MWD SYSTEMS

Power Supply Assembly

Maintenance Manual
Version Number
Serial Number
Issued to
Date of issue

Copyright Geolink (UK) Ltd.

This Training Manual is supplied in confidence and may not (1) be used for any other purpose than that of its supply, (2) be copied,
reproduced or electronically stored by any means and (3) be communicated to any other person or organisation without specific
written permission from Geolink (UK) Ltd.

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

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Version:
PSA99

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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

2. Workshop Inspection and Assembly Procedures

2.1 Workshop Inspection ................................................................................... 2-1
2.2 Assembly Procedures .................................................................................. 2-1

AT

3.0 Power Pack Maintenance ............................................................................ 3-1

3.1 Battery Test Procedures ............................................................................... 3-1
3.2 Battery Life Calculations ............................................................................ 3-3

4.1 Physical Inspection ..................................................................................... 4-1

4.2 Electrical Tests ............................................................................................ 4-1
4.3 Final Installation in the Housing with Coupling Connector ....................... 4-1

5. Post-job Inspection and Test

Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test

3. Workshop Maintenance and Test Procedures

4. Pre-job Inspection and Test

Introduction

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

6. Parts List

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5.1 Physical Inspection ..................................................................................... 5-1

5.2 Tests on the Battery Cartridges ................................................................... 5-1
Appendix

Parts List ............................................................................................................ 6-1

7. Appendix

Index

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7.1 Appendix A: General Battery Handling and Safety

7.1.1 General Battery Information .................................................................... 7-1
7.1.2Battery Composition ................................................................................. 7-1
7.1.3 Workshop Practices ................................................................................ 7-1
7.1.4 Battery Storage ......................................................................................... 7-3
7.1.5 Battery Shipping and Disposal ........................................................... ..... 7-3

7.2 Appendix B:Safe Handling and Return of Equipment Damaged by Battery

Pack Venting
7.2.1 Introduction .............................................................................................. 7-4
7.2.2 Damage, Products and Hazards associated with Battery Venting.. .......... 7-4
7.2.3 Battery venting at the Wellsite - Identification................................ ........ 7-5
7.2.4 Identifying battery venting is not always straightforward.............. ......... 7-5
7.2.5 Battery Venting at the Wellsite - Procedures ....................................... 7-5
7.2.6 Dismantling the Equipment ................................................................... 7-6
7.2.7 What can be Salvaged? ............................................................................ 7-7
7.2.8 How to return Contaminated Items .......................................................... 7-7
GEOLINK MATERIAL SAFETY DATA SHEET ........................................... 7-9
7.3 Appendix C: Example Tool Hours Worksheet

7-12

8. Index

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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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2-1 Standard (Single D) Battery Assembly ....................................................... 2-2

2-2 Wiring Schematic for Standard Power Section ........................................... 2-2
2-3 PSA Test and Load using the Battery Monitor Box ................................... 2-3
2-4 Double-D Battery Assembly (UPPER)................................................... .... 2-4
2-5 Wiring Schematic, Double-D Power Section .............................................. 2-4
Section 3: Workshop Maintenance and Test Procedures

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3-1 Normal Battery Voltages .......................................................................

3-2
3-2 Testing the Battery Voltages ('Step Down' Procedure)..................... .......... 3-3

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Contents

Section 1

Introduction

Workshop
Inspection &
Assembly

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AT

Workshop
Maintenance
& Test

Post-Job
Inspection &
Test

Parts List

Appendix

Index

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Introduction

Pre-Job
Inspection &
Test

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GEOLINK 1999

1. Introduction
Contents

1.0 Power Supply Assembly (PSA) - General Description

The Power Supply Assembly is the part of the down hole MWD tool string
which supplies power to the Survey Electronics and charges the capacitors in the APC
electronics in order to operate the Transmitter (refer to Fig 1-1). The Power Supply
contains cartridges of high temperature, long life, lithium-thionyl-chloride batteries
(generally known as lithium batteries).

Gamma Ray
power packs are
dealt with in the
GRA Operating
and Maintenance
Manual

Currently, two types of cartridge are supplied by Geolink:-

Introduction

Workshop
Inspection &
Assembly
Workshop
Maintenance
& Test

Standard cartridge - one cartridge section containing 10 single 'D' size

lithium batteries.

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Pre-job
Inspection
& Test

DD cartridge - a pair of upper and lower cartridge sections each

containing 5 DD size lithium batteries.

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

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The individual cells come in three varieties:

a) Standard (D) cells rated to 150C.

Appendix

b) Long Life (DD) cells rated to 150C

Index

c) High temperature cells rated to 165C (DD only).

Note: cells or cartridges of different types cannot be mixed in a downhole tool.

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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.

1.1 Physical Description

Both Power Supply Assemblies consist of four main components: The Pressure Housing - machined from BeCu alloy.

The Coupling Connector - connects the PSA to the SEA.

The Battery Cartridge

The Bulkheads and Wiring Harness

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MWD Down Hole Assembly (Fig.1-1)

(70-00-100 Standard Assembly, 70-00-110 Double D Assembly)

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Transmitter Assembly (70-30-000)

The MWD Transmitter generates a series of mud pulses to transmit the downhole information to the surface. The transmitter is housed inside a specially machined
non-magnetic drill collar or Transmitter Sub.

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Actuator Power Controller Assembly (APC) (70-30-010)

The APC assembly directs the power to actuate the transmitter solenoids for
generation of the mud pulses.

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Power Supply Assembly (PSA) (Standard 70-30-020; Double D 70-30-022)

The Power Supply Assembly supplies power to the down-hole tool utilising
high temperature long-life Lithium Thionyl Chloride batteries. The PSA is available
in Standard, DD and High Temperature versions.

Survey Electronics Assembly (SEA) (70-30-030)

The Survey Electronics section contains triaxial magnetometers, inclinometers, a temperature sensor and control electronics which allow full directional surveying and steering operations over the complete range of 0 deg. to 180 deg.

Note: standard assembly shown in diagram

(not drawn to scale)

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1.1 Physical Description (contd)

Contents

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.

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1.2 Functional Description

The PSA supplies all the power required to operate the complete down-hole
assembly.

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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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Standard Assembly - 1.0 M Joules

DD Assembly - 2.4 M Joules

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

Down-hole operating temperature and temperature cycle history

Use cycle history
Variations in cell manufacture and supplier
Component of total energy dissipated by pulsing or quiescent
consumption (quiescent consumption is energy used supplying power to
the sensors in the downhole tool)

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).

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Standard Power Supply Assembly (PSA) (70-30-020) (Fig. 1-2)

MWD Downhole
Toolstring (Standard)
D Connector

(70-10-100)

and Harness

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Standard (D) Power Supply Internals (no batteries) (72-23-100)

(73-23-100)

D Battery Cartridge

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(72-23-110)

PSA Housing

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(23-11-0020)

Standard (D) Power Supply

Coupling Connector
(72-22-220)

O-ring (25-00-018)

Assembly, Field Ready

(70-30-020)

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1-4

GT-ring (25-10-003)

GEOLINK 1999

DD Power Supply Assembly (70-30-022) (Fig. 1-3)

Contents

Introduction

(70-10-100)

DD (Upper) Connectors

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and Harness (72-23-020)

DD (upper) PSA

DD Battery Cartridge (72-23-211)

MWD Downhole Toolstring (DD)

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)

DD Battery Cartridge (72-23-211)

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Parts List

Coupling Connector
(72-22-220)

(not to scale)

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Contents

Section 2

Introduction

Workshop
Inspection &
Assembly

OL

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Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

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Workshop Inspection
and Assembly

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2.Workshop Inspection and Assembly Procedures

Contents

2.1 Workshop Inspection

Power Supply Assemblies are shipped from Geolink with the battery cartridge
replaced by a transit spacer, to which the upper and lower bulkhead and wiring harness
is attached. It is necessary to ship the cartridges this way (and separately, in special
crates) due to special regulations and procedures regulating the shipment of batteries
(refer to Battery Shipping in the Appendix). The spacer should be removed (and stored
for future transit of battery harnesses), prior to use, and the bulkhead and harness
checked for any damage that may have occurred during transit.

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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.

2.2 Assembly Procedures

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

Battery Cartridge (1x72-23-110, 2x72-23-21, or 2x72-23-222)

(Standard, DD, or Hi Temp cartridges)
Battery Harness (1 x 73-23-020 or 1 x 72-23-020 plus 1 x 72-23-030)
(Standard or DD Upper and DD Lower)
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GEOLINK 1999

Standard (Single-D) Power Supply Assembly

Single-D Cells x 10

Chassis buffer O-ring x 2

Socket x 3

(25-00-008)

+ve

-ve
Lower

Bulkhead

Bulkhead

(not to scale)

Standard Wiring Harness

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Upper

Connector x 3

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Standard (Single-D) Battery Assembly (Fig. 2-1)

Wiring Schematic for Standard (D) PSA (Fig. 2-2)

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2.2 Assembly Procedures (cont)

Contents

Tools and Equipment (contd)

2.5mm Allen key
Contact Cleaner
RTV 3744 (13-50-002)
Super O-Lube (13-30-001)
Batt. Monitor Box (75-50-054)
Heat Gun
Loctite 242 (13-40-001)

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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Standard Power Supply Assembly

Multi-meter

Battery Monitor Box

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.

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DD Power Supply Assembly

DD cells x 5
Socket

Chassis buffer o-ring x 2

Connector

+ve

-ve
Bulkhead

Socket

Connector
DD wiring harness

Lower
Bulkhead
(not to scale)

AT

Upper

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DD Battery Assembly (UPPER) (Fig. 2-4)

Wiring Schematic for DD Power Section (Fig. 2-5)

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2.2 Assembly Procedures (cont)

Contents

Assembly Process (contd.):

f) Reconnect the multi-meter leads across test points VB+ and GND to read the
voltage across the positive side of the pack (or Upper cartridge in a DD assembly). The multi-meter should read between +17 and +18 volts.
g) Re-connect the multi-meter leads across test points GND and VB- to read the
NO LOAD voltage across the negative side of the pack (or lower cartridge in a
DD assembly). The multi-meter should read between -17 and -18 volts.

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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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2.2 Assembly Procedures (cont)

Assembly Process (contd.):
p) Hold the assembled cartridge vertically and use the heat gun to heat the Heat Shrink
while slowly rotating the cartridge. This will ensure an even shrinkage of the Heat
Shrink.
q) When the assembled cartridge has cooled, trim and remove the excess Heat Shrink
just inside both bulkheads using a single, smooth, cut to avoid creating weak points
which may split the Heat Shrink. Be very careful not to damage the wires as the cut
is made across the gap in the cartridge.

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.

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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

AT

Workshop
Maintenance
& Test

Workshop Maintenance
and Test

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3. Workshop Maintenance and Test Procedures

Contents

3.0 Power Pack Maintenance

Regular maintenance of the Power Supply Assembly will help to optimize the
life obtained from the batteries. When the Power Section is returned to the workshop
after down hole use the following checks must be carried out.
a) Remove the battery assembly from the pressure housing and check the Heat
Shrink for visual damage or signs of excessive abrasion. Remove the Heat Shrink.

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.

3.1 Battery Test Procedures

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

3.1 Battery Test Procedures (contd.)

a) (contd.) case of a DD assembly, connect the Upper and Lower cartridges with a Coupling Connector or test lead from the STB2 and attach the Monitor Box to the top of the
Upper battery bulkhead. Use the multi-meter to record the battery voltages.
b) Record the initial NO LOAD voltage from the positive and the negative sides of the
assembly: Positive across test points 1 & 3, Negative across test points 4 & 6.
c) Switch the BMB to PWR. After 5 minutes, record the LOADED voltage for both sides.
If the voltage is not within the accepted range (refer to Fig 3-1), wait an additional 30
minutes and record the voltage reading again (the BMB may switch to OFF-load after 30
mins. in which case it will be necessary to reset the BMB and LOAD the battery again).

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

OL

Standard and
DD Packs

AT

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

Normal Battery Voltages (Fig. 3-1)

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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3.1 Battery Test Procedures (cont)

Contents

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

Battery Monitor Box

(75-50-054)

AT

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

OL

17.5

Multi-meter
Appendix

PE
RF

Negative Probe

Index

Power Section (upper and lower

required for DD battery)

(not to scale)

Testing the Battery Voltage - Step Down Procedure (Fig. 3-2)

3.2 Battery Life Calculations

3.2.1 Introduction

Lithium-Thionyl-Chloride batteries have the design characteristic that once fully

loaded they produce a consistent voltage output for the majority of their operating life. It is
extremely important that the battery life is tracked to avoid downhole battery depletion.

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

3.2 Battery Life Calculations (contd)

Standard Assembly
DD Assembly
Hi Temp Assembly

= 1.0 million Joules

= 2.4 million Joules
= 1.2 million Joules

3.2.2 Battery Life Calculations - Standard and 3-1/2 (Ultraslim) Tools

For Gamma
Ray Assembly
power usage, refer
to the GRA
Operations and
Maintenance
Manual

From a knowledge of the energy consumption of the MWD assembly it is possible to

calculate the theoretical operating life of the Power Section. Using the manufacturers data, the
tool power consumption can be calculated from:= 281.6 Joules

Pulse Energy per Dynamic Survey

= 105.6 Joules

Sensor Energy per Static Survey

Sensor Energy per Dynamic Survey
Quiescent Consumption (0.52 watt)

AT

Pulse Energy per Static Survey

= 29.4 Joules

= 17.6 Joules

= 1872 Joules/hour (plugged-in)

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

PE
RF

For example:

Standard Power Section Assembly, initial energy = 1.0 million Joules

Plugged-in hours = 77

Number of pulses = 36,000

Est. Energy Remaining = 1,000,000 - (1872 x 77) - (20.5 x 36,000) = 117,856 Joules

3.2.3 Battery Life Calculations - 2-7/8 (Ultralite) Tools

The energy consumption (per pulse) of the 2-7/8 Transmitter is less than that of the Standard and 3-1/2 Transmitters. Thus the equation used for battery life calculations is as follows:
JoulesNEW = JoulesOLD - (1872 x Hr. P.I.) - (5.7 x No. Pulses)

3.3 Factors Affecting Battery Life

The actual battery energy remaining is affected by a number of factors which may combine
to reduce the effective battery life:
a) Operating temperature:
The Lithium batteries used in the Geolink tool are rated to 150 C. However because of the
battery chemistry an operating temperature between 80 - 125 C has an adverse effect on

CONFIDENTIAL

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GEOLINK 1999

3.3 Factors Affecting Battery Life (contd)

a) (contd) battery life. This is especially true for Standard battery cells. In addition the temperature cycle history can affect overall battery life with an increase in passivation layer build-up i.e. tripping out and in a hot borehole with
subsequent cooling and re-heating of the batteries or storage outside in a hot
climate.
b) Use Cycle History:
Variations in the tool operating mode may effect battery performance. Long
periods with no pulsing can cause a passivation layer to build up in the battery.
Again this is especially true for Standard cells.

Introduction

Workshop
Inspection
& Assembly
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

OL

AT

c) Variations in Manufacture: Battery performance can vary slightly between

different batches produced by the manufacturer (and does vary between different manufactures).

Contents

CONFIDENTIAL

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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

PE
RF

Pre-job Inspection
and Test

CONFIDENTIAL

GEOLINK 1999

4. Pre-job Inspection and Test

Contents

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

4.1 Physical Inspection

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.

4.2 Electrical Tests

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

PE
RF

Passing all the physical and electrical checks

The amount of energy already consumed
The estimated battery life remaining
The operational history of the pack (operating mode, downhole temperature etc)
The proposed run length and tool operating mode

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.

4.3 Final Installation in the Housing with the Coupling Connector

When the cartridge has passed the physical and electrical checks it can be fully assembled in the pressure housing with the coupling connector. It is assumed that the Pressure
Housing and Coupling Connector have already been inspected (refer to section 2.1).

Tools & Components:

Pressure Housing (23-11-002)

Lube, Super O ((13-30-001)
Coupling connector (72-22-220)
Loctite (Nutlock 242)
Battery cartridge assembly
Set of Allen keys
Screw M6x6 SKT CAP (x4) (20-00-012)
Contact cleaner
Installation Process:

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.
CONFIDENTIAL

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GEOLINK 1999

4.3 Final installation in the Housing with Coupling Connector (contd.)

b) Apply a light smear of O-lube to the upper O-ring and GT-ring on the Coupling Connector.
c) Insert the combined assembly into the Pressure housing. Carefully support the Coupling
Connector to avoid undue stress on the electrical connectors. Align the tool face key on the
Coupling Connector with the key slot on the pressure housing and push fully home.
d) Clean any excess O-lube from the pressure housing screw holes with a cotton bud soaked
in non-deposit contact cleaner.

AT

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.

OL

h) Before the Power Supply Assembly is finally passed for field operations, a full string
test must be performed (refer to String Test Manual).

PE
RF

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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GEOLINK 1999

Contents

Section 5

Introduction

Workshop
Inspection &
Assembly

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

OL

AT

Workshop
Maintenance
& Test

Post-Job Inspection
and Test

CONFIDENTIAL

GEOLINK 1999

5. Post-Job Inspection & Test

Contents

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.

5.1 Physical Inspection

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

PE
RF

f) Check the alignment and tightness of the ten pin connectors on the upper
and lower bulkheads. Do not over-tighten the locking screws.

5.2 Tests on the Battery Cartridges

a) Check the continuity and leaks to ground through the upper and lower ten
pin connectors on the Coupling Connector (Coupling Connector disconnected
from the cartridge).
b) Test the battery cartridge under NO LOAD and LOAD conditions (refer to
section 3.1).

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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GEOLINK 1999

5.2 Tests on the Battery Cartridges (cont)

e) Unplug the harness connectors and remove the upper and lower bulkheads. Try not to
twist or tangle the wiring harness as this will make it difficult to reassemble on a new
cartridge. Check the harness thoroughly for pinched wires or any other sign of damage
(refer to section 2.2 on re-assembly).
f) If the wiring harness is damaged or pinched the damaged section should be removed and
replaced. Replace any wiring harness connectors that may be damaged (when removing
the connectors, be sure to get all the old RTV out first. Small long-nose pliers may then be
used to ease out the connector).

PE
RF

OL

AT

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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GEOLINK 1999

Contents

Section 6

Introduction

Workshop
Inspection &
Assembly

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

OL

AT

Workshop
Maintenance
& Test

Parts List

CONFIDENTIAL

GEOLINK 1999

6. Power Supply Assembly Parts List

Contents

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

Heat Shrink Black

11-40-022

Heat Shrink Red

11-40-026

Heat Shrink Blue

11-70-001

Tape, Kapton, 1"

13-30-001

Lube, Super O

13-50-002

RTV 3744

20-00-016

SCR M3*3 Skt Set

20-00-030

SCR M4*0.7*8 Csk Skt

23-11-002

Pressure Housing, PSA, HSC, STD

23-11-003

Pressure Housing, PSA, HSC, HP

25-00-008

O-ring 220

70-30-020

D batter y assy, field ready

70-50-000

Conversion kit, D to DD

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

OL

AT

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

Batter y Cartridge, DD, BEI, 165C

6-1

GEOLINK 1999

Contents

Section 7

Introduction

Workshop
Inspection &
Assembly

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

OL

AT

Workshop
Maintenance
& Test

Appendix

CONFIDENTIAL

GEOLINK 1999

7. Appendix
Contents

7.1 Appendix A: General Battery Handling and Safety

If you are dealing with a known overheated or damaged battery
assembly, protective clothing, rubber gloves and a respirator must be worn.
If you are dealing with a battery assembly and it becomes clear that the
assembly has been overheated or damaged, STOP and put on protective
clothing, rubber gloves and a respirator. If the battery cells are involved in
a fire, do not use water to put out the flames. The fire should be
extinguished with a Lith-X (Graphite Class D fire extinguishing agent)
powder. Sodium Carbonate should be spread over all exposed parts that
are not burning.

Workshop
Inspection &
Test
Workshop
Maintenance
& Test
Pre-Job
Inspection &
Test

AT

7.1.1 General Battery Information

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.

OL

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

The battery storage area in a workshop or warehouse should be secure, clearly

marked as Battery Storage and be provided with the correct class of fire extinguisher.
Index

PE
RF

Passivation of cells occurs during any period of storage or non-use. An oxide

layer builds up on the Lithium cathode. This has the advantage of minimising the
degradation of the cells performance over time but this passivation layer must be
broken down by appropriate loading (refer to Section 2.2 for details) before a battery
assembly is ready for field use.
Individual cells may swell slightly in use depending on the load applied and the
maximum temperature to which they are exposed.
7.1.2 Battery Composition

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.

CONFIDENTIAL

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GEOLINK 1999

7.1 Appendix A: General Battery Handling and Safety

7.1.3 Workshop Practices
Lithium batteries are not re-chargeable and it is hazardous to apply a reverse voltage
to them.
If you have to deal with individual cells for any reason (Geolink normally sends out fully
assembled battery cartridges) double-check the orientation of each cell for correct polarity to
ensures that you do not reverse the cells.

AT

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.

OL

Overheating or self-heating: a violent chemical reaction takes place if Thionyl Chloride

comes into contact with molten Lithium metal. A battery cell will rupture or explode if the lithium
within it reaches its melting point. A substantial safety margin is essential in order to allow for
internal self-heating in normal operation, the possible occurrence of hot-spots and unexpected
changes on operational conditions. For these reasons, the maximum operational temperature
limit for cells which have not been specifically designed for higher temperatures is 150 deg. C
(302 deg. F).
If a battery cartridge or cell is hot for any unknown reason, it must be cooled to ambient
temperature before being handled. The cartridge or cell should be taken outdoors and cooled by
immersion in a large volume of water or by hosing down with copious quantities of water.

PE
RF

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:-

CONFIDENTIAL

7-2

GEOLINK 1999

1.

Keep all non-essential personnel away from the assembly.

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

OL

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

PE
RF

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

Used (depleted) Cartridges: these cartridges should be discharged under normal

load conditions until the battery has reached 0V on LOAD (refer to section 7.1.3). The
cartridge is then ready for disposal in the correct manner.
Used battery cartridges should be stored in a lockable steel container, filled with
vermiculite, located away from main traffic areas. The container should be waterproof
and be kept cool and dry. It should be labeled as containing battery cartridges or hazardous materials. Do not store in direct sunlight. Use protective tape on the ends and
wireway to prevent accidental shortcuts. Damaged or ruptured cells can be stored with
other used batteries provided they have been properly isolated.
7.1.5 Battery Shipping and Disposal
Lithium batteries are subject to special procedures regarding their shipping and
disposal. The rules and regulations for each country are different and it is the responsibility of the user to see that laws and regulations are fully complied with.
The customers freight and shipping department should be aware of all IATA
and DOT Dangerous Goods Regulations that may apply (see Section7.2) regarding the
shipping of lithium batteries
Lithium batteries must be disposed of through an authorised company that
specialises in the disposal of hazardous waste.

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.

AT

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

OL

Telephone:
Fax:
Out of Hours:

7.2.2 Damage, Products and Hazards Associated with Battery Venting

PE
RF

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

7.2.2 Damage, Products and Hazards Associated with Battery Venting

(contd)

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

AT

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

OL

7.2.4 Identifying a battery-venting incident is not always easy:

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

PE
RF

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.);

CONFIDENTIAL

7-5

GEOLINK 1999

7.2.5 Battery Venting at the Wellsite - Procedures (contd)

a) Re-make the Transmitter Sub/Drill Collar connection. Break the assembly out of the
drill string, fit steel thread protectors on both ends and lay the assembly down on the
catwalk.
b) Remove the assembly to a remote/safe area and arrange for water to be run through the
assembly. This will have the effect of cooling the battery pack and diluting/neutralising the
by-products.
2. If the incident is recognised when the tool string is broken out, remove the 'O' rings from
the APC/SEA coupling connector, make the string up again and then follow steps 1a and
1b above.

AT

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.

OL

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.

PE
RF

7.2.6 Dismantling the Equipment

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

CONFIDENTIAL

7-6

GEOLINK 1999

7.2.6 Dismantling the Equipment (contd)

must be made remotely so that personnel are in a safe area when the pressure housing
is punctured, perforated or communication with atmosphere otherwise achieved. Adequate ventilation must also be available in order to disperse any gases without danger
to personnel.

AT

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?

OL

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
RF

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.

CONFIDENTIAL

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GEOLINK 1999

7.2.8 How to Return Contaminated Items (contd)

2. If you suspect that pressure may be trapped in an item (e.g. the transmitter), make sure
that all pressure is relieved before packing the equipment.
3. The equipment should be packed in sealed polythene tubing containing Bicarbonate of
Soda powder.
4. The packaging should clearly state:

"HAZARD - GOODS CONTAMINATED BY BATTERY VENTING BY-PRODUCTS".

7.2.9 Conclusion

AT

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.

OL

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.

PE
RF

5. Use plenty of water to cool the equipment and flush away contaminants.

CONFIDENTIAL

7-8

GEOLINK 1999

GEOLINK MATERIAL SAFETY DATA SHEET

PRIMACELL LITHIUM/THIONYL CHLORIDE BATTERY
1.

Contents

Material Identification and Information

Introduction

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

Fire and Explosion Hazard Data

Extinguisher Media:

Post-Job
Inspection &
Test

Parts List

Dry Lithium Chloride, graphite powder, pyrene G-1,

Lith-X
Cover with dry Lithium Chloride or Lith-X powder.
Do NOT use water, moist sand, carbon dioxide or
soda-acid extinguisher. Wear protective breathing
apparatus

Appendix

Index

PE
RF

Special Fire Fighting

Procedures:

Pre-Job
Inspection &
Test

OL

3.

Workshop
Maintenance
& Test

AT

2.

Workshop
Inspection &
Test

Unusual fire and

explosion hazards:

4.

Do not short circuit, recharge, over-discharge,

puncture, crush or expose to temperatures above
150C.

Reactivity Hazard Data

Stability:

Stable

Conditions to Avoid:

Temperature in excess of 150C

High humidity for extended periods of time

Hazardous Decomposition
Products:

Sulphur Dioxide, Hydrogen Chloride

5.

Health Hazard Data

Primary routes of entry

Inhalation

Health Hazards:

Acute - vapours very irritating to skin, eyes and

mucous membranes
Chronic - Overexposure can cause symptoms of
non-fibrotic lung injury

CONFIDENTIAL

7-9

GEOLINK 1999

Signs and Symptoms

of Exposure:

Eye and mucous membrane irritation

Medical Conditions
Generally Aggravated by
Exposure:

Asthma, other respiratory disorders, skin allergies,

eczema

Emergency First Aid

Procedures:

Seek medical assistance for further treatment

Eye Contact: Flush with running water for at least
15 minutes. Hold eyelids apart. Seek immediate medical
treatment

AT

Skin Contact: Rinse with large amounts of running water. If

burns develop, seek medical treatment
Inhalation: Remove to fresh air. If breathing is difficult,
administer oxygen and seek medical treatment
Control And Protective Measures

Respiratory Protection:
Protective Gloves:
Eye Protection:
Ventilation To Be Used:
Other Protective Clothing
and Equipment:
7.

Acid Gas Filter Mask

Butyl Rubber Gloves
Chemical Worker Safety Glasses
Local exhaust
Chemical Laboratory Safety Glasses and Apron

OL

6.

Precautions For Safe Handling and Use

Do not breathe vapours or touch liquid with bare hands

PE
RF

Steps To Be Taken If
Or Released:
Waste Disposal Methods:

Neutralise spill with soda lime, seal leaking battery and

soda lime in plastic bag and dispose of as hazardous waste

Precautions To Be Taken
in Handling and Storage:

Do not short circuit, do not expose to temperatures

above 150C. Do not recharge, over-discharge, puncture or
crush

Other Precautions and/or

Special Hazards:

Do not store batteries in high humidity environments

for long periods

8.

Transportation Information

US DOT (per 49CFR 172.01)

Proper Shipping Name:
UN#:
Hazard Classification:
Labels Required:
Other:

CONFIDENTIAL

Lithium Batteries, Liquid Cathode

UN 3090
Flammable Solid or Class 9 (Miscellaneous)
FLAMMABLE SOLID or MISCELLANEOUS
DOT E-7052 Exemption required
CARGO AIRCRAFT ONLY

7-10

GEOLINK 1999

ICAO or IATA
Contents

Proper Shipping Name:

UN#:
Hazard Classification:
Labels Required:
Other:

Lithium Batteries, Liquid Cathode

UN 3090
Class 9 (Miscellaneous)
MISCELLANEOUS
CARGO AIRCRAFT ONLY

Introduction

Workshop
Inspection &
Test

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

OL

AT

Workshop
Maintenance
& Test

CONFIDENTIAL

7-11

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

OL

CIRC. SE R .N O .

PE
RF

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.

7.3 Appendix C: Example Tool Hours Worksheet

GEOLINK 1999

Contents

Section 8

Introduction

Workshop
Inspection &
Assembly

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

OL

AT

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
RF

OL

Battery Assembly. See Workshop Procedures: Assembly Procedures

Battery Harness Identification
Lower Harness 2-1
Upper Harness 2-1
Battery Life. See Battery Life Calculations
Battery Life Calculations 3-3
2-7/8 (Ultralite) Tools 3-4
Factors Affecting Battery Life 3-4
Standard and 3-1/2 (Ultraslim) Tools 3-4
Battery Life Variation 1-3
Battery Rupture. See Appendix B
Battery Safety. See Appendix A: Battery Handling & Safety
Battery Venting. See Appendix B

Pre-Job
Inspection &
Test

Chemical Characteristics. See Safety Data

Control Measures. See Safety Data
Coupler Inspection. See Workshop Procedures: Inspection

D Battery Diagram 2-2

D Battery Wiring 2-2
D cells 1-1
Damaged Batteries. See Appendix A: Battery Handling & Safety
DD Battery Diagram 2-4
DD Battery Wiring 2-4
DD cells 1-1
Double D Cartridge 1-1

Explosion Hazard Data. See Safety Data

Fire Hazard Data. See Safety Data

H
Health Hazard Data. See Safety Data
High Temperature Cells 1-1
CONFIDENTIAL

8-1

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

Maintenance & Test 3-1

Battery Test Procedures 3-1
Normal Battery Voltages 3-2
Step-Down Test 3-3
Power Pack Maintenance 3-1
Material Identification. See Safety Data

OL

Output Voltage
DD Assembly 1-3
HT Assembly 1-3
Standard Assembly 1-3

PE
RF

Parts List. See PSA Parts

Personnel Procedures. See Appendix B
Physical Characteristics. See Safety Data
Post-Job Inspection & Test 5-1
Physical Inspection 5-1
Tests on the Battery Cartridges 5-1
Pre-job Inspection and Test 4-1
Tool Installation 4-1
Pre-Job Inspection and Test
Electrical Tests 4-1
Physical Inspection 4-1
Protective Measures. See Safety Data
PSA
DD Assembly 1-5
Downhole Assembly 1-2
Functional Description 1-3
Output Voltage 1-3
Physical Description 1-1
Standard (D) Assembly 1-4
PSA Parts 6-1

Reactivity Hazard Data. See Safety Data

Safe Handling. See Safety; Safety Data

Safety. See Appendix A: Battery Handling & Safety
Safety Data 7-9
Salvage of Parts. See Appendix B: Salvage
Standard Cartridge 1-1

CONFIDENTIAL

8-2

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

Upper Harness (D). See Battery Harness Identification

Workshop
Maintenance
& Test

Pre-Job
Inspection &
Test
Post-Job
Inspection &
Test

Parts List

Appendix

Index

PE
RF

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

8-3

GEOLINK 1999