Chapter 05

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Part # D003967 PowerDrive Maintenance Manual Page 5-i

Revision # AD Detailed System Description October 2001
Table of Contents
5 Detailed System Description .......................................................................5-1

5.1 Control Unit Electronic Modules......................................................................................... 5-1
5.1.1 Upper Torquer Module............................................................................................... 5-1
5.1.1.1 Phase Switch Boards .......................................................................................... 5-2
5.1.1.2 Switched Mode Power Supply............................................................................. 5-4
5.1.1.3 PWM & F/V Converter Board .............................................................................. 5-5
5.1.1.4 ShortHop Processor Board.................................................................................. 5-6
5.1.2 Communications Module ........................................................................................... 5-8
5.1.2.1 Command and Control of System ....................................................................... 5-8
5.1.2.2 Accelerometer and Tachometer Sensor Voltage Measurement ......................... 5-9
5.1.2.3 Data Logging of Sensor Readings ...................................................................... 5-9
5.1.2.4 Memory Size........................................................................................................ 5-9
5.1.2.5 Serial Communications Protocol Interface (SPI) ................................................. 5-9
5.1.2.6 Serial communications (RS232) ........................................................................ 5-10
5.1.2.7 System Timekeeping ......................................................................................... 5-10
5.1.2.8 Battery Backup .................................................................................................. 5-10
5.1.2.9 Processor Reset ................................................................................................ 5-10
5.1.2.10 Shock Accelerometers .................................................................................... 5-10
5.1.3 Sensor Module......................................................................................................... 5-10
5.1.3.1 Collar Magnetometers ....................................................................................... 5-12
5.1.3.2 Start Gyro .......................................................................................................... 5-12
5.1.3.3 Fluxgate Magnetometers................................................................................... 5-12
5.1.3.4 Shock Accelerometers....................................................................................... 5-12
5.1.3.5 TRAX ................................................................................................................. 5-13
5.1.4 Lower Torquer Module............................................................................................. 5-13
5.2 Bias Unit .............................................................................................................................. 5-13

5.2.1 Overview .................................................................................................................. 5-13
5.2.2 Filter Extension Sub................................................................................................. 5-14
5.2.3 Bias Unit................................................................................................................... 5-14
5.2.3.1 Kalsi Series Choke ............................................................................................ 5-14
5.2.3.2 Control Shaft...................................................................................................... 5-14
5.2.3.3 Valve Housing (Spider)...................................................................................... 5-15
5.2.3.4 Pads................................................................................................................... 5-15
5.2.3.5 Pistons ............................................................................................................... 5-15
5.2.3.6 Pads................................................................................................................... 5-16
5.2.4 Mod Recaps (MRs) .................................................................................................. 5-16
5.3 Surface Unit......................................................................................................................... 5-16
5.4 ShortHop ............................................................................................................................. 5-17

5.4.1 ShortHop Receiver .................................................................................................. 5-17
5.4.1.1 ShortHop Receiver Electronics ......................................................................... 5-17
5.4.1.2 Analogue PCB ................................................................................................... 5-18
5.4.1.3 CPU Board ........................................................................................................ 5-20
5.4.1.4 PSU Board......................................................................................................... 5-21
5.4.1.5 ARC5 Modem .................................................................................................... 5-22
5.4.1.6 Antennas ........................................................................................................... 5-22
5.5 Software............................................................................................................................... 5-22

5.5.1 Surface Software ..................................................................................................... 5-23
5.5.1.1 SCB Editor Program .......................................................................................... 5-23
5.5.1.2 Surface Link Program........................................................................................ 5-25
Confidential Copyright © Schlumberger

Part # D003967 PowerDrive Maintenance Manual Page 5-ii

5.5.1.3 Process Program............................................................................................... 5-25

5.5.1.4 Downlink Program ............................................................................................. 5-25
5.5.1.5 PDLA Program .................................................................................................. 5-25
5.5.1.6 Module Downloader........................................................................................... 5-26
5.5.1.7 Scope Program.................................................................................................. 5-26
5.5.1.8 CU Supply (Meter)............................................................................................. 5-26
5.5.1.9 Nozzles Spreadsheet Program ......................................................................... 5-26
5.5.1.10 Surveys Spreadsheet ...................................................................................... 5-26
5.5.1.11 Down Telemetry Spreadsheet......................................................................... 5-26
5.5.2 Control Unit Software............................................................................................... 5-26
5.5.2.1 Data Types ........................................................................................................ 5-26
5.5.2.2 System Control Block (SCB) ............................................................................. 5-28
5.5.2.3 Downwards Telemetry....................................................................................... 5-28
5.5.2.4 Steering Settings ............................................................................................... 5-28
5.5.2.5 Telemetry........................................................................................................... 5-30
5.5.2.6 Control Unit Timing Sequence .......................................................................... 5-33
5.5.3 ShortHop Software .................................................................................................. 5-34
5.5.3.1 Software Overview ............................................................................................ 5-34
5.5.3.2 Defaults.............................................................................................................. 5-34
5.5.3.3 IDEAL Data Points (Dpoints) ............................................................................. 5-36
List of Figures
Figure 5-1 Control Unit Electronic Modules ............................................................................ 5-4
Figure 5-2 Transmit Waveform Generation............................................................................. 5-7
Figure 5-3 Data Transmission Format..................................................................................... 5-7
Figure 5-4 Sensor Module Block diagram............................................................................. 5-11
Figure 5-5 ShortHop Receiver Block Diagram ...................................................................... 5-19
Figure 5-6 Standard SCB map with uniform distribution....................................................... 5-29
Figure 5-7 SCB Map with biased distribution ........................................................................ 5-30
Figure 5-8 Transmission Delay ............................................................................................. 5-32
List of Tables
Table 5-1 Table of Schematics, Upper Torquer module........................................................ 5-2
Table 5-2 Table of Schematics – Communications Module .................................................. 5-8
Table 5-3 Table of Schematics – Lower Torquer Module.................................................... 5-13
Table 5-4 ShortHop Receiver Schematics .......................................................................... 5-18
Table 5-5 Signals Digitised by Comms processor’s eight channel 8-bit ADC ..................... 5-27
Table 5-6 Digitised by Sensor processor’s eight channel 8-bit ADC ................................... 5-27
Table 5-7 Derived values from calculations within the Sensor processor ........................... 5-27
Table 5-8 Logged Slow Data................................................................................................ 5-28
Table 5-9 Pump Flow rates for data transmission to tool .................................................... 5-32
Table 5-10 ShortHop Default Values..................................................................................... 5-35
Table 5-11 V1 ShortHop Dpoint Data (Tool ID=132) ............................................................. 5-36

Part # D003967 PowerDrive Maintenance Manual Page 5-1

5 Detailed Syste m Description

The general theory of operation was described in chapter 4 of this manual. This chapter gives
a much more detailed description of the component parts of the PowerDrive system. This is
aimed specifically at those who need a more detailed understanding of the mechanical and
electronic component parts for repair and refurbishment purposes.
5.1 Control Unit Electr onic Modules

The Control Unit contains four separate electronics modules;
• Upper Torquer (Controller and Generator)
• Communications
• Sensor
• Lower Torquer Controller

Each torquer is coupled to a generator. In the case of Upper Torquer, this actually contains
two sets of generator windings – one to generate the electrical power for the system and the
other to provide the retarding torque to control the Control Unit angular position within the
collar. Note that an upper or lower torquer controller refers to the electronics module without
the generator part attached. In production, the generator of the Upper Torquer is built onto the
Upper Controller Module, whereas the Lower Torquer Module and Lower Torquer Generator
are kept separate and only assembled together into the Control Unit.
Figure 5-1 shows a block diagram of the electronic modules within the system and the
interaction between them.
Product Part Number Filecode

Control Unit - PD675 A1272 PD675CU-AA
Control Unit - PD900 A2511 PD900CU-AA
5.1.1 Upper Torquer Module

The design of the Upper Torquer Module electronics has evolved over its life into two
variants, known as MK1 and MK2. In the later variant the design has been revised to increase
reliability and ease of manufacture. Both variants fulfil the same function and are
interchangeable. PD900 Control Units are assembled with Mk2 Upper Torquer Modules by
default. PD675 Control Units may be fitted with either type.
More recently, a ShortHop variant has been added which incorporates a transmitter and
antenna. This is identical to a standard Upper Torquer Module (MK2) but with the addition of
another electronics board. The assembly is finished with a longer spindle, onto which the
transmitter antenna is mounted.


The Upper Torquer Module comprises five printed circuit boards (pcbs) on a central
aluminium bracket (six for ShortHop). The printed circuit boards comprise;
• Three identical phase switch boards, which provide the variable loads to the outputs of the
3-phase generator.
• A switched mode power supply board which converts the 3-phase power into several DC
voltage rails.
• A PWM to analogue voltage converter and a frequency to voltage converter.
• Transmitter pcb (ShortHop modules).

The schematic diagrams for the Mk1 and Mk2 variants Upper Torquer Modules differ so the
reader should ensure that the correct schematic is used for fault finding. Refer to Table 5-1 for
the correct drawing number.
Upper Torquer Part No. Module Schematic Diagrams

Module Filecode
Mk1 A1752 PDUTM-AA Phase Switch Board – SD2310
Freq Conv / Mod Amp Board - SC-02-06-0067
PSU Board – 02-01-0296
Mk2 A3478 PDUTM-BA Phase Switch Board – SD3277
PWM Converter and F-V Board – T1202021
PSU Board – 02-01-0296
ShortHop As MK2 with the addition of;
ShortHop processor Board – T1022241
Table 5-1 Table of Schematics, Upper Torquer module
5.1.1.1 Phase Switch Boards

Refer to the relevant torquer schematic.
An analogue signal in the range 0 to +5v (VMOD) forms one input to a comparator (IC1A pin
2). The second comparator input (pin 3) is connected to a series RC network fed from the
torquer generator phase voltage. The capacitor is charged via the resistor to a point when the
voltage across it (at IC1A pin 3) is higher than that at the other input (IC1A pin 2) and the
output (IC1A pin 1) will switch to a high state.
The output from the first comparator (IC1A pin 6) is fed to another comparator (IC1B pin 5)
where it is compared with a fixed DC reference voltage of approx. 50mV. This nominal
reference provides some measure of noise immunity and compensates for any offset from the
first comparator section (IC1A). When the output of IC1A goes high, this level exceeds that at
IC1B pin 6 and forces the output at IC1B pin7 to go high. This output turns on the power field
effect transistor (FET), which switches the output from one generator phase into a load
resistor (0.1Ω/10W).


When the phase voltage goes negative, a diode conducts and is used to switch a shunt
transistor and FET to discharge C1 and clamp the voltage at IC1A pin 3 to 0 volts. This forces
the comparator (IC1A pin 1) to switch low which in turn causes the power FET to switch off.
The cycle then repeats on the next positive part of the sinewave from the generator.
The Mk2 variant incorporates an additional FET connected across C1 that dumps the charge
on this capacitor when the +12v rail is low, ensuring a controlled start-up sequence.
External zener clamping diodes are fitted to some earlier units to prevent excessive transients
when the generators are first started up.
The VMOD demand signal controls where in the cycle the power FET is switched on and
thus controls the loading on the generator. Three identical phase switch boards are fitted to
each torquer module, one for each phase of the generator.


Figure 5-1 Control Unit Electronic Modules
5.1.1.2 Switched Mode Power S upply

A common switched mode PSU board is used in all Upper Torquer Modules, for both PD675
and PD900. Refer to the PSU schematic diagram, drawing 02-02-1-08-4.
Diodes D1 to D6 are configured as a 3-phase bridge rectifier and convert the AC output from
the generator to DC on the ‘POUT’ line. C1 acts as a smoothing capacitor to reduce the ripple
on this line.


For test purposes, an ‘AUX PWR’ input is provided, allowing an external DC supply to be
used to apply power for test and repair work. A series diode, D7, is used to prevent this line
from being energised by power from the generator. A logic level signal, via the potential
divider R1/R2, provides an ‘APS’ output signal to the CU when auxiliary power is being
applied. When the APS (auxiliary power supply) line is high, the tool believes it is in surface
mode - allowing downloading of firmware / data logs etc. When the APS signal is low, the
tool believes it is in down-hole mode. It is sometimes useful to short APS to 0V while
powering the CU from an external source to ‘fool’ the CU into down-hole mode for certain
tests.
The rectified DC is used to supply IC1, a current mode switching power supply IC, operating
in a flyback configuration at a frequency of approximately 100KHz. The DC supply to IC1 at
this point is proportional to the speed of the generator, which in turn is proportional to the rate
of mud flow. This DC level can vary from approx. 11VDC to 50VDC (corresponding to
approximately 550RPM to 2500RPM at the generator).
The switched mode supply uses a transformer (TR1) to convert the available DC supply
voltage to four other voltage rails. These are,
• +5V @ 250mA
• +12V @ 50mA
• ±12V @ 50mA – Isolated

Feedback from the +5V rail is provided via R13 and R12. There is provision to adjust the
voltage of the +5V rail by an additional SIT resistor, R11. Additional power rails are
generated using other, separate windings on transformer TR1, with subsequent half wave
rectifiers and smoothing capacitors. Note that only the +5V rail supplies feedback to IC1 for
regulation.
The resistor network formed by R8 & R9 provides under-voltage protection. Resistor R14
provides for over-current protection and the RC network formed by R10 and C3 provide some
measure of frequency compensation.
Transistor T1 is used to sense the frequency of the generator output waveform, sharpen up
this pulse and pass this signal to the ‘RPM’ output for control and logging purposes.
5.1.1.3 PWM & F/V Converter B oard

There are two variants of this board that exist in either Mk1 or Mk2 Upper Torquer modules,
see Table 5-1. Both boards perform the same functions, but using different circuit topologies.
They are not interchangeable
5.1.1.3.1 PWM & F/V Board - Fitted to Mk1 Upper Torquer Modules
A potential divider formed by R18 and R19 reduces a voltage from the stator of one phase of
the generator. This signal is then ac coupled, clipped and filtered before being fed into IC3a at
pin 3. The resultant ac signal from IC3a is rectified and amplified by IC3b. The gain of IC3b
is adjusted by an SIT resistor. The output signal ‘VW’ represents an averaged DC signal of
1.5V when a signal at 50Hz is applied to the input (H). As the generator is a 4-pole device,
this represents a mechanical speed of 750 RPM.
The PWM circuit is designed to take the demand ‘PWM’ signal and convert it to a
proportional DC signal that is sent to the phase switch boards.


The ‘PWM’ signal is first applied to a 2-pole filter configured around IC1b and then fed to a
non-inverting amplifier (gain +1.18x) formed by IC1c. The board has the provision for using
a filtered reference signal ‘VR’ as an offset signal for IC1c, however this is not implemented.
The amplified signal at IC1c pin 10 is filtered by a 3-pole filter formed around IC1d, and
output onto the ‘VMOD’ line. The output at IC1d is offset by +2.5V with the addition of IC2
at pin 15.
The ‘VMOD’ output is approx. +5V at 0% demand on the torquer and 0V for 100% demand.
5.1.1.3.2 PWM & F/V Board - Fitted to Mk2 Upper Torquer Modules
This board incorporates the functionality of the Mk1 board but with improved noise rejection
and fault protection.
Monitoring two of the three voltage phases and using the logic gates U4b and U4d configured
as an R-S latch is used to sense the speed of the generator. The resultant signal is a negative
pulse dependent upon speed and amplitude of the input signal. The negative pulse is used to
trigger a monostable multivibrator formed using U4a and U4b. This has a nominal pulse
width of 5mS. The supply to U4 is accurately set to 7V by the voltage regulator formed by
U1, U3b and Q1. Thus the output of the monostable is controlled in both amplitude and pulse
width and it can accurately track the rotational speed of the generator. The output pulses from
the monostable are filtered by three, cascaded RC sections and buffered by U3a before being
output as the ‘VW’ signal. The SIT resistor, R13, achieves final gain trimming.
The PMW signal is filtered by two, cascaded 2-pole filters formed around U2a and U2b. The
filter, formed by U2b, has an offset of 2.5V achieved using the voltage reference IC, U1. The
output appears as the ‘VMOD’ signal. The ‘VMOD’ output is approx. +5V at 0% demand on
the torquer and 0V for 100% demand.
5.1.1.4 ShortHop Processor Bo ard

The ShortHop Processor Board accepts ASCII data from the Comms. Module and coverts this
data into amplitude modulated (on/off) signals, which drive current into a magnetic loop
antenna.
Data from the Comms Module (RS232 format) is buffered by U3 (LTC1382) and fed to the
microprocessor, U1 (68HC711) at TTL logic levels. This processor - operated in single-chip
mode - takes the ASCII data from U3, converts the data to a binary stream, adds a check-sum
and converts all this to a 10-baud data stream at 575Hz. All timings are done within the
processor and are controlled by the reference crystal oscillator built around X1.
An inverter circuit, built around Q2 and Q10 generates a negative power rail of approximately
–11V. There is also provision for data to be sent to the processor IC from an external receiver.
At present, these facilities are not used.
Three outputs are used from U1, being the arranged to switch the output in stepped fashion to
approximate a sine wave. The antenna is not tuned, so the shaping of the transmit drive
waveform helps to maximise efficiency and reduce harmonics. The signals drive a full
bridge circuit consisting of bipolar pre-drivers and FET output stages. Additional circuitry has
been added to ensure that both halves of the bridge cannot conduct simultaneously.
There is no control over the transmit output power level. The system has been designed to
operate, and is specified, at the minimum supply voltage provided by the minimum flow rate.


Figure 5-2 Transmit Waveform Generation
Figure 5-3 Data Transmission Format
Figure 5-2 shows the stepped drive waveform to the antenna. Note that the first and last
transmit cycles in a bit sequence will be truncated by 1/16th of a cycle to reduce harmonics
and increase efficiency. Figure 5-3 shows the envelope of the transmitted waveform and the
structure of the transmitted data.
The data format is typically as follows,
• 2.5 second wake-up burst of 575 Hz.
• Start bit, first block of data (8-bits), stop bit.
• Remaining blocks of data, with start and stop bits.
• Data bits are 0.1 sec per bit, 100% carrier.
• Data is sent in reverse order (LSB first).


5.1.2 Communications Mod ule

There are two variants of the Communications Module. These modules, whilst being similar,
are not directly interchangeable and utilise different memory technology and structure. Mk2
Communications Modules have serial numbers 10964 and above.
This section describes the Communications Processor hardware, the differences between the
Mk1 and MK2 designs and the mechanical and electrical interfaces. It does not describe the
overall system operation in detail, or the software interface requirements. Due to the complex
nature of the modules and their construction, it is recommended that faulty items be returned
to SHPC for repair and test.
Further reference may be made to the relevant schematic diagrams, as detailed in Table 5-2.
5.1.2.1 Command and Control o f System

Using data received from its sensors and a suite of control parameters, the Communications
Processor commands the Sensor Module to apply controlled amounts of torque to the upper
and lower torquer modules independently. The upper and lower torquers rotate in opposing
directions. The control unit is free to rotate between the upper and lower torquer and is
therefore able to control its own angular position.
The gyro, magnetometer, accelerometer and other sensors on board the control unit allow the
system to determine its absolute orientation and also the speed of the collar affixed to the drill
string. The control unit is attached to a bias unit that is designed to divert the flow of mud
passing through the centre of the drill string. The bias unit has a number of flaps which, when
open, will apply a force to steer the drill. By controlling its own relative angular position, the
control unit is able to force the bias unit to energise its flaps at a fixed angular position and
hence control the direction of the drill string.
In normal usage, the Communications Processor will execute a predetermined sequence of
controlled movements defined by a system control block that is downloaded when the unit is
on the surface. Sending a message to the control unit, using the mud as the transmission
medium, the drill steering angle and build index can be changed. The speed of the mud is
slowly varied which is detected by the varying speed of the upper and lower torquers. The
received control message will select a different set of control parameters stored in memory
and defined by the system control block.
Communications Part No. Filecode Schematic Drgs.

Module
Mk1 A1763 PDCM-AA Schematic, Comms Processor – SC-02-01-0073
Schematic, Comms module – SC-05-02-0103
Mk2 A3336 PDCM-BA Schematic, Communications Module – SD3336
Schematic, Communications CPU – SD3036
IC, Programmed ACTEL, Communications CPU
– A3103
Table 5-2 Table of Schematics – Communications Module


5.1.2.2 Accelerometer and Tach ometer Sensor Voltage Measurement

The X,Y and Z axis accelerometers together with speed and current readings from the upper
and lower torquer modules, are measured by an 8-bit analogue to digital converter internal to
the processor IC. These measurements are used as system control variables and are also
periodically logged. The 3-axis shock accelerometer within the Mk1 Sensor Module is
replaced on later, Mk3 Sensors. A single-axis ‘shock’ accelerometer is incorporated directly
into the Mk2 Communications Module.
5.1.2.3 Data Logging of Sensor Readings

The measured sensor values together with other system variables and status information is
stored in one of two non-volatile data memories. Each record is stored with the time & date
that the measurements were taken.
• One data memory area is used for ‘slow’ data, which is added to the data memory until
full. When full, no further readings will be added and additional readings will be lost.
• The other data memory is used for ‘fast’ data. The software configures this memory to act
as a cyclic buffer. Data is added to the memory until full. When full, the oldest data will
be overwritten with the new data therefore the memory will contain the latest N readings.
The Mk1 design uses one-time programmable (OTP) electrically programmable read-only
memory (EPROM) for monitor code storage and electrically-erasable read-only memory
EEPROM for the application code. The OTP EPROM is contained in a WSI PSD301 device.
Battery backed RAM is used on the Mk1 design to store the whole data log memory. The
microprocessor’s internal EPROM is not used within either Comms Module.
5.1.2.4 Memory Size

The Mk1 design has 4M bytes of battery backed Static Random-Access Memory SRAM,
which is physically located on a separate memory board, and has 2.5Kbytes of SRAM for use
by the microprocessor. This design has 32Kbytes of downloadable application code space
(EEPROM) and 8K bytes of fixed memory used for the monitor code.
The Mk2 design has just under 2.5Mbytes of memory located on the processor board. This
2.5 Mbytes is split between Flash and SRAM arranged as 2Mbytes of Flash (256 pages of
8Kbytes/page) and 0.5Mbytes of SRAM (63 pages of 8Kbytes/page). The new design has
48Kbytes for the total application code (stored in another Flash device) and 7.5K of SRAM to
allow for future requirements. There is no fixed monitor code in the Mk2 design.
Memory implemented using FLASH, EPROM or EEPROM memory technology does not
require battery power to maintain its contents. Memory implemented using Static RAM
technology requires battery backup power to maintain its contents.
5.1.2.5 Serial Communications Protocol Interface (SPI)

Communications between the Communications Processor and Sensor Module Processor is by
way of a serial bus that conforms to the Motorola SPI bus protocol. The Communications
Processor will usually be the master SPI bus controller. The real time clock device is also
accessed via this bus.


5.1.2.6 Serial communications (RS232)

The Communications Processor handles all communications to external devices though a
RS232 serial link. This is connected to a PC for uploading of data and downloading of system
control messages and application software. The RS232 link is also used for system test
purposes.
5.1.2.7 System Timekeeping

Data stored in the data log memory is time stamped with the actual time of day that the data
was measured. This is used to correlate data with certain events when the data is analysed. A
real time clock IC that runs continuously (provided battery power is available) maintains the
time of day and date. It is normal for the clock to be set (and the memory initialised) just
before the system is used. The system software reads the real time clock once at power up and
from then on maintains its own internal clock.
5.1.2.8 Battery Backup

Main system power is supplied by the generator on the upper torquer module, which is rotated
by the flow of mud. When the flow stops (or drops to a low rate) the main system power will
be lost. To prevent data loss, an internal Lithium battery provides back up power to maintain
logged data and time of day. The Communications Processor will provide automatic switch
over to battery power for the SRAM and real time clock IC in the event of power loss.
5.1.2.9 Processor Reset

As the power supply is frequently interrupted, a ‘clean’ reset pulse is needed to ensure correct
operation and to prevent data corruption. The Communications Processor will be forced into
reset if the main power supply drops below approximately 4.65 Volts. The SRAM will also be
disable to prevent spurious write commands. No warning is given of an impending power loss
and therefore the processor is stopped immediately. If this occurs during a data log sequence,
this record may be lost.
5.1.2.10 Shock Accelerometers

The Mk1 Communications Module design uses the 3 axis accelerometer located in the Mk1
Sensor Module to measure shocks, but has no peak hold mechanism to record maximum
levels. Since data is sampled and logged periodically, shocks occurring outside of the
sampling period are not be registered.
The Mk2 Communications Module design incorporates a single axis accelerometer to enable
shock levels to be recorded. The data from the accelerometer has a preset severity threshold
and is not an measurement of shock amplitude. Thus any shock over 50g (fixed threshold set
in hardware) will be logged into the memory for diagnostic purposes.
5.1.3 Sensor Module

There are two variants of Sensor Module, referred to as Mk1 and Mk3. A Mk2 unit did not
reach production. The two versions differ slightly and this will be described below. Mk1 units
are of a smaller diameter than Mk3 units. Mk3 units have 5-figure serial numbers,
commencing with 10706.


Due to the complex nature of the Sensor Module and its calibration, it is recommended that
faulty items be returned to SHPC for repair and test. For this reason, the circuit description
will be at a relatively high level.
A block diagram of a Sensor Module is shown in Figure 5-2 .
The Sensor Module contains the sensing elements, interface circuitry and processor that are
used to calculate the position of the Control Unit and send the correct drive levels to the
torquers such that the correct position is maintained. For logging purposes, signals are passed
via the SPI bus to the Communications Module. Command and control signals are passed
back from the Comms. Module to the Sensor Module.
Figure 5-4 Sensor Module Block diagram
The Sensor Module consists of a 2-part aluminium bracket to which the sensors and pcbs are
attached. The lower part of the bracket (nearest to the drill bit) holds the collar fluxgate
magnetometers, the rate-gyro and the TRAX. These sensors are discrete items within their
own cases, which are securely attached to the bracket.
The three fluxgate magnetometers, shock sensors (where fitted) and printed circuit boards are
attached to the upper half of the bracket. Interconnecting wires are used between the two
halves of the module set into pockets machined into the outer surface of the bracket. The two
halves of the bracket are attached with two bolts and fitted within a cover tube.


The differences between the two variants are;

PCBs - 4 fitted to upper part of bracket on MK1, only 3 fitted to Mk3.
Shock sensors – 3 fitted to Mk1, none fitted to Mk3.
5.1.3.1 Collar Magnetometers

Two magnets with opposing poles are fitted into the Control unit collar. To sense the
rotational speed and direction between the collar and the Control Unit, two fluxgate
magnetometers are used. These magnetometers sense the magnetic polarity of the two
magnets set into the collar. This information is used to determine the speed and rotational
direction of the Bias unit relative to the collar.
5.1.3.2 Start Gyro

The Start Gyro is a roll-rate gyro used to control the position of the Control Unit rotation.
This is used when the system is performing a ‘survey’ i.e. taking data and allowing the system
to settle before finding its required position under the control of the main control loop.
As this is a rate gyro, the output is proportional to the Control Unit rotation. This should be
considered when analysing the output (particularly the log files) as any offset from either the
gyro and in-built conditioning circuitry, will cause the Control Unit to slowly rotate rather
than remain static within the collar.
5.1.3.3 Fluxgate Magnetometer s

These sensors are inserted into pockets within the upper half of the sensor module. They are
used to sense the position of the tool when it is in a near vertical position.
The signals from these magnetometers are fed to conditioning circuitry on the sensor support
pcb (Mk1 modules) and onto the processor board (Mk3 modules). These signals are then
digitised and used for steering the tool and are logged to memory for later downloading and
analysis.
5.1.3.4 Shock Accelerometers

Mk 1 variants of the Sensor module incorporate three shock sensors (accelerometers). These
ware active in 3-axis at all times, but were logged only at programmed intervals. Thus it was
found that shocks could occur outside of the sampling period which would not be logged to
file and would not be useful for later analysis. The shock sensors were not fitted to MK3
modules for this reason.
As discussed in 5.1.2.10 the Mk2 Communications Module incorporates a shock sensor,
which counts shocks over 50g. It is recommended that the Mk3 Sensor Module be used with a
Mk2 Communications Module so that shock data is stored as the X-accelerometer channel. If
a Mk3 Sensor Module is used with a Mk1 Communications Module any logged data on the 3
shock accelerometer channels will be erroneous.


5.1.3.5 TRAX
The TRAX module consists of a small cylindrical module, which fits into the lower half of
the sensor bracket. The module contains the three axis accelerometers that are used for
positional sensing when the tool z-axis is greater than 5° from vertical. The TRAX module
also includes a temperature sensor whose output is logged for temperature compensation and
log analysis.
5.1.4 Lower Torquer Module

The Lower Torquer Module is very similar to the Upper Torquer Module in both operation
and construction. The Lower Torquer does not, however, have a PSU board.
The Lower Torquer Module has three variants. Two variants exist for the PD675 (known as
Mk1 and Mk2) plus a third for the PD900. Essentially, the two variants for the PD675 utilise
the later pcb designs as described for the Upper Torquer Module. The PD900 version has a
change of resistor value for one component only.
The various part numbers are shown in Table 5-3.
Lower Torquer Part No. Filecode Schematic Drgs.

Module
PD675 – Mk1 A1764 PD6LTM-AA Phase Switch Board – SD2310

Freq Conv / Mod Amp Board - SC-02-06-0067
PD675 – Mk2 A3322 PD6LTM-BA Phase Switch Board – SD3277
PD900 A3485 PD9LTM-AA Phase Switch Board – SD3277
Table 5-3 Table of Schematics – Lower Torquer Module
For a description of the circuit operation, refer to the Upper Torquer Module section of this
document.
5.2 Bias Unit
5.2.1 Overview
Bit deviation (turn and/or build) of the drillstring is achieved mechanically by using a Bias
Unit (BU). The BU assembly comprises a Filter Extension Sub and BU inserted in the
drillstring between the PowerDrive Control Unit (CU) Collar and the drill bit. The BHA
therefore comprises CU Collar/Filter Extension Sub/Bias Unit/Bit. The PD675 Filter
Extension Sub being a pin/pin NC50 (PD675) connection both ends. The PD900 Filter
Extension Sub being pin/pin - 7⅝” pin up/NC70 pin down. Connection with the drill bit is
provided by a 4½” IF regular box (PD675), or 6⅝” IF regular box (PD900) and screws
directly into the downhole end of the BU body. A multiple thread recut feature is incorporated
in the design of the drillstring tubulars. The BU provides a timed lateral force to the BHA
such that the direction of the bit is deviated within the hole.


5.2.2 Filter Extension Sub

Drilling mud is fed to the Filter Extension Sub from the CU Collar. The Filter Extension Sub
has a rebated annulus machined into the internal bore, mud can enter the rebated annulus only
via passing through a cylindrical metal element filter which filters, and prevents, large
particulates being fed to the dynamic parts of the downstream BU assembly. The filter is
fitted with sealing elastomers at each end of the cylinder to prevent drilling mud by-passing
the filter elements. When the Filter Extension Sub is made up with the BU the filtered mud is
directed to a port in the Kalsi Series Choke fitted within the BU. Under normal conditions
approximately 17½ Usgpm (PD675) or 40 Usgpm (PD900) of the drilling mud is demanded
by the dynamic components in the BU.
5.2.3 Bias Unit

Drilling mud is channelled through the bore of the BU directly to the drill bit. Filtered mud
from the Filter Extension Sub is directed to the dynamic parts of the BU via special chambers,
valves, bores and chokes before finally being discharged externally into the annulus flow to
the surface. Filtered mud from the Filter Extension Sub is directed to a port in a BU assembly
component known as the Kalsi Series Choke (KSC).
5.2.3.1 Kalsi Series Choke

The KSC is a sub-assembly of the BU and performs 4 functions:-
• Collects filtered mud from the Filter Extension Sub to feed to the BU dynamics.
• Provides the mounting mechanism, bearings and lubrication system for the Control Shaft
• When fitted to the Valve Housing (Spider) it creates the chamber within which the valve
upper rotor and its mating valve stator are housed.
• Where the operator wants to run bit pressure drops above 800 Usgpm the KSC can be
configured with a set of chokes.
The Kalsi Series Choke is so named because it is designed to take nozzled chokes to limit the
pressure within the valve chamber in the event of high bit pressures being encountered,
however, this feature is seldom used. Kalsi refers to special seals used to meter lubrication of
the Control Shaft.
5.2.3.2 Control Shaft

The upper end of the Control Shaft is fitted with a spear point that incorporates a drive dog.
When the BU assembly is made up to the CU Collar the spear point and dog projects upwards
through Filter Extension Sub and engages with the mule shoe connector creating mechanical
connection with the CU.
Control Shafts are available in a selection of overall lengths dependent on the BU body and
Filter Extension Sub body thread recut status. The Control Shaft is mounted on bearings
lubricated by an oil reservoir. The oil reservoir is pressure equalised and provides oil to the
Control Shaft bearings fitted to the KSC body. Special Kalsi seals, designed to provide
protection to rotary bearings from drilling mud, provide oil retention and a rotary seal. Kalsi
seals operate by expelling a very small amount of oil each rotation. The direction of the
movement of oil is always outward into the mudstream thereby ensuring the bearings are not
contaminated by mud under normal working conditions.


Filtered mud flows through the Kalsi Series Choke bores into the valve chamber at the
downhole end of the KSC body. The downhole end of the Control Shaft projects into the
valve chamber and is specially machined to provide an oriented location for the ported Valve
Upper. The Valve Upper has an oriented port which, when fitted to the oriented location on
the lower end of the Control Shaft, gets its orientation relative to tool face from the oriented
mechanical connection with the CU. Thus the CU determines the tool face and therefore the
position of the port in the Valve Upper relative to formation.
5.2.3.3 Valve Housing (Spider)

The Valve Housing (Spider) is fitted with a valve Stator. The valve Stator has 3 equi-spaced
ports connected to the external BU Pads via dedicated bores in the BU body. The face of the
valve Stator mates with the face of the Valve Upper. Both faces are protected with a PDC
layer. Provision is also made for the Valve Upper to lift if necessary due to particulates or
extreme back-pressure events. The Valve Upper on the PD900 BU is fitted with a spring
return mechanism to assist re-seating the Valve Upper onto the valve Stator. At a future date a
similar enhancement may be added to the PD675, an MR will be issued if this is introduced.
When the CU is demanded to hold a toolface, via the mechanical connections described in
5.2.1.2 & 5.2.1.3 above, it positions the port in the Valve Upper at the required angle relative
to formation. The single port Valve Upper allows filtered mud to flow through each of the 3
ports in the rotating Stator when aligned with the stationary Valve Upper port held at the
demanded toolface angle. The Valve Housing (Spider) and Stator rotate with the drill string at
drill string speed at all times.
5.2.3.4 Pads
From the Stator the filtered mud is directed via individual drillings in the Valve Housing
(Spider) and the BU body to an individual piston and pad sub assembly located on the outside
of the BU body. When assembled in the drillstring the only external BU components are the 3
clamp plates, 3 pads, 3 hinges and 3 upper and lower pad travel restrictors known as kickers
complete with sets of fasteners. The 3 pads are the primary BU contacts with the wellbore.
These pads are equi-spaced around the BU circumference. Junk slots are provided between
the pad facets. Each pad is fitted with a hinge on its’ leading edge such that the major area of
the pad trails the hinge relative to drillstring rotation. Each pad is activated once per
revolution of the drillstring being a fed through the ported valve rotor and stator to feed
pressurised, filtered mud diverted from the bit feed. The energy to activate the pads is
provided by the flow and pressure differential between the annulus pressure and the BHA
internal pressure - the pressure drop across the bit generating the hydraulic force across the
stroke of the pad. The pad is attached to a piston operating in a bore which receives a timed
charge of filtered mud, therefore the design area of the piston determines the magnitude of the
force applied to the pad for a given bit pressure drop. PD675 pads and pistons are separate
entities requiring assembly. PD900 pads have the pistons integrated as one entity.
5.2.3.5 Pistons
Design requirements necessitate that the Piston axis is offset relative to the Hinge Pin axis,
resulting in the Piston motion describing an arc during its stroke. Therefore the bore, in which
the Piston stroke is a sector of a torus, is referred to as a ‘toroidal bore’. The toroidal bore is
held in place on each BU body facet using a Clamp Plate. The Clamp Plate is bolted and
staked to the BU body, where the Clamp Plate mates with the BU body an o-ring seal
prevents the escape of pressurised filtered mud.


The Piston circumference is machined with a profiled form to provide controlled clearance
and free movement of the Piston throughout its stroke. PD675 Pistons are doweled to the pad
to aid orientation of the piston-profiled form relative to the pad and bore. PD900 piston/pad
orientation is not relevant, as it is determined in the design as a single entity. All PowerDrive
Pistons are fitted with an elastomer Seal. The Seal is shaped to give a specific contact
pressure with the bore form and is oriented relative to the piston/pad/bore. The Seal is held
captive on the piston using a clamp ring and circlip fastening. This Seal has to cope with high
temperatures, high pressures and the abrasive mud as it strokes within the toroidal bore.
Relative to demanded toolface and formation each piston chamber is sequentially charged
with timed, pressurised and filtered mud delivered from the valve chamber via the stator and
drillings. As pressurised filtered mud charges the piston chamber, the piston/pad assembly
strokes thereby pushing the hinged pad outwards until the pad face contacts the well bore. The
pads are prevented from overstroking by the Kickers.
When the stator port is closed by the heel of the valve upper, the pressurised filtered mud in
the piston chamber is discharged to the well bore for return to the surface via the an exit
choke and an exhaust port machined each piston body. As the pressure depletes pad contact
with the well bore returns the pad and discharged piston to the retracted position pending
recharging during the next rotation of the BU body when the stator port will be recharged
from the port in the valve upper. The piston exit choke is integral with the Piston assembly,
the choke is small relative to the toroidal bore diameter, but sufficient to allow the pressurised
mud to escape into the well bore.
5.2.3.6 Pads
The pad is a stainless steel substrate coated with tungsten carbide hard facing into which
highly wear resistant PDC buttons are embedded. Tungsten carbide tiles, arranged to provide
protection from impact and erosion, provide further wear resistance. The pad hard facing,
PDC buttons and tiles are the primary BU parts in direct contact with the well bore. The PDC
provides most of the resistance to wear whilst pushing against the hole. Under high wear
conditions lower Kickers with extra hardfacing are available.
Bit Pin Restrictors are also available for PowerDrive, however these have not been used at the
time of writing.
5.2.4 Mod Recaps (MRs)

MRs and TIRsappropriate to PowerDrive tools will be issued to the Field and must always be
referred to for the latest design modifications. These are logged on Sophia.
5.3 Surface Unit

The PowerDrive Surface Unit is used to program the Control Unit and monitor the mud
pressure during communication with the Control Unit whilst it is downhole. The unit is built
into a rugged transportation case.
The PowerDrive software installed on the PC is detailed in section 5.5. It consists of a suite of
programs for setting up the tool, monitoring the mud pressure whilst drilling is in progress
and logged data extraction and analysis.
The main elements of the Surface Unit are a laptop computer, printer, back-up tape drive,
Intrinsically Safe (IS) barrier and analog-to-digital converter.


The unit has separate power supply modules for the printer (10.6V), tape drive (16V) and
computer (18.5V). There is a further 24V supply which provides power to the PowerDrive
Control Unit, the IS barrier and to the RS-232 opto-isolator. These are all universal supplies
able to operate over a 100V to 260V range of AC power input voltages.
A rear-panel, 6-way connector provides the interface to the control unit. This interface
provides +24V control unit power, supplied via a dedicated control unit power switch on the
front panel and protected by means of a 500mA fuse on the rear panel. It also provides a two-
wire RS-232 connection (RXD, TXD) from the COM1 port of the laptop, which is connected
via an opto-isolator to protect the computer from any voltage transients induced on the cable
connection.
The IS barrier is also powered by the +24V supply via a separate front panel power switch.
When powered it provides an isolated 4-20mA loop drive on the hazardous side to a well-
head pressure transducer. On the safe side of the barrier the pressure transducer voltage is
sampled by an analog to digital converter. The converter is located on a PC card, inserted in a
slot in the laptop, which connects to a transition PCB via a ribbon cable. The transition PCB
is used for 24V supply distribution and samples the control unit supply voltage and current,
which are also acquired by the analogue to digital converter.
The laptop parallel port is connected to the tape drive, from where it is daisy-chained to the
printer port connection on the rear panel. A printer power connector is also located on the rear
panel. The printer is stowed within the surface unit cabinet for transit, but is removed and
connected to the rear panel when in use. The tape drive is built into the surface unit and
accessed on the front panel.
5.4 PowerDrive Xtra

The PowerDrive Xtra system is an additional development. It allows data from the
PowerDrive sensors to be fed to the surface whilst drilling. However, as the PowerDrive
Control Unit is not physically coupled to the drill string, the data from the sensor needs to be
coupled from the Control Unit to a receiving unit that is attached to the drill string. To achieve
this, a ShortHop module utilises a magnetic induction system to transmit and receive the data.
The ShortHop system consists of a Control Unit with a special Upper Torquer (see Upper
Torquer Module section) incorporating the transmitter, housed within a ShortHop Collar. All
other CU modules are identical to those used within the standard PowerDrive tool. The upper
CU hanger on PD675 is changed to accommodate the longer UTM assembly. A Receiver is
housed in a Stabilizer above the Control Unit Collar.
5.4.1 ShortHop Receiver

The Receiver is mounted within the stabilizer section. Electronic circuitry within the Receiver
performs the receiving and decoding functions and incorporates an ARC5 modem to link with
the LTB bus. The bus connection is made with a standard Anadrill LTB wet connector.
At present ShortHop is a simplex system (data is transmitted one way only). Half-duplex
operation may be a future option.
Modulation is class A1D - amplitude modulation, single channel data transmission.
5.4.1.1 ShortHop Receiver Elec tronics

The ShortHop receiver contains four pcbs,


• Analogue receiver board,
• CPU board,
• PSU board, and
• ARC5 modem board.

These boards are mounted on a bracket with a separate antenna assembly. Early brackets were
manufactured from stainless steel whilst later units are machined from aluminium.
The following sections describe the electronic circuitry on each of the pcbs within the
Receiver. It is recommended that the user refer to the appropriate schematic diagram to gain a
thorough understanding of the circuit operation.
Board Part No. Schematic

Analogue Receiver T1022210 Schematic diagram, T1022211, sheets 1&2
CPU Board T1022220 Schematic diagram, T1022221
PSU Board T1022230 Schematic diagram, T1022231
ARC5 Modem S-269780 N/A (See ARC5 manual)
Table 5-4 ShortHop Receiver Schematics
5.4.1.2 Analogue PCB

The Shorthop receiver analogue pcb receives data sent by the Shorthop Control Unit. The
analogue pcb amplifies the signal received on the antenna, filters and detects the received
575Hz tones and passes these to the processor pcb as a binary data stream. The processor pcb
decodes the data stream and sends it to the surface via the ARC5 modem pcb. Refer to
T1022211.


Figure 5-5 ShortHop Receiver Block Diagram
The antenna signal is passed through Q13 to a low noise amplifier stage (U9) that has a gain
of x10 (20dB) gain. Q13 will be switched off if the DC level on the antenna signal is greater
than about 1V. This can happen when in transmit mode and prevent overload in R78 and U9.
The signal is then passed through an automatic gain control (AGC) stage that attempts to
maintain a constant output level on TP11. Q1 acts as a voltage controlled resistor varying the
gain of U6B and is controlled by the integrator U7B. The gain range of U6B is about x1 to
x400 (0-52dB). U6A is a wide band bandpass filter centred on 575Hz and applies a fixed x32
gain (30dB). The output of U6A (TP11) is half wave rectified by U7A which acts to opposed
a fixed current into the integrator provided through R60. If the output level is too high, U7A
and R58 will supply increased negative current - greater than the positive current through
R60. The excess negative current will cause the integrator to ramp more positive to increase
the effective resistance of Q1. This in turn lowers the gain in U6B to reduce the signal level
on TP11. The reverse effect will occur if the signal level is too low. When in equilibrium,
TP14 will be a half wave rectified signal, at approx. 7.8V peak. The integrator output voltage
is passed to a processor A/D channel to indicate signal strength.


The received signal then is amplitude limited to ±185mV by the precision bi-directional
limiter U5A and U5B. The clipping circuit prevents mixer overload caused by the AGC
circuit transient response. The clipped signal is passed to a differential amplifier that gives
inverted and non-inverted outputs. These outputs drive two mixer circuits in U4 that are
driven by locally generated 575Hz clocks phase shifted by 90°. The mixer outputs will
contain the sum and differences of the incoming signal and the local oscillator frequencies.
Separate 9Hz low pass filters, formed by in U3, pass only the difference frequency
components. Therefore, if the input signal frequency is exactly the same as the local
oscillator, then the mixer output will be a DC signal. Two channels are required, as the phase
of the input frequency is not known. If one channel is exactly in phase with the input signal
then that channel will give a maximum output while the other channel will give no output. As
the phase varies, one output will increase while the other decreases but at no time will both be
at zero.
Both filtered outputs are full wave rectified and summed by U2A, B & D and passed to a
comparator U1. U2C, D1 and C4 form a peak-detect and hold circuit. This captures the peak
level of the signal. Half of this signal is used to generate the comparator’s threshold voltage
(ensuring the comparator switches in the centre of the waveform to preserve the mark-space
ratio). U1B blanks the output if the signal level is too small thus reducing spurious noise
reaching the processor.
The FPGA U8 is fed with a 2300Hz clock from the processor that is divided by four to
generate the quadrature signals for the mixers. The FPGA also contains logic to drive a ‘H’
bridge antenna drive circuit. This is not used at present, as transmission is currently only
simplex (in one direction). In bi-directional communications mode, the FPGA will decode the
two signals from the processor using rising or falling edges of the data line while the clock is
high or low (high for transmission, low for receive). The FPGA mode is set by installing R64
or R66. R66 sets 'receive only' mode and is clocked at 2300Hz, R64 sets transmit and receive
and is clocked at 6900Hz.
At present the system is only configured for simplex operation. Future development may lead
to a half-duplex system.
5.4.1.3 CPU Board

The following sensor data is sent from the Comms module to the Upper Torquer module,
• Inc, Azi,, BTM, HS, Gtot, Btot, Dip, Qinc, Qazi, CU, Vib (11 types)
The firmware, within the Comms. module, will have modified the raw sensor readings as
follows,
• Compensate readings for temperature and axis alignment.
• Averaged each reading over a 30-second period.
• Converted readings from ‘tool-cartesian’ to ‘world-polar’ co-ordinates.
• Scaled each value to 12-bits and added a 4-bit tag (data ID), making 16-bits per measured
value
This is then passed by RS232 link, in ASCII/Hex, to the Upper Torquer Module ShortHop
processor (CPU) board, and through the ShortHop link and receiver to the CPU Board.


The Receiver CPU board receives the TTL level data from the Receiver Analogue Board
(T1022210). The data is input to the processor, a 68HC711 (U2) via R19. Resistor R19 and
diode D3 provide protection to the input line.
U1 is a low voltage detector IC which provides a defined reset level to the processor if the
supply voltage should drop below 4.6V.
The processed data is buffered and converted to RS485 levels by U3, an ultra-low power
driver IC. This data is available on connector J1. Note that data is sent to the PowerPulse
Interface (PPI). No data is received back from that module.
The firmware within the CPU (U2) acts upon the received data in performing the following
functions,
• Samples the TTL levels from the Receiver Analogue Board (the envelope of the 575Hz
signal).
• Extracts the data/tag/checksum components.
• Validates the checksum bytes. If no data or incorrect data is decoded, the processor adds
default data values. This also applies if the receiver times-out.
• Measures the AGC level.
• Add status flags to some of the fields.
• Converts the data to the correct format for transmission to the ARC5 modem board.
The firmware within the CPU is not configurable within the field.
5.4.1.4 PSU Board

The switched mode power supply board utilises the same topology, and is very similar, to the
PSU board within the Upper Torquer Module.
The DC from the LTB interface is passed through a low-pass filter formed by L1, L2, C34
and C35 thus providing good rejection of AC signals. This configuration allows both the DC
power and the AC signals to be carried on the same line. Transistors Q1 and Q2 ensure that
the switching device (U1) does not start until the supply voltage has reached a level of at least
7.5 volts and shunts the oscillator within the IC if the supply drops lower than this.
U1is a current-mode switching power supply IC, operating in a flyback configuration at a
frequency of approximately 100KHz. The switched mode supply uses a transformer (T1) to
convert the available DC supply voltage to four other voltage rails. These are,
• +5V @ 250mA
• +6V @ 50mA
• ±12V @ 50mA – Isolated

Feedback from the +5V rail is provided via R12 and R11, thus regulating this voltage rail.
The additional power rails are generated using other, separate windings on transformer T1,
with subsequent half wave rectifiers and smoothing capacitors. Note that only the +5V rail
supplies feedback to IC1 for regulation. An RC network formed by R10 and C3 provide some
measure of frequency compensation for the converter.


5.4.1.5 ARC5 Modem

The ARC5 modem will not be described in detail within this manual. Readers wishing to gain
more knowledge of this device should refer to document S-269780, the ARC5 Manual.
For this application, the standard ARC5 modem board has custom firmware. This is not
configurable within the field, however it can be upgraded. Earlier versions of ShortHop
emulated the GST tool – using the IDEAL tool ID of 132. V2 ShortHop firmware within the
ARC5 modem utilises tool ID 133, giving ShortHop its own ID. This change requires the use
of IDEAL 7 and HSPM 7 software. A Mod Recap will be issued prior to this change.
Refer to section 5.5.3 for further details on D-Points used with specific firmware versions.
5.4.1.6 Antennas
In order to transmit the data across the link, the ShortHop system utilises a magnetic
induction link. Passing current through a multi-turn coil achieves the magnetic field. The coil
is designed to produce a large magnetic field, proportional to the product of the energising
current and the number of turns. Unfortunately, the material forming the outer cover of the
antenna and the proximity of the stabilizer have a pronounced effect on the magnetic
waveform. The effect of the ferrous materials is to act as both a shorted turn around the
antenna coil and a shield. This reduces the efficiency of the system and affects the distance
over which the link will be effective.
Both the transmit and receive antennas are of a similar design. The units are encapsulated
within their housings and cannot be dismantled.
5.5 Software
There are a number of software components within the PowerDrive system. As might be
expected, the current release of software may change between updates of this manual
therefore it is recommended that the current release is checked on the PowerDrive website,
http://www.stonehouse.oilfield.slb.com/website/download_now.htm
The software items used with the PowerDrive System are.
• PowerDrive program software suite.
• Communications Module firmware.
• Sensor Module firmware.
• ShortHop CPU firmware.

The firmware code downloaded into the tool is not configurable within the field or
maintenance base. The latest version is available from the Stonehouse web site. These items
are downloaded into the tool using the Surface Link program.
The PowerDrive program suite was designed for operation under either Windows 3.11 or
Windows 95/98. Some parts of these programs may not function under Windows NT4 or
Windows 2000. It is recommended that any problems encountered with Windows NT4 or
2000 are forwarded through the PowerDrive ‘In-Touch’ page.


5.5.1 Surface Software
5.5.1.1 SCB Editor Program

This program is used for customising a System Control Block (SCB) to the specific
requirements of a run. The Editor presents various editing screens, each of which provides
access to a related group of parameters.
5.5.1.1.1 Control
High and Low torquer RPM levels used in overspeed protection. If either torquer exceeds the
upper level, both torquers are progressively braked to attempt to reduce the speed (and hence
the generated voltage) until both torquers are below the lower level. Then the additional
braking is gradually reduced. (Default torquer limits are 2207 and 2002 RPM)
5.5.1.1.2 Logging
This specifies the fast data logging rate (fast data is acquired through the processor ADC at 5
msec intervals (min). To log at this rate would choke the system – so 100 msec is typically
used)
Memory partitions for logging memory are expressed as percentages. For Mk I Comms, the
memory is a 4Mbyte block of battery-backed static RAM which holds all the partitions.
Fast and Slow logs are single-pass (logging stops when full).
Telemetry and diagnostic are rollover logs (diagnostic is analogous to a black-box recorder of
fast data).
For Mk II Comms, Fast and Slow data is logged to a 2 Mbyte block of flash RAM, again
single-pass. Telemetry and diagnostic data are logged to 0.5 Mbyte of battery-backed RAM.
5.5.1.1.2.1 Time Intervals
The time intervals specified are;
• From start to first survey.
• Survey synchronisation period. For ShortHop it is recommended to set this period to 5

seconds. This allows time for the CU to settle after being demanded to stabalize from its
neutral mode.
• All subsequent surveys - second survey starts when the first drilling cycle starts (end of
‘Bit’ period). Thereafter, this field defines the interval.
• Slow log period - duration of each survey (logging of 5Hz hi-res Gxyz & Bxyz signals at
5Hz).
• Fast log delay - time delay from start of slow log period to start of fast log period.
• Fast log period - duration of logging fast data channels (acquired at 200 Hz, logged at 10
Hz typically).
As an example, the fast log period may be 3 seconds, delay 10 seconds and slow log period
30 seconds. In this way, there is a mid-survey view of all fast and slow data concurrently.


5.5.1.1.2.2 Acquisition
This determines the order in which slow (high-resolution survey) data channels are acquired.
5.5.1.1.3 Navigation
This section defines aspects of the repeating drilling cycle and the initial steering setting for
the tool. After the start-up sequence, the ‘cycle time’ period repeats until power-off. Within
each ‘cycle time’ period, the Control unit stabilises for ‘Proportion’ percent of the cycle time
at an angle depending on the Toolface setting. Toolface is the desired angle of departure of
the borehole relative to highside in gravitational mode or relative to magnetic north in
magnetic mode. In each case, the frame of reference is to be looking downhole along the
tool’s longitudinal axis. The steering setting may alternatively be specified in cartesian terms
of build and turn, although this is rarely used.
On entering a toolface and proportion pair, the ‘Validate’ button is used to find the nearest
point in the steering map – itself viewable via the ‘Map’ button.
Telemetry may be set to 3-pulse or 4-pulse operation. If it is known that the tool will be
steering exclusively under Gravity or Magnetic control for the duration of the run, then the
mode can be pre-defined in the SCB and all telemetry sequences will be 3-pulse, defining
build and turn only. In all other cases 4-pulse telemetry should be specified, in which case the
build, turn and mode are redefined completely in each telemetry sequence.
Typically, magnetic steering mode is used within about ten degrees of vertical, gravitational
at higher inclinations. The steering mode is entirely under the control of the user. There is no
automatic change between modes. (The Control Unit’s angle relative to highside bears no
relationship to its angle relative to magnetic north).
The Toolface Phase Shift is an angle that relates to the Bias Unit. It signifies the angular
difference between the Control Shaft, which mates with the CU/BU Connector, and the
ultimate departure direction of the hole relative to highside (or magnetic north). This is
largely based on drillings within the Bias Unit body between the disk valve ports and their
corresponding actuators.
5.5.1.1.4 Downlink
The downlink parameters specify the physical characteristics of each telemetry pulse. Given
normal and low (in-pulse) flow rates and the falling and rising time constants of the mud
system (by observation), the characteristics of pulses as seen downhole are calculated.
5.5.1.1.5 Uplink
This section contains definitions of Diagnostic and Bit periods.
5.5.1.1.6 Mechanical
This details the calibration of the radial position of the Control Unit Connector (Mule Shoe)
relative to the Control Unit’s X-axis.
The actual angle at which the Control Unit stabilises for steering is computed in the Control
Unit software as the sum of three angles;
• The intended steering direction relative to highside (or magnetic north) which is the basic
demand angle from the user’s point of view as initially set in the SCB or telemetered to
the tool.


• The connector (mule shoe) Phase Angle as determined above.
• Toolface Phase Shift (see above).
5.5.1.1.7 Ancillary
A password protects access to two further panels for;
• Servo Gains – alteration is likely to seriously upset the behaviour of the Control Unit.
• The Navigation Table.
5.5.1.2 Surface Link Program

This program provides the majority of data transfer functions between Surface system and
Control Unit when the two are connected by cable. It allows the following functions;
• Transfer executable code into Comms Mk I and Sensor Modules
• Transfer SCB to Control Unit
• Basic ‘Terminal Mode’ for querying software versions, log sizes, RTC setting and
checking, initialisation of log memory
• Extract data logs to disk file in surface system
• Extract programs, SCBs and Calibration table post-run
• Diagnostic sensor readout, both numerical and graphical

When a Control Unit is powered on the bench, the torquer current channels IT1 and IT2 show
the current stage of CU operation (see Control Unit Timing sequence above) and a countdown
in seconds.
5.5.1.3 Process Program

This program converts raw data logs, as extracted from the Control Unit, into tabulated text
format. Refer to the software release documentation with the latest issue for further details,
such as file extensions.
5.5.1.4 Downlink Program

Using a copy of the SCB, as loaded into the Control Unit, this prepares a telemetry pulse
sequence to communicate a new steering setting to the Control Unit. It is vital that the SCB is
the same as that in the Control Unit otherwise the interpreted steering angle and proportion
will be indeterminate. The functionality of this software is very similar to the Downlink
screen in the SCB Editor, but it creates an addition hardcopy listing of the telemetry pulse
timing sequence.
5.5.1.5 PDLA Program

This program provides a graphical screen and hardcopy presentation of selectable log data
curves. The program itself is datatype-independent and uses various configuration files to
define the content of each type of log file.


Select file type, then file, then up to 4 curves (some curve-pairs are available, e.g. quadrature
signals). There are facilities for panning, zooming, scaling, time-correlation, X-Y plots, etc.
plus an option of a direct hardcopy of screen display. Displayed curves may be deleted and
replaced by others, more than one log can be open simultaneously.
5.5.1.6 Module Downloader

This program is specific to the MK2 Communications Module and runs only under Windows
95/98 and NT4. It is a three-stage loader (Bootstrap, PreLoader and Application Loader. A
separate user guide is available.
5.5.1.7 Scope Program

This is a DOS program that gives a scrolling graphical presentation of standpipe pressure. For
use of this program, refer to the PowerDrive UOP Manual.
5.5.1.8 CU Supply (Meter)

This is a DOS program that displays graphical volt and ammeters indicating Control Unit and
Pressure transducer supply voltages and CU current drawn.
5.5.1.9 Nozzles Spreadsheet Pr ogram

This program is used to select the optimum bit nozzles and series choke nozzles depending
upon flow rate, bit size, etc.
5.5.1.10 Surveys Spreadsheet

This program takes given data sets of Measured Depth, Inclination and Azimuth, derives
Eastings, Northings, Vertical section, Dog legs, etc.
5.5.1.11 Down Telemetry Spread sheet

The functionality of this program has been incorporated into the SCB Editor’s Downlink
panel.
5.5.2 Control Unit Software

The firmware (the imbedded software downloaded into the Control unit) is used with the SCB
to control steering, logging etc. The details of the logged data are as follows.
5.5.2.1 Data Types

All log data is time-stamped at power-up and within each set.
5.5.2.1.1.1 Fast Data
Contains three subsets of data as shown in the following tables;


Variable Function Comment
RPM T1 Lower Torquer RPM 0….255 represents 0….2500 RPM

IT1 Lower Torquer Current
RPM T2 Upper Torquer RPM 0…255 represents 0….2500 RPM
IT2 Upper Torquer Current
ax X-axis vibration
accelerometer
ay Y-axis vibration
accelerometer
az Z-axis vibration
accelerometer
vbatt Comms battery voltage 0.02 volts per bit
Table 5-5 Signals Digitised by Comms processor’s eight channel 8-bit ADC
Rx Roll Gyro 5.55 bits per RPM (signed)

Ry Slew Demand
Bx2 Low Res view of earth’s field
By2 Low Res view of earth’s field
Cx CU’s X-axis response to
transverse Collar field
Cy CU’s Y-axis response to
transverse Collar field
A2x
A2y
Table 5-6 Digitised by Sensor processor’s eight channel 8-bit ADC
MainPWM Torque demand on Lower torquer 0..9900

AuxPWM Torque demand on Upper torquer 0..9900
PosSum Servo error term from which PWMs are derived.
Table 5-7 Derived values from calculations within the Sensor processor


5.5.2.1.1.2 Slow Data
VGx Measures X-axis component of the earth’s gravitational ± 3000

field
VGy Measures Y-axis component of the earth’s gravitational ± 3000
field
VGz Measures Z-axis component of the earth’s gravitational ± 3000
field
VBx X-axis of control unit relative to the local magnetic field ± 3000
VBy Y-axis of control unit relative to the local magnetic field ± 3000
VBz Z-axis of control unit relative to the local magnetic field ± 3000
VRO Reference voltage applied to bipolar signals before 3000 - 4000
digitising (should be 2.5 ± 0.01V)
VT Temperature of sensor (within TRAX unit) 2000 - 4000
Table 5-8 Logged Slow Data
5.5.2.2 System Control Block (S CB)

The Comms and Sensor Modules both contain specific executable code, but their behaviour in
detail is governed by the content of a System Control Block (SCB) which is loaded to the two
modules. The SCB contains various data tables, flags and parameters.
A copy of the SCB is maintained in the surface system. Thus, for example, when a new
steering setting is telemetered to the tool, the pulse sequence is constructed in the Surface
Unit and interpreted by the Control Unit in a uniform way.
5.5.2.3 Downwards Telemetry

When PowerDrive is prepared for a run, an initial steering setting is set in the Control Unit,
analogous to specifying toolface and bent sub angle in the context of a motor.
As the borehole is drilled, the steering requirements are likely to change in response to
reservoir, geological or formation considerations.
Commands can be sent from the surface to the tool to re-specify the steering setting. This is
achieved by modulating the mud flow rate in a sequence which depends upon the new setting.
5.5.2.4 Steering Settings

The steering setting is expressed as a vector of gravitational or magnetic steering angle,
relative to highside, with a length depending on how hard the tool is required to turn.
Within the SCB is a table of vectors defining various steering angle and turn proportion
combinations. This navigation table is visually presented as circular map with typically 49
(maximum 81) points distributed throughout. Different navigation tables may be used in
which the distribution of points satisfies the dominant needs of the current section of the
borehole.


Figure 5-6 Standard SCB map with uniform distribution


Figure 5-7 SCB Map with biased distribution
Figure 5-3 shows the standard distribution of points where the requirement for any vector is
likely. Figure 5-7 shows a biased distribution as might be used when the dominant
requirement is to build and turn right.
In both maps there are 49 points, each of which is the end of a vector whose origin is at the
centre. Despite the circular distribution, the points can be conveniently mapped onto a
rectilinear 7 * 7 matrix in the SCB.
The centre point in each map represents the straight-ahead case. The periphery of the circle
represents deviation at the tool’s full capability.
A point at 90°and at half-radius represents right turn at half the maximum capability of the
tool. Points along the 180° radius represent drop, and so on.
Any given point is uniquely defined by its two indices in the matrix.
5.5.2.5 Telemetry
To command the tool to steer according to a new vector, the Field Engineer selects the closest
available point to satisfy the continuing requirements of the well bore. The Surface Unit
software identifies the selected point by its indices in its copy of the navigation table and
encodes a sequence of pulse modulation.
The pulses are periods of departure from normal flow rate, generally a reduction of twenty
percent. The PowerDrive Control Unit detects flow rate variation by observing the rotational
speed of its upper torquer/generator.


Each pulse must be of sufficient duration and amplitude to be detected by the Control Unit.
Pulses as detected by the Control Unit can be heavily distorted versions of the step change
applied to the pump controls. The pump control system may slew at a constrained rate to
prevent damage to the pump - the inertial effects of varying the momentum of approximately
one ton of mud per hundred feet of borehole must also be considered. The resultant time
constant is typically in the order of 2.5 seconds per thousand feet of borehole.
A pulse is therefore taken to be a reduction in flow rate for a nominal period followed by a
similar period to allow for recovery to the normal flow rate.
The pulse sequence is encoded on a timebase of a Digit Time parameter, which is a part of the
SCB.
A pulse is separated from its neighbour by a time period, which is the product of the Digit
Time and the encoded value (in addition to the Digit Time for pulse recovery).
The matrix is numbered 0, 0 for the top left point, 6, 6 for the bottom right. The first index is
the row (vertical) and the second is the column (horizontal).
Either three or four pulses may be sent. The time between the first and second pulses
represents the first (vertical) index and the time between the second and third pulses
represents the second (horizontal) index. If a fourth pulse is sent it represents value 0 or 1
indicating magnetic or gravitational steering mode.
The Control Unit is receptive to telemetry pulses at a specifiable time after powering up.
The encoding of a new steering setting by the surface software is best demonstrated with an
example.
• The point 332°, 75%, shown ringed in Figure 5-3 , is in the second row and third column
of the matrix. This encodes as point 1, 2 as numbering starts at zero.
• Suppose that four pulses will be sent, and that gravitational steering is required.
• Given a Digit Time of 20 seconds and that the sequence starts two minutes after power-
up, the modulation sequence is as shown in Table 5-9.


Time Action Comment
0 : 00 Pumps up
2 : 00 Lower flow by 20% Start first pulse
2 : 20 Restore normal flow End first pulse20 sec recovery + 1 * 20 secs
3 : 00 Lower flow by 20% Start second pulse
3 : 20 Restore normal flow End second pulse20 sec recovery + 2 * 20 secs
4 : 20 Lower flow by 20% Start third pulse
4 : 40 Restore normal flow End third pulse20 sec recovery + 1 * 20 secs
5 : 20 Lower flow by 20% Start fourth pulse
5 : 40 Restore normal flow End fourth pulse
Table 5-9 Pump Flow rates for data transmission to tool
The effects of transmission delay on a pulse through the transmission medium (mud) are
shown in figure Figure 5-8.
The three lines within the figure represent;
1. DD operates Pump controls.

2. Effect of pump controller limiting rate of change
3. Flow rate downhole.
These traces show the typical degradation of a pulse. The lower trace is the trace that would
be seen at the Control unit.
Figure 5-8 Transmission Delay


5.5.2.5.1 Pulse Interpretation
The Control Unit observes flow rate indirectly from its effect on the RPM of the upper
torquer/generator’s rotor. This signal is averaged, as a noise reduction measure, and filtered,
revealing the relative times of the leading and trailing edges of each pulse.
Due to dispersive effects in the transmission of a pulse, the length of the pulse as detected
downhole may be up to 50% longer than the nominal pulse as sent.
The interval between the trailing edge of one pulse and the leading edge of the next is
therefore not sufficiently reliable. However, the interval between detection of two successive
falling edges can be determined with much greater accuracy. From this is subtracted the
nominal pulse width to reveal the interval from trailing edge of one pulse to the falling edge
of the next. Thus the represented numbers are determined. The Control Unit software looks
up the new toolface and proportion values using these indices into its copy of the navigation
table.
5.5.2.6 Control Unit Timing Seq uence

From power-up, when the mud flow rate is sufficient to turn the upper torquer/generator’s
impeller fast enough to generate enough voltage for the processor to operate, the Control Unit
follows a specific sequence of stages. For each stage, there are various user-definable
parameters, notably duration.
• Stage 0 - Idle period (time to first survey): Control Unit is inert for 10 to 255 seconds,
zero rotation by roll-rate gyro sensor. Its purpose is to allow other BHA components to
perform necessary activities without risk of CU interference.
• Stage 1 - Survey: CU takes a standard survey, still non-rotating. Typically the collar will
be non-rotating, or only slowly rotating, with the bit off-bottom, leading to a good quality
survey.
• Stage 2 - Diagnostic: Control Unit rotates at a fixed (specifiable) rate with the Upper
torquer hard-wired to half-load. During this period, the average flow rate (as Upper
Torquer rpm) is established as a reference for the Telemetry Window.
• Stage 3 - Telemetry window: CU continues under the same conditions and a software
filter runs, looking for a falling edge in the flowrate which signifies the start of the first
pulse in a sequence for re-defining the tool’s steering setting. If no pulses are sent, the
window times-out after four nominal pulse-widths - otherwise, the window remains active
until the sequence is complete (subject to further timeout constraints).
The Control Unit rotates at a constant speed relative to space during the Diagnostic and
telemetry periods. During a shallow-hole test, when the drillstring should be static, the
rotation of the CU drives the Bias Unit valve that should cause uniform pressure dips
when each port is opened in turn.
• Stage 4 - Bit period indicates whether telemetry has been received. Different rotation
rates are defined for the cases of successful receipt of telemetry and no telemetry (or
failed transmission / interpretation).
The start-up sequence is now complete and the drilling phase starts. Until power-off the
Control Unit alternates periods at fixed angle relative to space (to achieve maximum turn in
the required direction) with periods of collar-relative rotation (to achieve straight drilling).
These are stages 5 and 6 respectively. For 100% proportion, stage 6 never occurs (continuous
maximum turn). For 0% proportion, stage 5 never occurs (continuous slew).


5.5.3 ShortHop Software

The Control Unit makes survey measurements at intervals of typically one minute to five
minutes. These measurements are required on the surface in real-time - subject to propagation
delays – to allow the position of the BHA to be monitored. For PowerDrive a survey data set
consists of a number of data values which include inclination and its quality, azimuth and its
quality, Control Unit highside, Total G, Total B (or H), etc.
As the Control Unit rotates independently of the collar in which it is mounted and PowerPulse
is physically mounted, a non-contact transmission path is necessary to transmit the survey
data between modules. ShortHop performs this function. The modem within the ShortHop
sub makes the data frames (structured blocks of survey data) available to the PowerPulse
module. PowerPulse polls the BHA tools via the LTB for the necessary data to map onto the
necessary Dpoints which are subsequently sent to the surface for display and monitoring.
The development of ShortHop included the ‘mapping’ of ShortHop data onto the GST data
points for the majority of the development work. Essentially, ShortHop reported values to
IDEAL as if it were a GST tool. This was basically known as ShortHop V1.At present V2
ShortHop will continue to use the GST Dpoints that V1 ShortHop used and will remain with a
tool ID = 132. The scaling is different to allow clean migration to bespoke PowerDrive
Dpoints when IDEAL 7 and HSPM 7 become established in the field.
Later ARC5 firmware and IDEAL software will allow ShortHop to have its own tool ID
(133). This will be incorporated into V2 ShortHop during 2002. A Mod Recap will be issued
when this change is to take place.
5.5.3.1 Software Overview

The survey data is encoded in the Comms module and passed to the ShortHop transmitter,
over the link, through the ShortHop Receiver and through the ACI modem to PowerPulse.
The system has been designed to be flexible – the code within the Comms Module resides in
EEROM whilst the code in both the transmitter and receiver reside in EPROM. The ACI
modem is also re-programmable so that Dpoints may be re-mapped.
Up to 14 data variables may be sent over the ShortHop link. These consist of 2-bytes (16-bits)
of which the 4 MSBs are reserved for the data type and 12-bits for the data value. The data
type 0 is not used and the data type 15 is used as a check-sum.
The software controls the transmitter timing (see ShortHop Processor Board) and the
structure of the transmitted signal.
The receiver extracts the binary data from the envelope of the received signal, verifies valid
data by checksum then re-orders and transmits the data as an LTB packet to the ACI modem.
The modem, in turn, passes this data to PowerPulse for final display onthe IDEAL system.
5.5.3.2 Defaults
There are a number of defaults that are transmitted if any element of the system is unable to
see other elements within the data flow chain. These defaults, as seen on IDEAL, are;


Dpoint No PowerPulse ARC5 Receiver Receiver

of default seed timeout
(PD) bits default
(11 min)
FFFF FEFE FDFD FCFC

Inc (NBSSAT) 16 65535 65278 65021 64764
Inc (ACR) 12 4095 3838 3581 3324
Azi (TF) 4095 3838 3581 3324
PTF (ACZ) 4095 3838 3581 3324
Btot (ACT) 4095 3838 3581 3324
Gtot (INCL) 11 2047 1790 1790 1662
Btot (BATT) 10 1023 766 509 831
GTF (GTOT) 1023 766 509 831
Qazi (RPM) 9 511 254 509 252
Steer (CRPM) 8 255 254 253 252
Qinc (GR) 254 253 252
Sig Str (TEMP) 16 65535 65278 509 Real value
CU_S (GRFRL) 8 255 254 253 13
VIB 8 255 254 253 0-15
Table 5-10 ShortHop Default Values


5.5.3.3 IDEAL Data Points (Dpo ints)

At the time of writing, V2 of ShortHop will continue to use the GST Dpoints that are
employed with V1. It may be noticed that the scaling is different to allow clean
migration to bespoke PowerDrive Dpoints when IDEAL 7 and HSPM 7 become
established in the field. This move is anticipated during 2002.
The tool will remain with an ID of 132 and have the following Dpoints
ShortHop Variable GST Variable DATP ID No of bits Scale Units
inclination NBSSTAT 2641 16 .03125 degrees

inclination ACR_n 2645 12 .03125 degrees
Azimuth TF_n 2656 12 .125 degrees
GTotal INCL_n 2657 11 1 mG
Btotal BATT_n 2642 10 .0625 Micro Tesla
Btotal ACT_n 2646 12 .015625 Micro Tesla
Gravity TF GTOT_n 2653 10 .5 degrees
Gravity TF ACZ_n 2647 12 .125 degrees
Signal strength NBS2_n 2652 16 .03125 unitless
Inc quality GR_n 2654 8 .125 Degrees
Azim quality RPM_n 2680 9 .25 degrees
Count on good Rx GRF_n 2650 8 1 unitless
Receive quality GRFRL_n 2698 8 1 unitless
Steering Setting CRPM_n 2696 8 1 unitless
Table 5-11 V1 ShortHop Dpoint Data (Tool ID=132)
ShortHop Variable GST Variable DATP ID No of bits Scale Units

1
inclination NBSSTAT 2641 16 /20 degrees
1
inclination ACR_n 2645 12 /20 degrees
1
Azimuth TF_n 2656 12 /10 degrees
GTotal INCL_n 2657 11 0.5 + 984 mG
Btotal ACT_n 2646 12 0.48 Micro Tesla
Gravity TF ACZ_n 2647 12 0.1 degrees
Signal strength TEMP_n 2644 9 1 unitless
Inc quality GR_n 2654 8 0.1 Degrees
Azim quality RPM_n 2680 9 0.1 degrees
Count on good Rx GRF_n 2650 8 1 unitless
Receive quality GRFRL_n 2698 8 1 unitless
Steering Setting CRPM_n 2696 8 1 unitless


Table 5-13 defines the PowerDrive Dpoints that are embedded into IDEAL 7 and
HSPM 7. Note that a ShortHop receiver sub modem software change to V7.0 is also
required to implement this change. A Mod Recap will be issued to cover this change
when appropriate.
Abbrev. Data No. Param. Conversion Eng.Units Full Name

Name Point of Algorithm
bits No. (after conv.)
(ID) X -> AX+B
A B
INC 3780 12 1 0.05 0 Degrees Inclination
1
AZIM 3781 12 2 0.1 0 Degrees Azimuth
GT 3782 6 3 0.5 984 Milli G Gtotal
BT 3783 11 4 48.0 0 Nano Tesla Btotal
Spare_1 3784 12 5 1 0
STEER 3785 8 6 1 0 unitless Steering setting (build,
turn and gravity or
magnetic mode)
Spare_2 3786 2 7 1
Spare_3 3787 4 8 1
2
PTF 3788 12 9 0.1 Degrees CU toolface
INCQ 3789 4 10 0.1 0 Degrees Inc standard deviation
AZIQ 3790 4 11 0.1 0 Degrees Azi standard deviation
SHKRSK 3791 2 12 1 0 unitless Shock risk
Spare_4 3792 4 13 1
Spare_5 3793 16 14 1
not used 3794 15 reserved for CU
checksum
1
AZIM_LO 3795 10 16 0.4 0 Degrees Azimuth (low res .4
deg)
2
PTF_LO 3796 6 17 6 0 Degrees CU grav/mag toolface
(low resolution 6 deg)
3
SIG 3797 12 18 1 0 unitless Received signal &
noise
3
SIG_LO 3798 6 19 1 0 unitless Received signal &
noise (low resolution)
SIGQ 3799 4 20 1 0 unitless Received signal quality
AGE 3800 16 21 1 data age from modem
1. AZI available in two resolutions, normal (0.1 deg) and LO (0.4 deg). The same source data is
available.
2. Control Unit tool face will be available in two resolutions, normal and LO resolution (6.4 deg) -
for use where bandwidth is limited.
3. SIG_LO, SIG_HI (Signal Strength) is also available in two resolutions, 12 and 6-bit. The 6-bit
version cuts off at approx. 50% receiver input saturation.
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Part # D003967 PowerDrive Maintenance Manual Page 5-i

5 Detailed System Description .......................................................................5-1

5.2 Bias Unit .............................................................................................................................. 5-13

5.3 Surface Unit......................................................................................................................... 5-16

5.4 ShortHop ............................................................................................................................. 5-17

5.5 Software............................................................................................................................... 5-22

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5.5.1.3 Process Program............................................................................................... 5-25

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5 Detailed Syste m Description

5.1 Control Unit Electr onic Modules

• Upper Torquer (Controller and Generator)

• Lower Torquer Controller

Product Part Number Filecode

5.1.1 Upper Torquer Module

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Part # D003967 PowerDrive Maintenance Manual Page 5-2

• A PWM to analogue voltage converter and a frequency to voltage converter.

• Transmitter pcb (ShortHop modules).

Upper Torquer Part No. Module Schematic Diagrams

Table 5-1 Table of Schematics, Upper Torquer module

5.1.1.1 Phase Switch Boards

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Figure 5-1 Control Unit Electronic Modules

5.1.1.2 Switched Mode Power S upply

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• ±12V @ 50mA – Isolated

5.1.1.3 PWM & F/V Converter B oard

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5.1.1.4 ShortHop Processor Bo ard

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Figure 5-2 Transmit Waveform Generation

Figure 5-3 Data Transmission Format

• 2.5 second wake-up burst of 575 Hz.

• Start bit, first block of data (8-bits), stop bit.

• Remaining blocks of data, with start and stop bits.

• Data bits are 0.1 sec per bit, 100% carrier.

• Data is sent in reverse order (LSB first).

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5.1.2 Communications Mod ule

5.1.2.1 Command and Control o f System

Communications Part No. Filecode Schematic Drgs.

Table 5-2 Table of Schematics – Communications Module

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5.1.2.2 Accelerometer and Tach ometer Sensor Voltage Measurement

5.1.2.3 Data Logging of Sensor Readings

5.1.2.4 Memory Size

5.1.2.5 Serial Communications Protocol Interface (SPI)

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Part # D003967 PowerDrive Maintenance Manual Page 5-10

5.1.2.6 Serial communications (RS232)

5.1.2.7 System Timekeeping