Extreme Networks PowerDrive Orbit User guide

Extreme Equipment Rentals
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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
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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.

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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.

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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.

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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

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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

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Extreme Equipment Rentals
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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
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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

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Extreme Equipment Rentals
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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.

PowerDrive Orbit & X6
Quick Operations Guide - rev1.4
Extreme Equipment Rentals
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2.2 Flow Restrictor Installation
Assembly of the Flow Restrictor is
dependent on the size of the body.
The 475 uses a threaded lock-nut to
hold the nozzle. This set is then
inserted through the base of the
housing and tightened. The 675 uses
a threaded nozzle that is inserted
through the base of the housing. The
900 requires the nozzle to be fitted to
the top of the body and a lock-nut is
then torqued down to secure it. All
connections on the restrictor
assemblies should be hand-tight.
Over-tightening can lead to cracks
and washout of the restrictor, housing,
or Bias Unit.
The Flow Restrictor sits in the base of
the bias/steering unit and is held in
place by a set of O-rings and secured
by the Bit Pin. It should be inserted
just prior to making up the bit and
removed immediately on breaking off
the bit post run to prevent thepotential
of loss into the open hole.
Flow Restrictor Assembly / Installation Steps:
1. Ensure that the nozzle O-ring has been fitted inside the restrictor body. Not applicable for 900.
2. All nozzles must be fitted in the correct orientation as shown in the assembly schematics above.
3. The nozzle retainers should only be hand-tight. Overtightening will lead to cracking and washout.
4. Ensure that the two O-rings on the OD of the body are in place and undamaged.
5. Insert the restrictor assembly into the “Bit Box” of the PowerDrive Bias Unit. If necessary, the slide
hammer can be used to gently tap the restrictor into place. Do not use excessive force with the slide
hammer or it may be damaged, preventing it’s use for housing removal at the end of the run.
6. Install and torque the bit.
2.3 BHA Makeup
Torqueing the Bit:
•Tongs should be placed ABOVE the PD pads/kickers when torqueing the bit.
•Never place tongs on the pads or kickers of the bias unit.
Torqueing the Collar:
•Do not place tongs, slips, or collar clamps on any recesses in the PowerDrive control collar including
anchor bolt holes.
•In general, tongs should be placed at least 12” from a box, and 6” from a pin connection.
2.4 Surface Testing –Not Advised
It is not recommended to surface test PowerDrive under normal circumstances. The surface test often
gives inconclusive results due to magnetic interference from the rig or improper testing procedure. Emag
communications can also be intermittent or completely lacking due to interference. The surface test can
also cause drilling fluid to overrun the stack and create an environmental issue for some clients. The
only time a surface test might be performed is in the event of re-running a tool. This will be covered in
Section 3.8.
675
Restrictor
900
Restrictor
◼Green = Nozzle
◼Orange = Jam Nut
◼
Grey = Housing
◼Black = O-Rings
475
Restrictor

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3 Job Execution
3.1 Tripping In / Filling Pipe
There are no PowerDrive-Specific requirements on how frequently to fill pipe while tripping in.
When filling pipe, it is advised to break circulation and pump at the tool’s Minimum Drill Flow for 5-10
minutes. This will help prevent the torquers from jamming with solids or metallic debris before reaching
bottom. This is especially critical with mud weights above 12 ppg or when used mud has recently been
added to the active system from an unknown source.
Be aware that when PowerDrive is run below a motor, any circulation will result in rotation of the
PowerDrive and any other BHA components located below the motor. Use caution and monitor shock
and vibration in this scenario, especially while inside casing.
3.2 Reaming / Back-Reaming
During reaming operations, the drill string has greater freedom of motion as it is not constrained by WOB.
With this greater freedom of motion comes a greater potential for Shock damage. If running with
RealTime PowerDrive Communication, pay close attention to the PD’s shock & vibration measurements.
MWD shock sensors are mounted up the string and may see reduced shock amplitudes due to their
distance from the bit. Reaming at low rpm reduces the energy in the system, decreasing the amplitude
and the number of shocks to the tool. It is recommended to rotate as slow as is practicable to achieve
the necessary hole cleaning effects of reaming.
Reaming in the hole:
In certain formations, it is often necessary to ream small sections while running in the hole. For longer
sections of reaming such as a curve that was drilled with a slick BHA, suggest a separate, stabilized
reaming run prior to picking up PowerDrive.
If a short period of reaming is necessary while running in the hole:
•Reduce flow to the PowerDrive’s Minimum Drill Flow. This will reduce pad pressure significantly
but still allow for adequate cleaning of the torquers to prevent jamming.
•Be sure to ream at a high penetration rate to avoid forming a ledge and inadvertently sidetracking.
•Set the PowerDrive (TF/%) as if you were drilling this section to prevent an accidental side track.
oIf reaming a curve with DLS greater than 8 deg/100 ft, set the tool in 0/100%.
oIf reaming a lateral, set the tool in 0/25%.
oFor all other scenarios, select the setting that would achieve the DLS of the section being
reamed.
Back-reaming:
Ordinarily, back-reaming should not be planned into the drilling program. On occasion, offset well
experience may show that plastic formations flow or swell and constrict the wellbore after a given period
of time. In these cases, regular wiper trips and back-reaming may be unavoidable. In many other cases,
back-reaming is not effective and can actually consume rig time and damage the wellbore and/or our
BHA components.
If back-reaming becomes unavoidable:
•Drill the stand down, pick up off bottom, and reduce the rpm to approximately 40 to 60 rpm.
•Reduce flow to the PowerDrive’s Minimum Drill Flow. This will reduce pad pressure significantly
but still allow for adequate cleaning of the torquers to prevent jamming.
•Monitor real-time shock and vibration levels from the BHA and monitor the annular pressure readings
if available.
•Slowly start backreaming while continuously monitoring real-time data.

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3.3 Casing Drillout
When drilling out the shoe, keep in mind that Cement Plugs, Float Collar, Cement and Shoe Track are
very different materials compared to the formation intended to drill. The bit is not designed to drill this
material, especially when drilling in a soft rock environment where bits with low blade count and big
cutters (aggressive design) are used.
The real-time shock and vibration levels should be actively monitored, and steps taken to mitigate shock
and vibration levels. The stick slip measurements use the tool’s magnetometers to detect collar rotation,
so the measurement will be unreliable inside the casing. Stick slip can still be detected on surface from
erratic and cyclic torque and RPM readings
The following guidelines for drilling out of the casing shoe and rathole should be followed:
1. Inclination hold mode or HIA mode must not be used while drilling out the casing shoe.
2. During the drilling of both the shoe track and the shoe, the flow rate should be reduced to
approximately 75% of planned drilling flow (yet above the minimum drilling flow rate of the Control
Unit). This reduces the pressure drop across the Bias Unit seals and limits the degree of contact
between the pads and the casing.
3. Rotary speed should be limited to approximately 60 rpm while inside the casing string to minimize
shock and vibration.
4. Start drilling Float equipment with medium RPM and low weight. Watch shock and vibrations and
adjust parameters accordingly. Slow down whenever a material change is expected. Watch
shakers for pieces coming up. Always use float equipment with a locking feature to assist in drill
out.
5. Increase the rotary speed only when the uppermost stabilizer is out of the shoe and into new
formation.
6. When drilling through the casing shoe and the larger diameter rathole, the BHA is unconstrained
and is susceptible to extremely high shocks. This can lead to catastrophic hardware failures.
Monitor shock and vibrations closely as soon as you start drilling. Manage this problem by
monitoring shocks and keeping the RPM as low as practicable until all the stabilizers have entered
the newly-drilled gauged hole.
3.4 Downlinking
3.4.1 Downlinking Basics
Downlinking is the method by which a directional driller communicates with the PowerDrive tool to
change steering settings. PowerDrive X6 and Orbit can accept both Flow and Rotary downlinks. Flow
downlinks are sent by varying the flow rate between high and low levels, typically 20% variance. Rotary
downlinks are sent by varying the surface RPM between high and low levels. The variance for Rotary
downlinks must be at least 40 RPM.
Warning: When sending Rotary downlinks to X6, the downlink timing sheet will need to be “tricked” by
selecting Orbit. This is because X6 outside of the U.S. cannot accept rotary downlinks.
There are 3 different bit periods available when sending downlinks. 18 second, 36 second, and 60
second. Just as a pulse MWD system might require slower and larger pulses as depth and mud weight
increase, PowerDrive may require larger bit periods and greater variations in flow as depth and mud
weight increase. The typical downlinking times are as follows. They may be longer if downlinking
immediately after a connection:
Bit Period Downlink Time
18 Second →4:57 minutes
36 Second →9:54 minutes
60 Second →16:30 minutes

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At any time, PowerDrive Orbit and X6 can detect the following downlinks:
•Flow Downlink at 18 or 36 seconds. Verify the initial setting using the Tool Paperwork
•Flow Downlink at 60 seconds
•Rotary (RPM) Downlink at 36 seconds
•Rotary (RPM) Downlink at 60 seconds
If sending several downlinks in a row, such as when kicking-off from vertical or when nudging up several
degrees, the following waiting times between downlinks must be followed:
Bit Period Waiting Time
18 Second →1.5 minutes
36 Second →3 minutes
60 Second →5 minutes
3.4.2 Sending the Downlink
The PowerDrive App is currently the only supported method to downlink to PowerDrive. It is
recommended to have your phone in airplane mode during a downlink to minimize interruptions. To
send a downlink, the following steps must be followed:
1. Open the App and select the “Downlinks” button
2. Select the Tool Type and manufacture code as verified on the OST
3. Select the Downhole Software Version
4. Select the CURRENT tool mode (Manual Toolface, IH, HIA, PowerV)
5. Select the downlink type (Flow or Collar RPM)
6. Select the Bit Period
7. Select Yes or No whether the tool has been powered up for 3+ minutes
8. Select the desired downlink. Note the manual settings can be found by clicking the “Choose TF
and SR Command” button.
9. Enter your high flow/RPM rate and then select one of the options for the low rate. Note these
high/low rates and ensure they are used for the entire downlink.
10. Click “Start Timer”
11. Follow the on-screen timing commands for high/low rates through out the duration of the
downlink. Note, if the downlink is stopped for any reason you will need to wait through the quiet
period which the timer in the App counts down.
12. Once the sequence has been completed, type the current depth. If Real-Time Communication is
available from the PowerDrive, confirm downlink acceptance using PDSTEER as shown on the
screen. Click “Done”
13. The next downlink cannot start until the required wait time has been completed.

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3.5 Kicking Off from Vertical
PowerDrive tools can be used to kick off from any inclination with extensive experience in vertical
kickoffs. The following points must be considered when kicking off from vertical:
1. Make any azimuth corrections early, as large changes can be made easily at low inclination
2. Do not work pipe close to bottom on connections to avoid wiping out initial build-up doglegs. Minimize
hole enlargement
It is recommended that you initiate the kick-off in MTF mode at 100% steering ratio, and then change to
GTF mode when the hole inclination is at least 2°. It is common to switch over to GTF mode when the
inclination is 6°-8°.
3.6 Inclination Hold (IH) & Hold Inclination and Azimuth (HIA)
3.6.1 Inclination Hold (IH)
Inclination hold is a PowerDrive steering mode that allows the tool to steer at a target inclination. This
feature is designed to drill in tangent and horizontal sections and hold an inclination while reducing the
overall downlinks that the Directional Driller will need to put in. While in this steering mode azimuth is
adjusted through corrections by incrementally increasing the steering ratio in either the left or right
orientation. Inclination Hold cannot be used under 3° inclination. Between 3° - 10° inclination it can be
used cautiously. Above 10° inclination is the normal operating range.
Before engaging Inclination Hold, you must obtain a good static survey to give you an accurate
reference inclination.
1. Go off bottom
2. Stop rotation
3. Cycle the pumps to reset the tool (bring the pumps down and back up again)
4. Wait at least 3 minutes for a static survey to be taken
5. Downlink to engage Inclination Hold using one of the following three sequences
When in Inclination Hold (IH) mode, the inclination can be adjusted in steps (nudges) of 0.5°:
•Downlink command 2-22 will nudge the inclination target up by 0.5°
•Downlink command 2-23 will nudge the inclination target down by 0.5°
When you use IH mode the tool will slowly approach the target inclination. When a single nudge is
applied, it adds 0.1° per drill cycle, so it will take 15 minutes before the full 0.5° nudge will take effect.
If two nudges are sent at the same time, it will add 0.5° in the first drill cycle and then add 0.1° during
the next five drill cycles. If three nudges are sent at the same time, it will add 1.0° in the first drill cycle,
and add 0.1° during the next five drill cycles.
When in Inclination Hold (IH) mode, the azimuth turn correction can be adjusted in steps:
•Downlink command 2-18 will increment the azimuth turn correction (more to the right).
•Downlink command 2-20 will decrement the azimuth turn correction (more to the left).
Put in azimuth turn correction while in inclination hold
To turn the tool to the right while in inclination hold, send command 2-18. The tool will turn in +12.5%
steering ratio increases for every command sent to a maximum of 50%. To turn PowerDrive to the left,
send command 2-20 and just like the right-hand turn, the tool will increase the steering ratio 12.5%
each time. PowerDrive will continue to turn until the turn correction is taken out. The following figure
shows two 2-18 commands being sent to the tool increasing the steering ratio 25% to the right:

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Note:
In Inclination Hold mode:
•You cannot make small changes to the tool’s Steering Ratio or TF azimuth angle.
•You can only steer the tool left or right by increasing or decreasing the SR in steps of 12.5%.
•The maximum SR is 50% of the tool’s maximum build rate.
Change turn correction left to right while in inclination hold
When in inclination hold the tool can be steered left to right using a series of commands. Command
2–17 is used to bring the tool back to the 0% turning position. The turn correction right command 2-18
is then used to steer the tool right. You do not have to send multiple 2-18 commands to get the
tool back to 0%. Sending command 2-17 will always bring the tool back to 0%.
Reduce turn correction while in inclination hold
When in inclination hold the turn correction can be reduced. For example, if you are drilling with 50%
turn correction to the right, you can reduce the turn correction by sending a turn correction left downlink
sequence. The turn correction will be reduced by 12.5% for every turn correction left downlink sequence
you send. The following figure shows the tool starting at 50% turn correction to the right, then two 2-20
commands are sent to the tool to reduce the turn correction to 25% right:
Disengage Inclination Hold
To disengage Inclination Hold mode you must send any absolute steering setting, commands 1-0 to 2-
12 from the Manual Downlink command list. The increase/decrease toolface and increase/decrease
steering ratio do not disengage inclination hold.
After inclination hold is disengaged, the tool will remain in GTF mode.
3.6.2 Hold Inclination and Azimuth (HIA)
Hold inclination and azimuth (HIA) provides simultaneous closed loop control of inclination and azimuth
which can be used to drill in laterals, tangents and low DLS profiles. HIA will not engage at
inclinations of less than 10° or more than 170°. This steering setting can be downlinked using
command 2-30. When engaged, HIA will ‘hold’ the inclination and azimuth captured at the last good
PowerDrive static survey.
While engaged in HIA, target inclination and target azimuth can be nudged independently. Inclination
is weighted more than azimuth, which means the tool prioritizes inclination over azimuth if it is aiming
for both.
Before you engage HIA you must do a static survey to obtain accurate references for inclination and
azimuth. It is recommended you do the steps that follow:
1. Pull the tool off the bottom.

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2. Stop the tool rotation
3. Cycle the pumps to take a survey.
4. If available, check for a good static survey by monitoring INCL_b and AZIM_b. If they deviate
significantly from their acceptable values, then either continue in manual mode or do the survey
again.
5. Send downlink command 2-30 to engage HIA. Note: Tool will switch to GTF after it engages HIA
6. If available, monitor IH_TRGT_b and AZI_TRGT_b to make sure they are acceptable. If they are
not correct, then disengage HIA and then either continue in manual mode or do the survey again
and engage HIA again.
Nudge the Inclination
The target inclination nudge size is fixed at 0.5°. Use the downlink commands that follow to change the
target inclination:
•2-22:Increase target inclination by 0.5°
•2-23:Decrease target inclination by 0.5°
The inclination nudges are applied over five drilling cycles in steps of 0.1°. If several nudges are sent
then all but the last nudge will be applied immediately, the last nudge will be applied gradually.
Nudge the Azimuth
The target azimuth nudge size depends on the tool’s inclination.
Use the downlink commands that follow to change the target azimuth:
•2-18:Increase target azimuth
•2-20:Decrease target azimuth
The azimuth nudges are applied over five drilling cycles. If several nudges are sent then all but the last
nudge will be applied immediately, the last nudge will be applied gradually
Disengage HIA
To disengage HIA, send an absolute downlink command: 1-0 thru 2-12. Tool will remain in GTF after
it disengages HIA.
3.6.3 Rate of Penetration Ranges
Inclination Hold and Hold Inclination and Azimuth have a downlinkable ROP Index, which can be
changed based on the ROP. The ROP index will define the gain of the Inclination control loop. In some
cases, at high rate of penetration, PowerDrive may oscillate around the target inclination. This
oscillation can cause micro-dogleg, increasing the tourtosity of the well. In this case it is recommended
to reduce the gain by downlinking command 2-21 Low Gain. It is recommended to only downlink
into the Low Gain setting if needed and not based on the actual ROP. If PowerDrive is downlinked
into the Low Gain setting and there is no improvement, then it is recommended to go back to the High
Gain setting.

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3.7 PowerV Lock/Unlock
PowerV mode is a vertical drilling mode using Gravity Tool Face (GTF) with a tool face of 180 degrees
and a steering ratio of 100%. The result of this setting is that PowerDrive will continuously seek to drill
vertical without further input from the directional driller at surface. The tool can either be configured in
PowerV mode at the shop or downlinked to engage PowerV while drilling. When the tool is in PowerV
mode it only responds to the downlink commands given in the following table:
Disengage PowerV
To disengage PowerV mode two consecutive downlink commands are necessary. It is critical that the
time constraints are strictly followed. The image at the end of these steps shows the entire process in its
entirety.
1. After ensuring that the tool has been powered up and the correct quiet time has passed, as shown
in the following chart, send command 2-29, PowerV Unlock/Engage to the tool.
2. Stabilize the stand pipe pressure by keeping steady flow for the quiet period given in the following
table:
3. Send a fixed steering setting command to the tool (1-0 to 2-12). Note: It is critical that this downlink
is started within the range provided in the table.
When the tool disengages from PowerV mode, it engages MTF mode.
Engage PowerV
To engage PowerV mode two consecutive downlinks are necessary. Both commands are the command
2-29, PowerV Unlock/Engage. The two PowerV Unlock/Engage commands must be sent consecutively.
To engage PowerV mode, do the steps that follow:

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1. After ensuring that the tool has been powered up and the correct quiet time has passed, as shown
in the following chart, send command 2-29, PowerV Unlock/Engage to the tool.
2. Stabilize the stand pipe pressure by keeping steady flow for the quiet period given in the following
table:
3. Send command 2-29 again, PowerV Unlock/Engage, to the tool. Note: It is critical that this downlink
is started within the range provided in the table.
PowerV mode is now engaged.
3.8 Sidetracking
All PowerDrive tools can be used to sidetrack a well. Typical sidetrack applications are a cement plug,
either in a vertical or deviated well or an open hole sidetrack, however in the case of an open hole side
track more care is required. Factors affecting the success of a sidetrack are the strength of the cement
plug, the existing hole profile, formation drillability and ensuring that adequate time is taken. Although
successful sidetracks have been achieved at all inclinations, both from cement plugs and open hole,
there are some situations where it will not be possible to sidetrack, such as soft cement and hard
formations.
Sidetrack off a cement plug
All PowerDrive tools can be used to sidetrack a well from a cement plug, either in a vertical or deviated
well. Open hole sidetracks can be performed, but more care is needed. As a guideline, the following
procedure should be used if there is no previous experience of successful sidetracking. Use of real-time
inclination will give an early indication of the progress of the sidetrack. Note: Cement cannot be pumped
though any PowerDrive system. There is a risk of plugging the tool and BHA and causing serious
damage to the internal components.
1. After making up the BHA, and before any circulation is attempted, make sure that the drillpipe is
clean and clear of any cement debris that may have accumulated when the cement plug was being
pumped. Use drillpipe rubber or sponge balls behind the cement when displacing to clean the
drillpipe.

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2. Allow the cement plug adequate time to harden. The cement plug must be of sufficient quality and
quantity. Avoid plugging the bit nozzles by washing down with a minimal flow rate until the cement
is tagged. The flow rate for washing down must be above the tool's minimum flow rate.
3. If the cement plug is not firm, the sidetrack should not be attempted on highside and should be
replanned with a low side exit if applicable.
4. If the cement is of sufficient quality, increase the flow rate and drilling parameters to 75% of normal
drilling levels, and dress off the cement plug to the required kick off depth. The top of the cement
plug will often be of poor quality due to mud contamination in the transition but, will harden with
depth.
5. Make sure that the drillpipe is spaced out to allow the sidetrack to be initiated without having to make
connections. Space should also be left above the sidetrack point to allow the pipe to be worked.
6. Set the tool to a suitable toolface with the maximum steering ratio (100%). Depending on the existing
profile of the hole and proximity to offset casing strings, either magnetic or gravity steering can be
used for the kickoff. Do not use the inclination hold mode or HIA mode for kicking off.
7. If the cement plug is firm and able to take weight, attempt to drill off using normal drilling RPM but
controlled ROP.
a. Control the ROP to 10% of the drilling rate at the same depth in the main wellbore. Maintain
this rate until a clear indication of new formation is seen in the returned cuttings. Do not
increase the ROP until new formation is seen in the cuttings.
b. When new formation is seen in the cuttings, increase the ROP to 30% of the offset ROP
until 60% new formation is seen in the returned cuttings.
c. When 60% of cuttings are seen, increase the ROP to 60% of the offset ROP until 100% new
formation is seen with no more than trace cement.
Note: The time taken to sidetrack will depend on the relative strengths of the cement and formation and
can vary from ten minutes to 24 hours or more.
8. If the cement plug remains soft, consider either waiting for the cement to harden or proceeding with
the sidetrack. More care and patience will be needed in this case. It may be possible to set another
cement plug if the first sidetrack fails.
9. After the sidetrack has been initiated, closely monitor the inclination to avoid excessive doglegs, and
monitor the cuttings for indications that the new hole may have started to track back into the cement
plug.
Open hole sidetracking
All PowerDrive systems can be used for open hole sidetracks to the low side. Use of real-time inclination
will give an early indication of the progress of the sidetrack. As a guideline, the following procedure
should be used if there is no previous experience of successful open hole sidetracking.
•The success rate for open hole sidetracks is dependent on the formation drillability, it may be
impossible to sidetrack if the formation is too hard. Hole inclination also plays an important role.
Open hole sidetracks should only be considered above 70° inclination. Subsequent BHAs and
casing strings or liners will need to pass the sidetrack, making the transition from the original
hole under the influence of gravity.
•Try to choose a sidetrack point with an abrupt change in profile or change in formation. A good
example is the transition between a rotated interval and an oriented interval in a section of hole
previously drilled with a motor. Consult the parameter sheets and plot continuous inclination
against depth to aid choosing an appropriate sidetrack point.
•Choose a sidetrack point as shallow as possible to allow a second sidetrack point to be chosen
at a deeper point, and still achieve the directional objectives.
•Depending on the formation drillability, an open hole sidetrack can take anywhere from one hour
to over 24 hours to initiate. Patience is vital to make sure that the first ledge that is created is
maintained and enlarged as the sidetrack progresses.
•Make sure that the drillpipe is spaced out to allow the sidetrack to be initiated without having to
make connections. Space should also be left above the sidetrack point to allow the pipe to be
worked and the sidetrack transition to be reamed.
•The open hole sidetrack is initiated by creating a ledge on the lowside of the hole. This ledge is
then elongated until the sidetrack deviates completely from the parent wellbore.
•Set the tool to the desired sidetrack toolface (usually lowside) using 100% steering and
commence reaming with high RPM and low ROP. Mark the drillpipe at the sidetrack depth, and