adjustable nozzle or
conditioner for air pressure. change out fixed nozzle to larger nozzle
and resend.

Step 4 Change out BPA basket. Increase flow rate by 10% and resend.

Step 5 Increase pulse length (if using the c0136


downlink firmware).

Step 6 Contact local technical support for usage


of altered downlink program for use in
ERD wells.

Comments It must be remembered that the air supply Use downlink spreadsheet to calculate
to the actuator requires a flow rate of 630 percentage flow diverted from stand pipe
l/m. pressure changes. If bad communication
between BCPM and master exist, there
should be desyncs in the real-time data to
indicate this.
On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-9 Downlinking Problems (continuation)

Downlinking problems

Problem Downlink recognized but tool transmits Downlink recognized, correct downlink
Raw survey during downlink. command and data, but downlink action
flag set.

Most likely Too much flow diverted causing tool power 1. Bad communication between Master
causes to drop out. and node to which it sent the
command.
2. Parity error.

Step 1 Decrease TFA of adjustable nozzle or Check that the firmware is correct for the
change out fixed nozzle to smaller nozzle down link being sent. The new firmware
and resend. versions only support 8 second bit
lengths.

Step 2 Increase flow rate by 10% and resend. Confirm in the real-time data that any data
from the node affected by the downlink is
good. (As an indication of node health.)

Step 3 Double-check that the downlink being sent


is a valid downlink. (I.E. not an illegal FID
swap.)

Step 4 Resend the downlink.

Step 5

Step 6

Comments Use downlink spreadsheet to calculate


percentage flow diverted from stand pipe
pressure changes.

On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-10 Downlinking Problems (continuation)

Downlinking problems

Problem Down Link sent Æ tool shuts Lots of false downlinks Downlink is recognized, but not
down but starts pulsing at the recognized, especially with the decoded correctly or tool starts
end of down link in middle of 4 ¾ AutoTrak pulsing again before the downlink
sequence has ended.

Most likely Desync Wrong firmware When the pulser shuts down it
causes interferes somehow the downlink
signal. This is still under
investigation.

Step 1 Is the tool transmitting desync Especially the 4 ¾ BCPM is Check whether the correct
pattern? more sensitive to flow changes downlink table is used.
and recognizes false down
links.
The BCPM should be loaded
with the firmware 77834TL153.
This will be changed when a
new version is released.
Step 2 During a desync there is When running BCPM downlink
generally no communication F/W 77834TL153 then change
between the master and the wake up sequence in the
BCPM. The down link will not dlkserver.ini from 16-12-8-12-8 to
be passed to master. 16-12-8-12-7. Go to
\\inteq\advantage\ctl\dlkserver.ini and
change the line “Open 3= 8” to
“Open 3 = 7”.
Step 3 Trouble shoot desync.

Step 4

Step 5

Comments This problem has been seen only


for the 4.3/4” AutoTrak / OnTrak
so far.

On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Table 5-11 General Issues

General Issues

Problem Missing Flow Off data in the OnTrak memory High (off scale) gamma counts

Most likely Flow Off data has not been recorded. Vibration
causes Flow Off data has not or not completely
transferred from the Pressure/ Gamma Flash
memory.

Step 1 Check whether conditions were met to record Follow anti vibration drilling practices
flow off data (min. pressure, power on events)
and whether the battery was enabled/ latched
on.

Step 2 Check out for PGAM.mem file. If running ADV Downlink gamma configuration to other sensor
1.4U1 and later versions this file is
automatically merged into regular memory file.
For earlier versions run pgmerge.exe in order to
merge this file to the OnTrak memory.
Step 3 Check OnTrak Battery, there is no flow off
pressure data after the battery died.

Step 4 If battery is good but large amount of missing


flow off data contact local technical support.
Data is probably stored in the P/G Flash and
can be recovered.
Do not change the battery without contacting
local technical support!
Step 5 In case of less than 7 minutes missing data
once in a while this is caused by a time drift.

Step 6 There is no data in case of a reset of the P/G


board during flow off and no power on
afterwards. Tripping data would be lost.

Comments See also page 5-4 of the chapter. Some of the This problem usually only affects one sensor,
problems are still under investigation. so changing gamma configuration should clear
it.Report this problem to technical services
Houston.

On occurance of a problem follow steps until problem resolved. If this fails to resolve problem contact local technical support.

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Trouble Shooting Failures from Memory Files


There is sometimes some confusion over the exact cause of a failure after the tool is pulled out of
hole. This can lead to excessive equipment being unavailable to extended periods for
troubleshooting. The memory contains some files which are written by the master and can give
some good insights into what actually went wrong with the tool. Additionally it is imperative that
a diagnostics log is produced at the end of every run. This can give indications of failing ribs, or
intermittent problems during what was considered a perfect run.
To carry out an analysis open Memproc and select the file open button. Select the files.

Figure 5-3 Memory File Selection in Memproc


The files of interest are detailed below.

OBE00000.m00
This file contains a list of all the communications errors experienced during the run. A
communication error is recorded every time the M30 master sends a message to another node and
the node does not reply within a 250Msec window. Due to the nature of the M30 bus there will
always be a certain amount of communication errors. The window below shows an example of
the opened file.

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Figure 5-4 Memory File OBE00000.m00


The time column holds the time of the event
The NODEM Column holds the node address of the node that did not reply. These nodes can be
looked up in the inteq\advantage\mwdcomms\comspecs directory on an advantage computer.
The CMDM column contains the hex command that was sent to the node that did not reply.
The Error code column details the type of error experienced the common ones are;
• 01 The node did not reply to at least one command but did eventually reply OK.
• 02 The node did not reply at all to any of the three retries
• 06 When the node received the request it sent back a busy signal. This is most often
seen from the directional sonde when the master asks for directional data before the first
directional.
The RETRIES column contains the number of times the master attempted to address the node.
The ACKM column contains the Adam bus acknowledgement returned by the node. In the
example above it can be seen that the directional returns a 02 acknowledgement when the
directional sonde is busy. In general there will be no acknowledgement if the node is not replying.
Attached to this manual is a spreadsheet that can be used to display the retries graphically. In this
way it is possible to judge the performance of bus transmission throughout the run. Care should
be taken however that the data used in the spreadsheet does not contain any data recorded when
the external nodes were not connected (e.g. during deck tests).
The memory file data can be exported into an excel format using Memproc.
• Select the EXP button at the top right hand corner of the screen.
• Tick the Export to ASCII box and unpick the Export to XTF.

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Figure 5-5 Export Memory File Screen


• Open the retries spreadsheet and the exported file.
• Copy all the data and header lines from the exported file and paste to cell A135 of the
retries spreadsheet (ATK-20-70-0000-09-04)

Figure 5-6 Bus Communication Investigation Spreasheet


The resulting graph shows the retries by Node. The example below shows a long and good run.
There are 805 retries on the 87 node (BCPM breaker) but these are all green which means that the
node replied after one or more attempts.

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900

800 0
0

700

600

500
Retries

400 805

0
300 0

200
338
0 0
0 0
100
153 149

0 0 2
1 0 0
2 0 0
7 1 0
4 0 0 0 0 0
6
85
0 3
86 87 88 c4
0 c5
0 c6 c8
0 c9 4
cc da
0 e4
0 ec
0 e7
0 e0
0 e1
0 0
8F
Err Code 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Err Code 6 0 3 0 0 0 0 0 0 0 4 0 0 0 0 0 0 0
Err Code 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Err Code 2 0 2 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0
Err Code 1 0 1 805 153 0 2 338 0 149 7 1 4 0 0 0 0 6
Nodes

Figure 5-7 Nodes Retry Graph, Normal Run


The example below shows a job which was not so successful. The red retries indicate that the
master is having difficulty communicating with all nodes. This looks like a general bus problem.
If only one node has significant retries this is an indication that this node has failed and is no
longer responding to the master. If for example you are getting zeroes transmitted for a particular
node it is likely that the retries on this node will be red and numerous. The blue on the CC node
indicates that a command is being sent to the CC node which is not recognised by the node. In
this case the directional sonde had been modified for azimuthal gamma whereby the VSS
functionality was removed. The master was still asking for VSS data so the high number of retries.

3000

2500

2000
0
Retries

1500 0
0

1000 1726
0 1104
1156 0
500
0
637 0 418 0
185 2831 0 0
122 0 0 0 129 0 0 0 222
0 0 15 38 88 0 0 92 0 36 17
16 4
46 78 0 0 82
85 86 87 88 c4 c5 c6 c8 c9 cc da e4 ec f4 e0 e1
Err Code 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
err Code 6 0 0 0 0 0 0 0 0 0 2831 0 0 0 0 0 0
Err Code 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Err Code 2 637 1156 122 185 0 0 418 0 129 17 4 0 0 0 1726 1104
Err Code 1 0 15 38 88 0 0 92 0 36 16 46 78 0 0 82 222
Nodes

Figure 5-8 Nodes Retry Graph, Severe Communication Problems

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0BE10000.m00
The OBE10000 file contains very useful text data that can be used to track a run. The firmware
has been written so that each time an interesting event occurs with the master it stores a text
comment to the OBE10000 file.
After the memory is initialized and the power is applied for the first time to the master it will
check on the bus for nodes present and store the software part numbers of nodes that reply. As
shown below. This functionality is very useful for confirming that the correct firmware has been
run in all the various sub nodes attached to the master.

Figure 5-9 Obe10000.m00 First Time Power Up

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For each subsequent power up the master stores only the master memory part number along with
the statement that the master was powered up or restarted. Generally the second line after the
power up indicates that the master checks the configuration of the BCPM. There are then
generally a number of lines (4 or 5) stating that the BCPM does not currently need data. This is
quite normal. If the OnTrak is powered while not rotating then there is a message stating that the
inclination and azimuth have been broadcast on the bus. This is the data used by the ORD sub to
calculate the binning for azimuthal density readings.

Verifies BCPM
configuration

Master powered up

Figure 5-10 Obe10000.m00 Events


Any other messages seen in this file generally indicate that something unusual has happened. All
messages are by no means terminal but can give an indication of what happened in the tool.
Below is an example of a file stored on a job where some problems were experienced.
The line at 06:33:28 {BugCatch 003, EE_MptFid[MPTFidIndex]:ff} indicates that the master had
a problem and reset it self. This can also be seen in the fact that the next time stamp with a large
clock happens at exactly the same time. The rig crew would have seen the pulser stop and start
again 30 seconds later. This is a known condition that will be solved in later versions of the
master memory code.

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The line at 07:44:29 {sensor sub Breaker Tripped Count 02…….} indicates that the lower
breaker on the sensor sub tripped. In this case the steering unit had a short circuit which led to the
breaker tripping. The symptom seen whilst in hole was that all the data transmitted from the
steering unit were zeroes.

Figure 5-11 Obe10000.m00 Reset and Breaker Trip

0BE20000.m00
This file contains status messages that occur when the master speaks to a node. A status is only
stored when it has changed.
Each time the master sends a message to an external node and it replies the reply always contains
a status word. This word is generally set up by the node firmware programmer to contain useful
information with respect to the health of the node. This data can just be for information i.e. the
battery in the OnTrak is switched on or can have more serious consequence like a gamma
detector failing or internal communications failures within a sub.

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Figure 5-12 Obe20000.m00 Node Status


This is an example of the node status screen. This is a normal file, though there are a lot of status
messages, these messages imply the normal start up of the tool

OBE30000.m00
This file contains details of the down links received by the tool. With this file it can be seen
whether down links sent from surface were correctly decoded by the down hole tool. Similarly if
a specific problem occurs with the tool the event can be compared to the down link file to see if
any particular down link had a negative effect on the tool. I.e. was a down link sent to switch on
the steering unit just before a desync.

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