Extreme Networks PowerDrive Orbit User guide

Extreme Equipment Rentals
Page 1 of 35
PowerDrive Orbit & X6
Quick Operations Guide
Revision 1.4
6 March 2020

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
Page 2 of 35
This document should serve as a basic guide for Extreme Equipment Rental clients for
planning and executing a successful PowerDrive Orbit or X6 job in North America.
Contents
1JOB PLANNING...........................................................................................................................................3
1.1 BHA DESIGN.........................................................................................................................................3
1.1.1 Stabilization....................................................................................................................................3
1.1.2 Motor Selection..............................................................................................................................3
1.1.3 Bit Selection...................................................................................................................................3
1.1.4 Additional Considerations ..............................................................................................................3
1.2 HYDRAULICS .........................................................................................................................................4
1.2.1 Optimizing Hydraulics ....................................................................................................................4
1.2.2 Pressure Calculator on the PowerDrive App .................................................................................4
1.2.3 Flow Restrictor Use and Availability ..............................................................................................5
1.3 MAGNETIC MATERIAL REMOVAL .............................................................................................................5
1.4 TOOL SPECIFICATIONS...........................................................................................................................5
2TOOL PREPARATION.................................................................................................................................6
2.1 REVIEWING TOOL PAPERWORK ..............................................................................................................6
2.1.1 Tool Configuration..........................................................................................................................6
2.1.2 Flow Loop Results .........................................................................................................................9
2.1.3 Operating Envelope.....................................................................................................................10
2.2 FLOW RESTRICTOR INSTALLATION........................................................................................................11
2.3 BHA MAKEUP......................................................................................................................................11
2.4 SURFACE TESTING –NOT ADVISED ......................................................................................................11
3JOB EXECUTION.......................................................................................................................................12
3.1 TRIPPING IN /FILLING PIPE...................................................................................................................12
3.2REAMING /BACK-REAMING ..................................................................................................................12
3.3 CASING DRILLOUT ...............................................................................................................................13
3.4 DOWNLINKING .....................................................................................................................................13
3.4.1 Downlinking Basics......................................................................................................................13
3.4.2 Sending the Downlink ..................................................................................................................14
3.5 KICKING OFF FROM VERTICAL ..............................................................................................................15
3.6 INCLINATION HOLD (IH) &HOLD INCLINATION AND AZIMUTH (HIA)..........................................................15
3.6.1 Inclination Hold (IH) .....................................................................................................................15
3.6.2 Hold Inclination and Azimuth (HIA)..............................................................................................16
3.6.3 Rate of Penetration Ranges ........................................................................................................17
3.7 POWERVLOCK/UNLOCK......................................................................................................................18
3.8 SIDETRACKING ....................................................................................................................................19
3.9 CLEANUP CYCLES................................................................................................................................22
3.10 RE-RUN EVALUATION ..........................................................................................................................23
4TROUBLESHOOTING................................................................................................................................24
4.1 LOW DOGLEG WORKFLOW...................................................................................................................24
4.2 ANTI-JAMMING PROCEDURE.................................................................................................................24
4.3 SHOCK &VIBRATION............................................................................................................................25
5REQUIRED END OF RUN DATA...............................................................................................................26
6DOCUMENT REVISION HISTORY............................................................................................................27
APPENDIX 1 –REAL-TIME D-POINTS:..........................................................................................................28
APPENDIX 2 –FISHING DIAGRAMS:.............................................................................................................29

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
Page 3 of 35
1 Job Planning
1.1 BHA Design
1.1.1 Stabilization
All PowerDrive BHA’s should have at least 2 stabilizers.The first stabilizer should be located on
the PD control collar or directly behind it. The 2nd should be 30-40 feet behind the first. Proper stabilizer
placement ensures optimal steering response and minimizes shock & vibration damage. Depending
on the BHA design, a 3rd stabilizer may be added another 30-40 feet behind the 2nd stabilizer. This
may aid in shock & vibration mitigation on the MWD but will have minimal effect on steering.
The first stabilizer should be 1/8” Under-gauge from the hole-size. The additional stabilizers may
be 1/8” or ¼” Under-gauge depending on the application.
Stabilizers should have spiral wrap, short gauge, and long tapers. A good rule of thumb is to aim
for a gauge length that is 50% of the hole-size and 60 degree taper. This design optimizes steerability
while preventing stabilizer jamming.
Roller Reamers may be used in place of stabilizers to reduce torque and stick-slip. Do not use
eccentric reamers or hole-openers in place of stabilizers.
1.1.2 Motor Selection
Bearing sections must be fixed-straight, not adjustable dialed to zero. Adjustable motors, even
when dialed to zero bend, have an offset that can initiate vibration.
Consider the PowerDrive RPM specification (220 for X6, 350 for Orbit) when choosing rev/gallon
of the power section. Exceeding the RPM specification will lead to reduced dogleg and tool damage.
1.1.3 Bit Selection
Extremely aggressive bits can cause stick-slip and whirl. These dynamics may lead to tool
damage, reduced dogleg, and lower ROP.
Tapering or under-cutting the back end of the gauge pad is recommended to maximize dogleg
and prevent excessive torque or stick-slip. This also allows for longer gauge lengths in
tangent/horizontal sections to improve stability.
“Active Gauge” bits should be avoided as the negative effects outweigh any benefits.
Depth of cut management features can aid in minimizing stick-slip but avoid placing them on the
shoulder of the bit as this may reduce dogleg significantly.
1.1.4 Additional Considerations
Flex Ponies and Collars should generally be avoided, especially in tangents or horizontals, as they
increase the odds of shock and vibration damage. A short Flex Pony directly on top of the PD tool will
increase the maximum dogleg by 1-2 degrees but should only be used if truly necessary.

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
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1.2 Hydraulics
1.2.1 Optimizing Hydraulics
The Bias Unit uses the mud flow to activate the steering
pistons or pads, exerting a side force on the bit. This
operational principle requires a pressure drop between the
steering unit and the annulus, which can be achieved by a
combination of bit nozzling and a flow restrictor inside the
steering unit.
The amount of steering force is proportional to the
differential pressure across the pistons or pads. Insufficient
piston or pad pressure will result in a reduced BHA steering
response, and excessive pressure will increase the risk of
causing damage to the tool. The following table should be
used when optimizing hydraulics.
Recent US Land experience has shown that excessive
pressure with Orbit may also lead to reduced steering
response by breaking down the formation rather than
pushing off of it. For this reason, it is advised to stay in the
green or lower-yellow regions unless local experience
suggests that running in the upper-yellow range is truly
necessary.
1.2.2 Pressure Calculator on the PowerDrive App
The Pressure Calculator on the PowerDrive App should be used during
the planning stages and on the rig for real-time hydraulics adjustments.
PD2is the old hydraulic calculation method, it requires installing a
separate program on a personal computer. The PowerDrive App has
the most accurate output and is the preferred method for calculating
PowerDrive hydraulics.
When planning an Orbit job, it is safe to use 0.08 mm as a default ball-
sleeve radial gap. But the DD’s must be sure to re-run hydraulics once
they know the gaps for their specific tool. These can be found on the
first page of the PD Outgoing Systems Test (OST) paperwork. Entering
incorrect ball-sleeve gaps can lead to inaccurate pad pressures.
Request the calculated bearing loss from the motor vendor for all mud-
lubed or sealed bearing motors. Be sure the motor vendor considers
the mud properties and higher than normal pressure drop below the
motor when providing their estimate. These should be entered into the
PowerDrive App for accurate pad pressure calculations. “Sealed”
Bearings may have more leakage than mud-lubed bearings. It is
suggested to request new radial bearings when ordering motors to
avoid excessive leakage. Some motors may leak over 25% fluid and
still meet the vendor’s re-use criteria.
The PowerDrive App is color coded as shown in the top image to turn
green when the pressure drop is within the optimal range. The
pressure drop will increase/decrease as the nozzle sizes are changed
or a flow restrictor is added. Important: The number of nozzles and
their sizes must be reflected on the downhole setup of the bit.
The Pressure Drop Chart can be utilized while drilling to update the
Real-Time Pressure Drop across the PowerDrive. This is critical as the
Mud Weight, Pump Rate and Total Leakage change during a run. It is
important to maintain a Pressure Drop in the green zone as these
parameters change.

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
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1.2.3 Flow Restrictor Use and Availability
If the desired pad pressure cannot be achieved by nozzling the bit alone, a flow restrictor can be used.
A PowerDrive Flow Restrictor provides additional pressure drop at the RSS tool to increase pad
pressure and force without affecting the bit TFA. PD2includes the ability to suggest a flow restrictor
size to achieve a desired pad pressure. Be sure to verify the suggested size is available in the standard
restrictor kit list below.
475 Restrictors (x/32“) - 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20, 22, & 24
675 Restrictors (x/32“) - 16, 18, 20, 22, 24, 26, 28, 30, & 32
900 Restrictors (x/32“) - 26, 28, 30, 32, 34, 36, & 38
1.3 Magnetic Material Removal
Magnetic material present in the mud is highly detrimental to the performance of the PowerDrive control
unit. Magnetic material passing through the torquers causes excessive friction and can lead to toolface
stability issues or complete torquer jamming. To mitigate magnetic material related issues, it is
mandatory to run ditch magnets in the circulating system and clean them at least twice daily.
Ditch magnets should be installed in the flow line, header tanks, and/or possum belly of the shale shakers.
Ditch magnets should be installed and cleaned prior to picking up PowerDrive to ensure the tool is
introduced to a clean system. When adding pre-mixed mud from an outside source, efforts should be
made to run that mud across the magnets prior to pumping it downhole for the first time.
1.4 Tool Specifications
Specifications
PowerDrive X6
PowerDrive Orbit
475 X6
675 X6
825 X6
900 X6
1100 X6
475 Orbit
675 Orbit
Mechanical
Nominal OD, in
4 3/4
6 3/4
8 1/4
9
11
4 3/4
6 3/4
Overall Length, ft
13.65
13.47
13.84
13.84
15.22
13.5
53
Hole Sizes, in
6 - 6 3/4
7 7/8,
9 7/8
10 5/8 –
11 5/8
12 ¼ –
18 1/2
20 - 28
6, 6 1/8,
6 ¼, 6 3/4
8 1/2,
8 ¾, 9 7/8”
Bit Speed, rpm
0 - 220
0 - 350
Max WOB, lbf
31,000
180,000
270,000
370,000
225,000
31,000
180,000
Max Torque on Bit, ft.lbf
9,000
18,500
45,000
45,000
70,000
9,000
18,500
Max Overpull, lbf
340,.000
1,100,000
1,100,000
1,800,000
2,500,000
340,000
1,100,000
Pass Through DLS (Sliding)
30
16
12
10
4
30
16
Bit Connection
3 1/2 Reg
4 1/2 Reg
or
6 5/8 Reg
6 5/8 Reg
6 5/8 Reg
or
7 5/8 Reg
7 5/8 Reg
3 1/2 Reg
4 1/2 Reg
Hydraulics
Flow Range, gal/min 1
120 - 310
210 - 970
280 - 2,000
280 - 2,000
280 - 2,000
170-310
210-970
Max Sand Content, %
1
Max Low Gravity Solids, %
8
Max LCM Material, ppb 2
35
50
50
50
50
35
50
Acidity, pH
9.5 - 12
Oxygen, ppm
1
Pressure &
Temperature
Max Temp, F
302
Max Pressure, psi
20,000
Measurements
Inclination Offset to Tool
Bottom, ft
6.76
7.13
7.60
7.70
9.00
6.93
7.19
Azimuth Offset to Tool
Bottom, ft
8.86
9.33
9.80
9.90
11.20
9.03
9.39
Gamma Ray Measurements
Average & 4-Bin
Average & 8 or 4-Bin API
Gamma Ray Range, cps
0 - 1,000
Shock Range, gn
0 - 625
Shock & Vibration Axis
Triaxial
Automation
Automated Loop
Inclination
Inclination & Azimuth
Downlinking Method
Flow & RPM
Specification Notes:
1. The Operating Envelop is heavily dependent on mud weight. Heavier mud allows for a lower
minimum flow rate. Be sure to consult the tool-specific paperwork to acquire the critical flow rates
for each tool.
2. Fibrous LCM such as cotton seed hulls and cedar fiber should be avoided entirely to prevent filter
plugging and flow kit jamming.

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
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2 Tool Preparation
2.1 Reviewing Tool Paperwork
The Rotary Steerable Outgoing Systems Test (OST) paperwork is a valuable document for the Directional
Driller. This paperwork will be provided by the Extreme Equipment Rental coordinator by the time tools
arrive on location. If not, contact the coordinator with the tool serial number so that the correct paperwork
can be provided. The tool serial number is stamped in the junk slot area of the bias unit, between two of
the PowerDrive pads as shown below.
2.1.1 Tool Configuration
The OST paperwork is full of information, not all of which is useful to the DD. Below is a list of the few
critical things to verify from each section. A PowerDrive should NEVER be picked up without first
verifying the tool is configured to meet the requirements of the job
Tool in Control Collar Load Out Sheet
1. Hole Size –This must match the hole size.
2. Bias Unit Serial Number and Type –Verify the BU type and serial number match what you have.
3. Orbit Ball/Sleeve Gaps –Enter these values into PD2as previously described in section 1.2.2.
Field Information Sheet
4. Battery Expiration –This is only relevant in the
rare event that the client needs recorded mode
gamma logs. PowerDrive does not use the
battery for normal operation.
5. RealTime Transmission –If running a MWD
capable of transmitting PD data, confirm this does
not say “Non RealTime” or “NRT”.
6. Gamma –Verify the tool contains a gamma
sensor if logging is planned.
4
5
6
PD Serial Number

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
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PDCU-xx Tool Configuration Report
7. Tool Firmware Version –The tool firmware version is entered into the downlink timing sheet
because different versions have different downlinks available.
8. Downlink Bit Period –The bit period the tool is initially configured to accept. Remember, the tool
will always accept 60 second bit period regardless of whether it’s in 18 or 36 second mode.
9. Desired Steering Mode –If PowerV, a specific downlink sequence must be sent to “unlock” the tool
and allow deviation from vertical. See section 3.8 for more details.
10. Desired Toolface –Initial Toolface setting. Typically, 0 or 180.
11. Desired Steering Ratio –Initial Steering Ratio. Typically, 0% (neutral) or 100% (PowerV Lock).
12. Desired Toolface Mode –Initial Toolface mode. Typically, Gravity.
7
8
9
10
11
12
13

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
Page 8 of 35
13. Uplink Type –Use the following Compatibility Matrix to determine what MWD receiver the
PowerDrive is compatible with.
MWD
Receiver
Uplink Type
Notes
Standard ShortHop
Extended ShortHop
Flex ShortHop
Clink
Extended Clink
Flex CLink
ShortHop
Yes
Yes
No
No
No
No
X-Hop
Yes
Yes
No
No
No
No
Confirm MWD is configured to receive &
send Standard, Extended, or Flex data or
communication issues will occur.
H-Hop
Yes
Yes
Yes
No
No
No
C-Link
No
No
No
Yes
Yes
Yes
CLPS
No
No
No
Yes
Yes
No

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
Page 9 of 35
2.1.2 Flow Loop Results
Purpose
The Flow Loop Analysis provides the critical flow rates for each specific tool and allows the DD to adjust
these rates depending on mud weight as the run progresses.
Flow Loop Analysis Verification
1. Mud Weight –Minimum flow and tool turn on rates are dictated by the flow loop results as well as the mud
weight. The higher the mud weight, the more torque that will be exhibited on the flow kit, and the lower flow
the tool can handle. If this is not within 0.5 ppg of the planned or current mud weight, the operating envelop
on the following page should be used to adjust these critical flow rates.
2. Maximum Drilling Flow Rate –Damage or toolface instability can occur if pumping above this rate.
3. Density Corrected Minimum Drilling Flow Rate –Never pump below this flow rate if drilling. Try to stay at or
above this flow rate as much as possible when circulating off bottom to avoid torquer jamming.
4. Density Corrected Minimum Tool Turn on Flow Rate –This is the flow rate at which the control unit will turn
on and record data. While the tool will be on, it cannot steer nor is it cleaning as optimally as it is when flow
is kept above the Minimum Drill Flow [4] and therefore the risk of torquer jamming is higher. Never go below
this value when downlinking or the tool will turn off and the downlink will be dropped.
1
2
3
4

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
Page 10 of 35
2.1.3 Operating Envelope
The Flow Loop Analysis provides the critical flow rates for each specific tool and enables the DD to
adjust these rates depending on mud weight as the run progresses. The operating envelop contained
in the OST package is specific to that particular tool and is based on the torque measurements taken
while flowing that tool in the shop. The DD must be careful to use only the Operating Envelop that
matches the exact tool being run since all tools have slightly different ranges.
PowerDrive’s steering performance is based upon a balance of frictions. Internal frictions exist within
the tool’s many bearings and assemblies which the tool must be able to overcome in order hold a
steady toolface. This is determined by the Torque output from the flow kit. As mud weight increases,
the flow kit generates more torque. Therefore, the tools minimum flow rates will decrease with
increasing mud weight.
Before picking up tools, the DD must refer to the specific tool’s Operating Envelop and adjust
the minimum flows accordingly. This is especially important if a tool was transferred from a
different job with different mud weight. If the mud weight is less than what the tool was
originally planned for, its minimum flows will be higher. If the flow rates are not adjusted for
mud weight, there is a high probability of tool failure due to insufficient torque.
1. Telemetry, Not Drilling Zone: This region can only be used for downlinking (Telemetry) off-bottom. The tool
cannot generate enough torque to hold a steady toolface in this range and therefore drilling cannot be done
at flow rates below the “Min Drilling Flowrate”.
2. Drilling and Telemetry Zone: This region can be used for both downlinking (Telemetry) and Drilling.