Directional Drilling I

Drilling Motors

Revision 8

© 2006 Weatherford. All rights reserved.

Drilling Motor Types

Turbine Motor Positive Displacement Motor

© 2006 Weatherford. All rights reserved.

1
 Weatherford Drilling Motors

• Formerly known as Computalog

CommanderTM
– Oil lube / sealed
• ComDrill™
– Mud lube
• PrecisionDrill™
• 1:2 to 7:8 lobe configurations
• Standard, extended, and air motor
power sections
• 1 3/4” to 11 1/4” sizes designed
• 3 3/8” to 9 5/8” sizes commonly
available
• Global Motor fleet of over 700
© 2006 Weatherford. All rights reserved.

Weatherford Drilling Motors

• Dynamometer Testing
• Break-out Machine
• Pre & Post Drilling - Motor
Performance Evaluation Report
• International Manufacturing and
Repair Kontrol System (IMARKS)
System
– Modeled after airline industry
protocol
– Individual parts tracking
– Preventative maintenance
scheduling

© 2006 Weatherford. All rights reserved.

2
 Weatherford Drilling Motors

• Developing, manufacturing, and servicing down hole

drilling motors for over twenty years
• Extremely reliable - operational experience
surpasses 120,000 hours per year
• Drilling Tools group in Edmonton, Canada and is ISO
9001:2000 registered
• Scope of certification includes:
– drilling motor design, development, assembly
– repair and maintenance of MWD and downhole
tools

© 2006 Weatherford. All rights reserved.

Drilling Motor Research & Development

• Development of New Technologies

– High Torque High Flow (deep water)
– Thin Wall Motor prototype (less elastomer)

- Technical Support
- Failure Analysis
- Product Testing

© 2006 Weatherford. All rights reserved.

3
 Drilling Motor Applications

• Straight - Hole
• Directional Drilling / Sidetracking
• Horizontal Drilling
• Re - entry Wells
• Underbalanced Wells / Air Drilling
• River Crossings

© 2006 Weatherford. All rights reserved.

Components of PDM Motors

• Dump Sub
• Power Section
• Drive Assembly (CV)
• Adjustable Assembly
• Bearing Assembly
1/2 2/3 3/4

5/6 7/8 9/10

© 2006 Weatherford. All rights reserved.

4
 Dump Sub Assembly

• Hydraulically actuated valve located

at the top of the drilling motor
• Allows the drill string to fill when
running in hole
• Drains when tripping out of hole
• When the pumps are engaged, the
valve automatically closes and
directs all drilling fluid flow through
the motor

© 2006 Weatherford. All rights reserved.

Power Section

• Converts hydraulic power from the

drilling fluid into mechanical power to
drive the bit
– Stator – steel tube containing a
bonded elastomer insert with a
lobed, helical pattern bore through
the center
– Rotor – lobed, helical steel rod
• When drilling fluid is forced through the
power section, the pressure drop across
the cavities will cause the
rotor to turn inside the stator

© 2006 Weatherford. All rights reserved.

5
 Power Section

• Positive Displacement Motor ( PDM )

• Lobe Configurations
– Pattern of the lobes and the length
of the helix dictate the output
characteristics
– Stator always has one more lobe
than the rotor
• Stage
– One full helical rotation of
the lobed stator
– With more stages, the power
section is capable of greater
differential pressure, which
in turn provides more torque
to the rotor

© 2006 Weatherford. All rights reserved.

Power Section
1/2 2/3 3/4

5/6 7/8 9/10

• More lobes =
Increased maximum
torque
• More lobes =
Decreased maximum
rotary speed

© 2006 Weatherford. All rights reserved.

6
 Motor Selection

• These are the three common motor configurations which

provide a broad range of bit speeds and torque outputs
required to satisfy a multitude of drilling applications

© 2006 Weatherford. All rights reserved.

Drive Assembly

• Converts eccentric into concentric rotor rotation

Universal Joint

Flex Rod

Constant Velocity Joint

© 2006 Weatherford. All rights reserved.

7
 Adjustable Assembly

• Two Degree and Three Degree

• Field adjustable in varying
increments to the maximum
bend angle
• Used in conjunction with Drive
Assembly
• Provides a wide range of
potential build rates in
directional and horizontal wells

o
H = 1.962

© 2006 Weatherford. All rights reserved.

Bearing Assembly

• Transmits bit axial and radial loads to the drill string

• Thrust Bearing
• Radial Bearing
• Oil Reservoir
• Balanced Piston
• High Pressure Seal
• Bit Box Connection
• Can be mud lubed

© 2006 Weatherford. All rights reserved.

8
 Mud Lube Versus Oil Lube Motors

•Oil lubricated bearing motors have experienced

regained popularity as materials and reliability
have improved over previous designs.

•Mud lubricated drilling motors developed to

complement the oil lubricated bearing motor fleet.

© 2006 Weatherford. All rights reserved.

Mud Lube Versus Oil Lube Motors

• Two generations of mud lubricated motors

• While the rest of the industry sustains ten-year-old

mud lubricated motor designs, Weatherford designed
its first ML motor from the ground up in 2001

• Gained an already impressive track record – cases of

over 400 hours tool runs

© 2006 Weatherford. All rights reserved.

9
 Benefits of Mud Lubricated motors

• Predictable wear rates

• Higher operating temperature range

• Simplicity of service

• Simplicity of operation. Fewer parts

• No issues with flooding

© 2006 Weatherford. All rights reserved.

Specialty Motors

© 2006 Weatherford. All rights reserved.

10
 Motor Handbook

• Every possible motor

configuration is represented in
the Motor Handbook
– Dimensional Data
– Specifications
– Adjustable Housing Settings
– Performance Charts

© 2006 Weatherford. All rights reserved.

Motor Dimensional Data

© 2006 Weatherford. All rights reserved.

11
 Motor Specifications

© 2006 Weatherford. All rights reserved.

Estimated Build Rates

Kick Pad/Stab Kick Pad/Stab +

Below Adjustable Stab on Top Sub

© 2006 Weatherford. All rights reserved.

12
 Performance Charts

© 2006 Weatherford. All rights reserved.

Using the Performance Charts

• Differential Pressure
–Difference between the system pressure when the drilling motor
is on-bottom (loaded) and off-bottom (not loaded)
• Full Load
–Indicates the maximum recommended operating differential
pressures of the drilling motor
• RPM
–Motor RPM is determined by entering at the differential pressure
and projecting vertically to intersect the appropriate flow rate line
• Torque
–Motor torque is determined by entering at the differential pressure
and projecting vertically to intersect the torque line

© 2006 Weatherford. All rights reserved.

13
 Motor Performance Testing

© 2006 Weatherford. All rights reserved.

Motor Part History

© 2006 Weatherford. All rights reserved.

14
 Motor Service Report

© 2006 Weatherford. All rights reserved.

Motor Operational Constraints

• Temperature
• Weight on Bit (WOB)
• Motor Rotation and Bend Angle
• Drilling Fluids
• Differential Pressure
• Under-balanced Drilling

© 2006 Weatherford. All rights reserved.

15
 Operational Constraints

• Temperature
– Standard maximum operating temperature 219 °F / 105 °C
– Stator can be customized for temperatures up to 300 °F / 150 °C
– Special materials and sizes of components used

• Weight on Bit
– Excessive weight on bit stops the bit from rotating as the power
section of the motor is not capable of providing enough torque to
power through (Motor Stalling)
– Rotor cannot rotate inside of the stator, forming a seal
– Continued circulation will erode and “chunk” the stator

© 2006 Weatherford. All rights reserved.

Operational Constraints

• Motor Rotation and Bend Angle

– Rotating at bend angle greater than 1.83 degrees is not recommended
(housing damage and fatigue)
– Speed of rotation should not exceed 60 RPM (excessive cyclic load on
housing)
– No RPM limit for motor set with no bend angle
• Drilling Fluids
– Designed to operate with practically all types of drilling fluids such as
fresh and salt water, oil based fluids, mud with additives for viscosity
control or lost circulation, and with nitrogen gas
– Relining of stators in aggressive drilling fluids is recommended as
hydrocarbon-based fluids can be harmful to elastomers
• Invert, Envirovert, Enviro-drill, Cutter-D, Underbalanced Diesel,
Diesel, Native Crude, Drill Sol, Nitrogen, Potassium Silicate, Oil,
Pureoil 2000, Aphron
– High chlorine content can cause damage to internal components
– Keep solids content below 5%
– Keep sand content below 0.5%
© 2006 Weatherford. All rights reserved.

16
 Operational Constraints

• Differential Pressure
– Difference between the system pressure when the drilling motor is on-
bottom (loaded) and off-bottom (not loaded)
– Excessive pressure drop across the rotor and stator will cause
premature pressure wash (chunking), and impair performance

• Under-balanced Drilling (UBD / CPD)

– Proper gas/liquid ratio must be used to avoid motor damage
– Under high pressure operation conditions, nitrogen gas may permeate
into the stator and expand when tripping out of the hole causing
blistering or chunking of the stator

© 2006 Weatherford. All rights reserved.

Motor Failures in UBD / CPD Operations

– Nitrogen impregnation
– Stator swelling
• Temperature
• Fluid incompatibility
– Operating dry
– Over-speeding

© 2006 Weatherford. All rights reserved.

17
 Operational Features

• Stabilization
• Offset Kick Pad
• Rotor Bypass

© 2006 Weatherford. All rights reserved.

Stabilization

• May improve well bore centricity (straightness)

and control
– Screw-on stabilizer
– Integral blade stabilizers

© 2006 Weatherford. All rights reserved.

18
 Offset Kick Pad

• Adjustable pad located below adjustable bend

• Oriented with center of pad on low side of bend
• Provides lower pivot point on drilling motor to increase
build rate capability

© 2006 Weatherford. All rights reserved.

Rotor Bypass

• Increases the maximum allowable

flow rate rating of the power
section
• Diverts flow though center of the
rotor via a port (jet)
• All multi-lobe motors from 3 3/8’’
and larger include ported rotors
• May be field installed if required

© 2006 Weatherford. All rights reserved.

19
 Directional Drilling Problems

• Unexpected Pressure Increase

• Unexpected Pressure Decrease
• Loss of Drilling Rate (ROP)

© 2006 Weatherford. All rights reserved.

Unexpected Pressure Increase

• Motor stall
• Plugged motor or bit
• Under-gauge (tight) hole

© 2006 Weatherford. All rights reserved.

20
 Unexpected Pressure Decrease

• Dump sub valve stuck open

• Worn or damaged stator
• String washout / twist-off
• Lost circulation
• Gas kick

© 2006 Weatherford. All rights reserved.

Loss of Rate of Penetration

• Bit worn / balled up

• Worn stator / weak motor
• Motor stalled
• Formation change
• Drill string / stabilizer hang-up

© 2006 Weatherford. All rights reserved.

21