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PUBLICATION:
Power Supply Assembly
MWD SYSTEMS
Maintenance Manual
Revision
Amendment Detail
Revised and updated; includes
2.88"/3.125"tool.
Author Approved
G.Miller
S. Page
PUBLICATION
AMENDMENT
RECORD
Date
08/03/99
PE
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Version:
PSA99
CONFIDENTIAL
GEOLINK 1999
Table of Contents
Pages
Contents
1. Introduction
1.0 Power Section Assembly - General Description ......................................... 1-1
1.1 Physical Description.................................................................................... 1-1
1.2 Functional Description ................................................................................ 1-3
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Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
Introduction
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
6. Parts List
OL
7. Appendix
Index
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7-12
8. Index
CONFIDENTIAL
GEOLINK 1999
List of Illustrations
Pages
Section 1: Introduction
1-1 MWD Down Hole Assembly ...................................................................... 1-2
1-2 Standard Power Section Assembly ........................................................
1-4
1-3 Double-D Power Section Assembly ....................................................... 1-5
Section 2: Workshop Inspection and Assembly Procedures
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CONFIDENTIAL
ii
GEOLINK 1999
Contents
Section 1
Introduction
Workshop
Inspection &
Assembly
OL
AT
Workshop
Maintenance
& Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
PE
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Introduction
Pre-Job
Inspection &
Test
CONFIDENTIAL
GEOLINK 1999
1. Introduction
Contents
Gamma Ray
power packs are
dealt with in the
GRA Operating
and Maintenance
Manual
Introduction
Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
AT
Pre-job
Inspection
& Test
The Standard cartridges are supplied with blue heat shrink and fit inside one
pressure housing. The DD cartridges are supplied as an Upper and Lower pair and
require two pressure housings, one for each cartridge. The upper cartridge (+ve) is
supplied with red heat shrink and the lower cartridge (-ve) with black heat shrink.
Post-Job
Inspection &
Test
Parts List
OL
Appendix
Index
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See Appendix
for return of batteries to Geolink for
disposal.
Like all batteries, the Power Supply Assembly has a finite life which is variable
and is based on the tool operating mode and the total number of pulses. Due to the
physical make-up of the individual battery cells, the battery cartridges must be handled with care. If the cartridges are overheated or ruptured special precautions must be
followed to minimize the potential danger (refer to the Battery Safety Section in the
Appendix).
Once depleted the battery cartridge must be safely disposed of in accordance
with the local regulations in the country of operation.
Both Power Supply Assemblies consist of four main components: The Pressure Housing - machined from BeCu alloy.
CONFIDENTIAL
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GEOLINK 1999
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GEOLINK 1999
The Standard and DD Power Sections contain essentially the same components
(refer to Fig 1-2 and Fig 1-3). However because of the size of the cells the DD pack
requires two each of the above components to make one Power Section. It should also
be noted that apart from the Coupling Connectors and Pressure Housings the Standard
and DD packs are not interchangeable.
In both cases the Battery Cartridge is connected to the Bulkheads and Wiring
Harness. The whole assembly is contained within the Pressure Housing. The Coupling
Connector attaches to the Bulkhead at the bottom of the pressure housing and locks the
assembly to the MWD tool face. When the cartridge is depleted the Bulkheads and
Wiring Harness are reusable.
AT
The PSA supplies all the power required to operate the complete down-hole
assembly.
OL
The output voltage of the PSA is approximately 34 volts total or (+) and (-) 17
volts (Standard and DD packs). Due to the characteristics of the individual battery
cells, the voltage will vary slightly from this figure. Also, the batteries will exhibit a NO
LOAD and a LOADED voltage. It is the LOADED voltage that is of concern to the tool
operation; therefore, when testing to determine the usefulness of a PSA, the voltage
measurement should be made with the correct loading on the PSA.
The life of the PSA is dependent on the selected tool operating mode and the
number of pulses transmitted (refer to Section 3.2). The initial energy capacity (measured in Joules) is dependent on the type of battery assembly selected. The theoretical
energy capacity is given as:-
Introduction
Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
Pre-job
Inspection
& Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Note: the above figures are for battery assemblies made with the standard (150C)
cells.
High Temperature (DD only) assembly - 1.2 M Joules
In practise the actual energy capacity may vary from the theoretical figures.
This variation in battery life is caused by several factors:-
A record of the
energy remaining
in each pack that is
at the rig must be
kept to ensure that
the pack to be next
used has enough remaining energy to
complete the run.
CONFIDENTIAL
Battery life can be calculated at the completion of each run, and the operator can
estimate the battery life required to complete the next hole section prior to the start of
the run (refer to Field Operations Manual and to the Appendix for an example Tool
Hours Worksheet).
1-3
GEOLINK 1999
MWD Downhole
Toolstring (Standard)
D Connector
(70-10-100)
and Harness
AT
(73-23-100)
D Battery Cartridge
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(72-23-110)
PSA Housing
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(23-11-0020)
Coupling Connector
(72-22-220)
O-ring (25-00-018)
CONFIDENTIAL
1-4
GT-ring (25-10-003)
GEOLINK 1999
Introduction
(70-10-100)
DD (Upper) Connectors
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DD (upper) PSA
Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
Pre-job
Inspection
& Test
Post-Job
Inspection &
Test
Coupling Connector
(72-22-220)
DD (lower) PSA
Appendix
Index
DD (Lower) Connectors
and Harness (72-23-030)
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Parts List
Coupling Connector
(72-22-220)
(not to scale)
CONFIDENTIAL
1-5
GEOLINK 1999
Contents
Section 2
Introduction
Workshop
Inspection &
Assembly
OL
AT
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Workshop Inspection
and Assembly
CONFIDENTIAL
GEOLINK 1999
AT
The Standard and DD harness assemblies are easily distinguished by the number
of connectors on the wiring harness. A Standard harness has three connector pins and
a DD harness has one connector pin and one connector socket (refer to Fig 2-1 & 2-4).
In addition, the DD Power Section requires an Upper and Lower harness assembly to
make one complete operating power pack assembly. The Upper and Lower harnesses
are distinguished in the following ways:
a) The Upper (positive) harness will have an A engraved on the top bulkhead
and the Lower (negative) harness will have a B engraved on the top bulkhead.
Introduction
Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
Pre-Job
Inspection
& Test
Post-Job
Inspection &
Test
Parts List
OL
b) The Upper (positive) harness has Red and White wires attached to the small
connectors. The Lower (negative) harness has Black and White wires attached
to the connectors.
Index
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The coupling sub should be removed from the pressure housing. The O-rings,
GT-rings, and back-up rings should be checked for transit damage. The connectors
should be checked for continuity from pin to pin and for any leakage to ground. The
internal edges of the coupling screw holes must be checked to ensure that no sharp
edges or burrs are present which might damage 0-rings. The screw hole threads should
be free from grease and dirt.
Appendix
The battery cartridges are supplied separately as Standard (D) packs (10 cells)
or DD packs (5 cells). Two DD cartridges are required for a DD assembly. The DD
cartridges are identical and may be used for the Upper or Lower assembly. However
once the harness is attached, the Upper and Lower assemblies are not interchangeable.
The cartridges must be checked for signs of physical damage or faulty manufacture.
The assembly procedure is similar for both Standard and DD Power Sections.
Standard battery pack harnesses have a positive and negative power take-off pin and a
central power take-off pin. DD harnesses have a positive and negative power take-off
pin only, but an Upper and Lower harness is required for a complete DD assembly.
Due to wiring differences the Upper and Lower harnesses are not interchangeable (refer to Fig 2-2). The following equipment is required for the assembly process:Tools and Equipment
2-1
GEOLINK 1999
Single-D Cells x 10
Socket x 3
(25-00-008)
+ve
-ve
Lower
Bulkhead
Bulkhead
(not to scale)
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Upper
Connector x 3
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CONFIDENTIAL
2-2
GEOLINK 1999
Razor Knife
1 " Kapton Tape (11-70-001)
Small Pair Needle Nose Pliers
5mm Allen key
Multi-Meter
2 Heat Shrink (Blue or Red and Black)
V-blocks
Introduction
Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
Assembly Process:
AT
a) Each battery cartridge is marked with the positive and negative end. The
battery cartridge should be laid out alongside the wiring harness with the positive end to the top bulkhead on the wiring harness (refer to Figs 2-1 and 2-4).
b) The top and bottom bulkheads should be inserted in the end of the battery
cartridge. The bulkhead slots should be aligned with the channel on the cartridge. Care should be taken not to pull the wiring harness where it feeds from
the connector, or pinch the wiring between the cartridge and the bulkhead.
OL
c) The wiring harness power connectors should be inserted in their corresponding sockets in the battery cartridge. The DD-harness has one male and one
female connector. The Standard harness has three male connectors.
Pre-Job
Inspection
& Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Multi-meter
ISOL/PWR Switch
(not to scale)
PSA Test and Load using the Battery Monitor Box (Fig. 2-3)
d) Before proceeding further the battery voltage must be tested under NO LOAD
and LOAD conditions.This check can be performed with one Standard cartridge but requires both the Upper and Lower DD-cartridges to be joined with a
Coupling Connector or a male-male test cable from the STB2. Connect the IN
side of the Battery Monitor Box to the top bulkhead (positive end of the battery
assembly). A multi-meter should be connected across VB+ and VB- on the
battery test box (refer to Fig 2-3).
e) The initial NO LOAD voltage should be in the range of 34 to 36 volts which
is the voltage over the entire pack.
CONFIDENTIAL
2-3
GEOLINK 1999
DD cells x 5
Socket
+ve
-ve
Bulkhead
Socket
Connector
DD wiring harness
Lower
Bulkhead
(not to scale)
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Upper
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CONFIDENTIAL
2-4
GEOLINK 1999
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h) Re-connect the multi-meter across test points VB+ and VB-. Activate the
LOAD switch on the test box. This places a load across the cartridge(s). In a
new cartridge the initial load voltage may drop below 30 volts but will build
back up towards 33-36 volts (D cartridges will be slower to regain their voltage
levels than DD cartridges). If the cartridge is already LOADED the voltage will
drop very slightly under load but should remain between 33-36 volts across the
pack (refer to fig 2-4). If the battery voltage is too low to operate the BMB on
LOAD (the BMB will make a clicking noise), load the battery by connecting to
a transmitter (in a tool string or via the STB) and operating the transmitter for
half an hour. Re-connect to the BMB and check the voltages on LOAD.
Introduction
Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
Pre-Job
Inspection
& Test
Post-Job
Inspection &
Test
Parts List
OL
i) Check the positive and negative sides (upper and lower cartridges for DD)
under Load conditions as in f) and g) above. The voltage should be between
16.5-18 volts.
Note: The BMB will automatically switch to OFF-Load after 30 minutes. Check
the LED to see if the BMB is loading the PSA or not. If necessary, reset the BMB
and switch to LOAD again.
Appendix
Index
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j) Remove the Battery Monitor Box taking care not to pull on the bulkhead.
Line up the screw holes on the top bulkhead with the holes in the cartridge
housing. Insert the screws and tighten with the allen key, checking for alignment between the bulkhead and the cartridge (the screw holes in the cartridge
may be gently filed to ensure the screws do not protrude). Do the same for the
lower bulkhead (repeat the process for the Lower cartridge in a DD assembly).
k) Lay the wiring harness in the cartridge channel taking care not to overlap the
wires as this may cause the wires to crush during drilling operations. Carefully
bundle excess wire into the storage space provided in the bulkheads.
l) Apply a small amount of RTV 3744 to the top of the power take-off connectors to prevent them from backing out.
m) Secure the wire harness in the cartridge channel using several 2 pieces of
Kapton Tape, starting in the center and working out to the bulkheads.
n) Recheck the battery NO LOAD and LOAD voltages using the battery test
box and multi-meter. This will confirm all the electrical connections are good.
o) Insert the cartridge into the correct colour coded Heat Shrink. The Heat
Shrink is colour coded as follows:Blue - Standard cartridge (and Gamma).
Red - Double-D Upper cartridge.
Black - Double-D Lower cartridge.
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GEOLINK 1999
AT
r) Check the condition of the rubber isolation rings on both bulkheads (chassis buffer
O-rings). Replace them if they show signs of deterioration or damage.
s) Recheck the battery NO LOAD and LOAD voltages (both Upper and Lower cartridges are required for a DD assembly).
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t) The battery batch number and build date should be written on the Heat Shrink with
an indelible marker pen and the batteries should be tagged as ready for field use.
CONFIDENTIAL
2-6
GEOLINK 1999
Contents
Section 3
Introduction
Workshop
Inspection &
Assembly
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
PE
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OL
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Workshop
Maintenance
& Test
Workshop Maintenance
and Test
CONFIDENTIAL
GEOLINK 1999
Introduction
Workshop
Inspection
& Assembly
Workshop
Maintenance
& Test
b) Make sure the screws fixing the cartridge to the bulkhead are tight.
AT
c) Check both electrical connectors (10 pin connector) for damage. Look for
pushed or bent pins.
d) Check both electrical connectors for tightness and alignment. Ensure the set
screws holding the connector in place are tight. If any set screw is found to be
loose remove, clean, and replace using Loctite242. Do not over tighten the
set screw or this will pinch the connector.
OL
e) Check the battery voltage under NO LOAD and LOAD conditions (refer to
sections 2.2 and 3.1 for details).
f) Remove the Coupling Connector from the pressure housing. Check the ten
pin connectors for damage. Look for pushed or bent pins.
g) Check both electrical connectors on the Coupling Connector for tightness.
Ensure the set screws that hold the connectors in place are tight. If any set screw
is found to be loose remove, clean, and replace using Loctite242. Do not over
tighten the set screw or this will pinch the electrical connector.
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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h) Check the Coupling Connector for continuity between both electrical connectors, leakage to ground and for leakage between pins.
i) Check the O-rings and GT rings for damage (refer to Geolinks manual, Care
and Protection of Seals).
j) Clean the Coupling Connector screw holes. Remove any dry Loctite with a
cotton swab. Inspect the screw holes for sharp edges or burrs that might cause
damage to the O-ring sealing areas.
k) Inspect the half-shells for washing. Replace if damaged.
The PSA must be fully LOADED and tested before being passed for field operations. LOADING removes the passivation layer which is present in used and unused Lithium batteries. The same test procedures should be used when a PSA has been
returned from the field irrespective of whether the batteries are depleted or not.
Battery Test Procedures:
a) With the PWR/ISOL switch in the ISOL position, attach the IN side of the
Battery Monitor Box to the positive end (top) of the battery assembly. In the
CONFIDENTIAL
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GEOLINK 1999
Test Points
NO LOAD
With LOAD
after 5 minutes
Negative Side
Whole Pack
1&3
4&6
1&6
17 - 18 V
17 - 18 V
34 - 36 V
15 - 17 V
15 - 17 V
30 - 34 V
16.5 - 17.5 V
33.0 - 35.0 V
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With LOAD
after 30 minutes
Positive Side
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Standard and
DD Packs
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d) If the battery voltage has not reached the minimum acceptable value disconnect the test
box and remove the heat shrink and Kapton tape to gain access to the Wiring Harness. Check
the Harness for crushed or loose wires. Ensure the connectors are fully seated in the sockets.
16.5 - 17.5 V
e) Re-connect the BMB to the positive end of the battery. Apply the load and let the LOADED
voltage stabilize. If the voltage continues to slowly drop under load the batteries are most
probably fully depleted and the pack should be set aside for disposal.
f) If the voltage stabilizes at some lower value below the acceptable minimum it is probable that one or more cells are depleted or damaged. To check, place the batteries under
LOAD and leave the positive probe from the multi-meter connected to test point 1 and use
the negative probe to step down the battery pack (refer to Fig 3-2). Note that the insulation
must be broken in order to get to the battery terminals. Start with the first battery nearest
the top of the cartridge and keep the probe connected for several seconds until the voltage
stabilizes. Note the voltage and move down to the next battery in line. The voltage should
increase in almost equal increments as you step down the pack. For example: 3.5v, 7.0v,
10.4v, 13.9v, 17.3v (refer to Fig. 3-2).
g) To check the individual cell voltages disconnect the multi-meter from the Battery Monitor Box. Again step down the pack but this time connect the multi-meter probes between
two adjacent cells and note the voltage. For example: 3.5, 3.4v, 3.5v, 3.4v, 3.5v, 3.5v .
CONFIDENTIAL
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GEOLINK 1999
h) The test performed in f) and g) above will indicate the condition of the battery assembly. If all the cells read the same or similar low voltage the pack is
depleted and should be set aside for disposal. If one or more cells display an
abnormally low voltage while the majority show acceptable voltages this indicates probable mechanical failure of the individual cell(s). The cells must then
be disposed of in an approved manner.
Refer to
the Appendix for
information on
Battery Disposal
Introduction
Workshop
Inspection
& Assembly
Workshop
Maintenance
& Test
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Pre-Job
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Inspection &
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Parts List
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17.5
Multi-meter
Appendix
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Negative Probe
Index
(not to scale)
Geolink use the energy capacity of the batteries, measured in Joules, to monitor
battery life.
In general the theoretical energy capacity of the Power section from the manufacturers specifications is given as:CONFIDENTIAL
3-3
GEOLINK 1999
For Gamma
Ray Assembly
power usage, refer
to the GRA
Operations and
Maintenance
Manual
= 105.6 Joules
AT
= 29.4 Joules
= 17.6 Joules
OL
An estimate of the remaining battery life remaining can be calculated using the following
simplification:JoulesNEW = JoulesOLD - (1872 x Hr. P.I.) - (20.5 x No. Pulses)
where: Hr. P.I. = Number of hours the battery has been plugged in
No. Pulses = Total number of pulses
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For example:
Est. Energy Remaining = 1,000,000 - (1872 x 77) - (20.5 x 36,000) = 117,856 Joules
CONFIDENTIAL
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GEOLINK 1999
Introduction
Workshop
Inspection
& Assembly
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Contents
CONFIDENTIAL
3-5
GEOLINK 1999
Contents
Section 4
Introduction
Workshop
Inspection &
Assembly
OL
AT
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Pre-job Inspection
and Test
CONFIDENTIAL
GEOLINK 1999
Prior to sending a new or previously used Power Section Assembly to the field
the following test operations must be performed:-
Gamma Ray
power packs are
dealt with in the
GRA Operating
and Maintenance
Manual
Introduction
Physical Inspection
Electrical Tests
Final Installation in the Pressure housing with the Coupling Connector
Cartridge identification with energy remaining.
Workshop
Inspection &
Assembly
AT
The battery cartridge assembly must be carefully inspected to ensure that the
upper and lower bulkheads are tight and the heat shrink is undamaged. Check the
alignment of the electrical connectors and readjust if necessary.
OL
The Power sections must be tested under NO LOAD and LOAD conditions (Refer to section 3.1 for full details). If the Power section has been previously loaded the
LOAD voltage should stabilise very quickly to approximately 32-35V across the pack. If
the voltage stabilises at some lower level or continues to fall under LOAD, one or more
of the cells is depleted or damaged and the pack cannot be used. If a battery cartridge is
being rerun the amount of energy used should be calculated and marked on the heat
shrink with an indelible pen (Refer to section 3.2). It is an operations decision whether to
rerun a battery pack and will depend on the following criteria:-
Pre-Job
Inspection &
Test
Post-Job
Inspection
& Test
Parts List
Appendix
Index
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Workshop
Maintenance
& Test
It is not a good practice to re-run cartridges that have already consumed more
than 70% of their estimated total capacity unless the operator has calculated it is safe
to do so based on the history and proposed usage of the pack.
a) The ten pin electrical connector on the Coupling connector should be inserted into the bottom bulkhead connector on the cartridge assembly. The alignment pins on the Coupling connector will ensure the connectors are properly
aligned.
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GEOLINK 1999
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e) Apply a small drop of Loctite242 to the end of a pressure housing screw and insert into
the Power section assembly. Tighten the screw with the Allen key to 12 ft-Ibs. Repeat the
process for the other three pressure housing screws.
f) Place Silica Gel sacs in the open end of the housing followed by rubber protection caps on
the end of the pressure housing and Coupling Connector. Clearly tag the completed assembly
with the content details. e.g. Standard battery assembly, New, Energy remaining: 1 MJ.
g) If assembling a DD Power Section repeat steps 1 to 6 for the second cartridge assembly.
Tape the completed Upper and Lower Double-D assemblies together for shipping to the
field as one DD pack.
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h) Before the Power Supply Assembly is finally passed for field operations, a full string
test must be performed (refer to String Test Manual).
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Note: it is a good idea to load and check the PSA at least 10 minutes before connecting
the tool on the rig floor. This ensures the batteries are pulled up enough to operate the
tool during the shallow test which occurs just a short time after plugging in.
CONFIDENTIAL
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Contents
Section 5
Introduction
Workshop
Inspection &
Assembly
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Workshop
Maintenance
& Test
Post-Job Inspection
and Test
CONFIDENTIAL
GEOLINK 1999
When a Power Supply Assembly is returned from the field it must be checked
regardless of whether it has been used downhole. If the Power Section was unused a
quick physical inspection and a LOAD test should be performed. If the Power Section
passes the checks it should be re-tagged as fully operational and put aside for future use.
Gamma Ray
power packs are
dealt with in the
GRA Operating
and Maintenance
Manual
A Power Section assembly that has been used downhole must undergo thorough testing irrespective of whether there has been any downhole problem.
AT
The Coupling Connector should be disconnected and the battery cartridge removed from the Pressure Housing. The following checks should be carried out:a) Thoroughly clean the Pressure Housing and Coupling Connector. Remove
any old Loctite present in the pressure housing screw holes.
Introduction
Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
c) Carefully inspect the O-rings and GT rings on the Coupling Connector. Replace any O-ring that is damaged or has taken a permanent set.
Parts List
OL
b) Check the housing and Coupling Connector for any signs of washing (replace any half-shells that are damaged).
d) Check the alignment and tightness of both ten pin electrical connectors on
the Coupling Connector. Re-align and tighten if necessary. Do not over-tighten
the locking screws as this will pinch the ten pin connector resulting in difficulty
in mating the connector.
e) Inspect the cartridge assembly for signs of abrasion or damage to the heatshrink.
Appendix
Index
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f) Check the alignment and tightness of the ten pin connectors on the upper
and lower bulkheads. Do not over-tighten the locking screws.
Note: With a DD assembly the Upper and Lower cartridges must be joined with
a Coupling Connector to perform this test.
c) If the battery assembly passes the LOAD test it should reassembled in the
Pressure Housing with the Coupling Connector. Place protective rubber caps
on the end of the Coupling connector and Pressure Housing. Re-tag as partially
used, with the number of Joules remaining, and set aside for future use (see
Appendix for information on storage of new or used battery packs).
d) If the assembly fails the LOAD test the pack is probably depleted or one or
more cells may be internally damaged. To confirm this remove the heat shrink
and perform the step-down test (refer to section 3.1).
CONFIDENTIAL
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Note: Do not attempt to remove the connector without first removing the RTV and be sure
to grip the connector and NOT the wires or solder connections.
CONFIDENTIAL
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Contents
Section 6
Introduction
Workshop
Inspection &
Assembly
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Workshop
Maintenance
& Test
Parts List
CONFIDENTIAL
GEOLINK 1999
The following list details the spare parts available for the customer to service
and maintain the Power Supply Assembly. Except where noted all components apply
to both Standard and Double-D Power sections. Any parts not listed are available at the
Geolink service center only.
Introduction
Workshop
Inspection &
Assembly
Part Number
General Description
11-40-020
11-40-022
11-40-026
11-70-001
13-30-001
Lube, Super O
13-50-002
RTV 3744
20-00-016
20-00-030
23-11-002
23-11-003
25-00-008
O-ring 220
70-30-020
70-50-000
Conversion kit, D to DD
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Workshop
Maintenance
& Test
CONFIDENTIAL
72-23-020
DD Con/Harness No. 1
72-23-030
DD Con/Harness No. 2
72-23-100
D internal harness
72-23-110
D batter y cartridge
72-23-211
DD batter y cartridge
72-23-222
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GEOLINK 1999
Contents
Section 7
Introduction
Workshop
Inspection &
Assembly
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Workshop
Maintenance
& Test
Appendix
CONFIDENTIAL
GEOLINK 1999
7. Appendix
Contents
Workshop
Inspection &
Test
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
AT
Introduction
The Power Supply Assembly of the Orienteer MWD system utilises industry
standard, high energy, long life Lithium batteries. The voltage of these batteries is not
comparable to that of manganese or alkaline batteries. Therefore, never mix batteries of different types or model or chemistry in a battery pack.
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Batteries have a shelf-life of greater than ten years if stored at the manufacturers recommended temperature of 0 - 25 deg. C and in a dry, well-ventilated area. If
prolonged storage is anticipated, batteries should be protected against excessive humidity.
Post-Job
Inspection &
Test
Parts List
Appendix
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The batteries contain a Lithium ( or, in the case of higher temperature rated
cells, a Lithium alloy) cathode immersed in a Thionyl Chloride electrolyte. Lithium is
a metallic element that reacts violently with water, releasing hydrogen gas. Thionyl
Chloride is a toxic organic liquid which, in the presence of water or water vapour,
decomposes into the toxic gases sulphur dioxide and hydrogen chloride.
The individual cells are constructed so as to withstand internal pressures generated during operation and it is important to remember that the cell contents are highly
pressurised at elevated temperatures.
If the batteries should become damaged or ruptured, sulphur dioxide, hydrogen chloride and hydrogen will be released. Should the battery be ruptured to
the extent that the internals are exposed to the atmosphere, Lithium and Thionyl
Chloride saturated carbon would be present in addition to the above.
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GEOLINK 1999
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When the battery cartridges are no longer useable, they should have a normal load applied
to them to deplete them prior to being stored for disposal. A battery is depleted when it reaches 0V
DC under LOAD conditions. Under NO LOAD conditions, the open circuit voltage should stabilise at less than 0.5V DC after one hour. If the voltage recovers, the load should be re-applied for
24 hours or until such time as the voltage does not recover to more than 0.5V.
It must be remembered that the batteries are never 100% depleted and should still be
handled with care in all susequent operations.
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Damaged Power Sections: If the Power Section Assembly has been ruptured or flooded
whilst down hole, it is probable that one or more individual cells is also damaged. Hosing down
the battery assembly will complete any chemical reaction, and will reduce the temperature so that
the assembly can be safely handled and disposed of. Never attempt to open or disassemble a cell
or use undue mechanical force when dealing with the battery cells or cartridges.
Notes:
i) An intact cell or cartridge can safely be immersed in water or hosed down. This is
the best and safest way to deal with it.
ii) If the electrolyte and or/lithium metal is exposed, these materials can be rendered harmless by immersion or hosing with large volumes of water, but there will
be a more or less violent reaction depending on the quantities involved. Personnel
should not approach closer than 20', and the work must be done out of doors
because the water lithium reaction liberates hydrogen which may burn transiently.
iii) If electrolyte is exposed in any significant quantity, protective clothing must be
worn and breathing apparatus may be necessary.
The following procedures should be adopted when dealing with damaged or overheated
battery cartridges:-
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GEOLINK 1999
1.
2.
Work outdoors.
3.
Have correct fire fighting materials to hand (Sodium Carbonate and Lith-X
Graphite powder for extinguishing Class D fires.
Introduction
4.
Wear protective clothing: protective coveralls or lab apron, rubber gloves and
boots, respirator and face shield (preferable over goggles).
Workshop
Inspection &
Test
5.
Hose down the damaged assembly until the chemical reaction is complete
and the assembly has cooled.
6.
Disassemble the PSA. When the damaged cartridge(s) has been isolated,
dispose of in the correct manner.
If these procedures are followed, the risk of explosion or harm from a damaged
battery assembly will be minimised.
7.1.4 Battery Storage
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
AT
Fig. 7-1
Contents
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Due to the chemical composition of the batteries, there are precautions that
must be adhered to when storing the battery cartridges:
New/Re-useable cartridges: cartridges should be stored in a cool (10-25 deg.C),
dry, weatherproof facility. Storage of the cells at temperatures above 32C (90F) could
adversely affect the life of the cartridges. Do not store in direct sunlight.
Parts List
Appendix
Index
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The cartridges should remain in their protective covering until they are ready
for use. This will protect the batteries from possibly becoming part of a short circuit.
Post-Job
Inspection &
Test
CONFIDENTIAL
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GEOLINK 1999
7. Appendix (contd.)
7.2 Appendix B: Safe Handling and Return of Equipment Damaged by
Battery Pack Venting
7.2.1 Introduction
Geolink lithium battery packs, properly used, are a safe and efficient power source designed to operate under today's drilling conditions. However, due to the unpredictable nature of
the drilling operation, from time to time they are exposed to conditions beyond the safe operating
limits and this can result in battery venting or even an explosion.
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When such an incident happens the first priority is the safety of personnel. Lower on the
scale of priorities, but still important, is the recovery of the equipment. This document for Geolink
customers gives guidance on procedures for safe handling of equipment so affected, what is worth
returning and what is not, how to notify Geolink and how to ship the material once Geolink have
agreed to accept it.
Please abide by these procedures for the convenience and safety of both your and Geolink's
employees. If you have any questions or suggestions, please contact Geolink Customer Support in
Aberdeen on one of the following numbers:
+44 (0)1224
+44 (0)1224
+44 (0)7850
778850
772333
786671
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Telephone:
Fax:
Out of Hours:
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Because of the high energy density inherent in lithium/thionyl chloride batteries, the potential for hazardous situations does exist. Most hazards are due to external or internal (caused by
internal or external shorting of the battery circuit) heating of a hermetically sealed battery. Overheating causes liquid electrolyte to expand beyond the volume allowed for in manufacturing,
increasing hydrostatic pressure inside the can, which might cause the battery to burst. Further
heating (well above the rated temperature for the battery) can cause the lithium anode to melt
which, in turn, will react spontaneously with the electrolyte and bring about explosive behaviour.
Please note that a High Temperature version battery pack is available which is capable of
operating to 165C and withstanding temperatures to 180C although this is achieved by a compromise on performance, especially at lower temperatures. Contact Geolink Customer Support
for more information.
When a battery ruptures the electrolyte breaks down into Sulphur Dioxide and Hydrogen
Chloride fumes. In a confined space these fumes can be very irritating and hazardous if they are
breathed at high concentrations. Details can be found on the data sheet attached. In the presence of
moisture (e.g. humidity in the air) these substances hydrolyse to Sulphuric Acid and Hydrochloric
acid respectively. By the time that this has occurred (except for extremely confined spaces) there
is very little hazard. If, however, venting takes place inside a tool there are two further hazards to
consider:
1. Acid residues (and by-products of the acid attack on the internal parts of the tool) will
still be present when the tool is broken out.
2. Despite the fact that there are no hermetically sealed connectors below the transmitter
bulkhead, the combination of heat and rapidly expanding acid gases can cause pressured
CONFIDENTIAL
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GEOLINK 1999
Contents
gas to be trapped in tool sections. This might result in rapid release of gases and
the contents of the tool section once it is broken into.
Finally, any remaining lithium can react with water to produce lithium hydroxide (which is relatively safe) and hydrogen gas, which is highly flammable. However,
exposing a ruptured battery to copious amounts of water in a well-ventilated area will
serve to neutralise the lithium at the same time as dispersing the resulting hydrogen.
7.2.3 Battery Venting at the Wellsite - Identification
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Wellsite battery incidents typically result from exposure of the battery pack to
temperatures or shocks outwith the safe operating range of the cell. Therefore it is
often possible to predict that you have a potential for a problem according to wellsite
operations. Most such incidents result from long periods on bottom without circulation when the circulating temperature has been near the operating limit of the tool
(150C) combined with jarring or other shocks to the drill string. Note that stabilised
bottom hole temperatures are normally in the region of 20C above those recorded by
the MWD tool during circulation. These circumstances will usually occur when the
string has been stuck on bottom for some time. The effects will normally be observed
while breaking out the tool string on surface.
Introduction
Workshop
Inspection &
Test
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
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When the Transmitter/APC combination is parted from the PSA you may observe
damage/blackening in the area of the LEMO connectors and you may smell or observe
acid fumes.
Index
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In extreme cases you may observe the perforation of one or more of the pressure
housings.
Appendix
You may observe that the coupling connector screws are hard to remove and that the
pressure housings appear to be being forced apart. This indicates that pressure may be
trapped inside the tool string.
7.2.5 Battery Venting at the Wellsite - Procedures
Once it is recognised that a battery pack has vented or exploded the first action
is to move all personnel into a safe area. Explain the hazard clearly so as not to cause
undue alarm. Often, the reaction will have stabilised or mud ingress into the tool string
will have neutralised possibly harmful substances by the time the tool has returned to
surface. However, it is possible that remaining cells are still unstable.
Once you have cleared the area, you must make an assessment of the potential
hazard and plan how you are going to deal with it. Once a plan has been established, all
those involved must be fully briefed so that everybody knows exactly what they are
required to do during its execution. Appropriate protective equipment (Acid Gas Filter
Mask, Butyl Rubber Gloves, Chemical Worker Safety Glasses and Chemical Laboratory Apron) should be worn during all procedures. The following are the only recommended courses of action at the wellsite:
1. If the battery incident is recognised from the external appearance of the tool
(e.g. perforation of pressures housings, pressure housings pushing out from
couplers, screws difficult to remove, etc.);
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GEOLINK 1999
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The condition of the battery pack should stabilise once it has had a chance to cool and
water has reached exposed internal components. It would be reasonable to leave the tool for a
minimum of 24 hours from the point at which it was laid down to the point where consideration is
given to moving the equipment. Once the water has been switched off, leave the tool for a further
6 hours. If there are any signs of temperature rise, change in the symptoms of internal pressurisation or other activity that may be associated with battery damage, continue the water flow for a
further 24 hours before repeating checks. The checks can reasonably be omitted in cases where
the battery pressure housing is perforated or the tool has been opened at the ends. No attempt
should be made to dismantle the equipment at the wellsite. This is better done in controlled conditions at base.
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The entire assembly should be dispatched back to base by surface transport. Local regulations concerning shipment of hazardous goods should be observed.
Note: it is very important that personnel dealing with equipment that may have been
involved in a battery venting incident stay clear of the ends of drill collars and pressure
housings. The contained items may be under extreme pressure which can be released
violently.
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Before dismantling a tool string that has been involved in a battery venting incident the
following potential hazards must be recognised:
1) The possibility that some batteries are still live and potentially unstable.
2) The possible presence of acidic gases or by-products.
3) The possibility that gases under pressure are trapped in the tool string. It is surprising how good the seal formed by battery debris and coupling connectors can be.
A plan of action must be drawn up before work starts and everybody involved must be
fully briefed so that they understand their part in the procedure. The work should be carried out in
the open air, if possible, and appropriate safety apparel must be worn.
If, at any point during the process, something unexpected or unplanned for occurs, the
procedure should stop, the area made safe and the plan of action modified according to the new
circumstances.
It is difficult to offer specific advice on how to dismantle a tool in this condition. However,
if there is any suspicion that pressure is trapped in the tool it must be released under controlled
conditions. There is a real danger that uncontrolled release of pressure could result in personal
injury by the release of gases under pressure or flying debris. Any attempts to relieve pressure
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GEOLINK 1999
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Under no circumstances should you attempt to dismantle the actual PSA/Battery Pack involved. This item should be removed to a safe area, immersed in a solution
of Bicarbonate of Soda in water for one week and then sent for packing (in Bicarbonate of Soda) and disposal according to local regulations pertaining to the disposal of
lithium batteries. In the event that the PSA is suspected as being unstable, proper precautions should be taken to ensure that it does not present a hazard to anybody handling the assembly.
Note: it is very important that personnel dismantling equipment that may have
been involved in a battery venting incident stay clear of the ends of drill collars
and pressure housings. The contained items may be under extreme pressure
which can be released violently.
7.2.7 What can be Salvaged?
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Because of the conditions prevailing when battery venting occurs all tool sections, even those which appear to be working and uncontaminated, should be considered as candidates for refurbishment. Pressure housings which have been exposed to
acid gases should be scrapped as the wall thickness may have been affected and 'O'
ring surfaces may be damaged.
The transmitter can almost always be salvaged from a vented battery string
because the high-pressure bulkhead prevents the ingress of venting by-products.
Contents
Introduction
Workshop
Inspection &
Test
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
PE
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Any tool section which displays charring of internal components or heavy contamination by battery by-products should be treated as hazardous waste and disposed
of accordingly.
Tool sections which are only lightly contaminated or apparently uncontaminated can be returned to Geolink for repair/refurbishment. Before they are shipped
they should be placed in a bath of Bicarbonate of Soda solution for 24 hours to neutralise acid residues.
Under no circumstances will Geolink accept vented or exploded battery packs
for salvage. In exceptional circumstances Geolink may be able to arrange for disposal.
Contact Geolink Customer Support before taking any action to move a battery pack in
this condition.
7.2.8 How to Return Contaminated Items
The following procedures must be followed when returning contaminated equipment to Geolink:
1. Fax Geolink with full details of equipment to be returned and its condition.
Geolink will acknowledge with a fax stating whether the equipment will be
accepted for repair or not. Under no circumstances must contaminated equipment be shipped without this acknowledgement.
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GEOLINK 1999
7.2.9 Conclusion
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5. The equipment should be shipped according to local and international regulations pertaining to hazardous goods.
Vented or exploded battery packs can be safely dealt with in all circumstances as long as
the following rules are observed:
1. Safety of personnel comes first.
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2. Make a plan and follow it. If circumstances change, stop, change the plan. Make sure
everybody involved knows his or her part in the plan.
3. Always observe local and international rules and regulations pertaining to hazardous
goods.
4. Always inform Geolink if you intend to ship contaminated equipment for repair.
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5. Use plenty of water to cool the equipment and flush away contaminants.
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GEOLINK 1999
Contents
Lithium
Thionyl Chloride SOCl2
Aluminium Chloride AlCl3
Lithium Chloride LiCl
Physical/Chemical Characteristics
Boiling Point
SOCl2:
Specific Gravity
SOCl2:
Vapour Pressure
SOCl2:
Melting Point
SOCl2:
Vapour Density (air=1) SOCl2:
Solubility in Water
SOCl2:
Water Reactive
SOCl2:
Appearance and Odour SOCl2:
77C
1.63
92mm Hg @ 20C
-105C
4.1
Decomposes
Hydrolyzes to form SO2 and HCl
Colourless to pale yellow; sharp
irritating odour
Extinguisher Media:
Post-Job
Inspection &
Test
Parts List
Appendix
Index
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Pre-Job
Inspection &
Test
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3.
Workshop
Maintenance
& Test
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2.
Workshop
Inspection &
Test
4.
Stability:
Stable
Conditions to Avoid:
Hazardous Decomposition
Products:
5.
Inhalation
Health Hazards:
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GEOLINK 1999
Medical Conditions
Generally Aggravated by
Exposure:
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Respiratory Protection:
Protective Gloves:
Eye Protection:
Ventilation To Be Used:
Other Protective Clothing
and Equipment:
7.
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6.
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Steps To Be Taken If
Or Released:
Waste Disposal Methods:
Precautions To Be Taken
in Handling and Storage:
8.
Transportation Information
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GEOLINK 1999
ICAO or IATA
Contents
Introduction
Workshop
Inspection &
Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
PE
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AT
Workshop
Maintenance
& Test
CONFIDENTIAL
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GEOLINK 1999
CONFIDENTIAL
7-12
TOT.PULS.
TOT.PULS.
JLS. REM.
JLS. REM.
TX
TX
PSA
PSA
GRA
GRA
SEA/SENSOR
SEA/ SENSOR
PSA
PSA
APC
A PC
TRANSMITTER
TRANSMITTER
SE R .N O .
SE R .N O .
D A TE:
P .I.
P .I.
CIRC. SE R .N O .
CIRC. SE R .N O .
D A TE:
P .I.
P .I.
D A TE:
CIRC. SE R .N O .
P .I.
P .I.
CIRC. SE R .N O .
CIRC. SE R .N O .
D A TE:
P .I.
P.I.
AT
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CIRC. SE R .N O .
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B A C K -U P T O O L S
TOTAL PULSES
JOULES REM.
GRA
SEA/ SENSOR
PSA
APC
TRANSMITTER
T O O L IN H O L E
L O C A T IO N :
W ELL N U M B ER :
F IE L D :
O IL C O M P A N Y :
CIRC. SE R .N O .
CIRC. SE R .N O .
D A TE:
E N G IN E E R 2:
E N G IN E E R 1:
F IN ISH D A T E :
ST A R T D A T E :
P .I.
P .I.
CIRC.
CIRC.
GEOLINK 1999
Contents
Section 8
Introduction
Workshop
Inspection &
Assembly
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
PE
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Workshop
Maintenance
& Test
Index
CONFIDENTIAL
GEOLINK 1999
8. Index
Contents
A
Appendix A
Battery Composition 7-1
Battery Handling & Safety 7-1, 7-2
General Battery Information 7-1
Workshop Practices 7-2
Battery Depletion 7-2
Battery Storage 7-3
Shipping and Disposal 7-3
Appendix B 7-4
Personnel Safety 7-6
Return of Equipment 7-4
Safe Handling 7-4
Salvage 7-7
Introduction
Workshop
Inspection &
Assembly
AT
Workshop
Maintenance
& Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
PE
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Pre-Job
Inspection &
Test
H
Health Hazard Data. See Safety Data
High Temperature Cells 1-1
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GEOLINK 1999
8. Index (contd)
I
IATA. See Safety Data
ICAO. See Safety Data
L
Lithium Batteries. See Appendix A: Battery Handling & Safety
Lower Harness (D). See Battery Harness Identification
AT
OL
Output Voltage
DD Assembly 1-3
HT Assembly 1-3
Standard Assembly 1-3
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GEOLINK 1999
8. Index (contd)
Contents
T
Temperature Limit. See Appendix A: Battery Handling & Safety
Transit Damage
Inspection. See Workshop Inspection
Transit Spacer. See Workshop Procedures: Inspection
Transportation Information. See Safety Data
Introduction
Workshop
Inspection &
Assembly
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test
Parts List
Appendix
Index
PE
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OL
AT
Appendix B
Battery Venting at the Wellsite 7-5
Workshop Maintenance and Test. See Maintenance & Test
Workshop Procedures
Assembly Procedures 2-1
Assembly Process 2-3
Load Test 2-3
Tools and Equipment 2-1
Inspection 2-1
CONFIDENTIAL
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GEOLINK 1999