Quartz School for Well Site Supervisors

Module – 8
Directional Drilling

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Section – 5b
Down Hole Motors
 Outline

Mud Motor Principles
– hydraulic Vs. mechanical power

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PowerPak motors
– Basic design, Bearings, Power sections
– Power curves
– Hydraulics issues
– Operational Considerations

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 Mud Motor Principles

Hydraulic Power (Hp) = Flow rate (GPM) x Pressure drop (psi) / 1714

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Mechanical Power (Hp) = RPM x Torque (ft.lbs) / 5252

Motor Efficiency % = 32.64xRPMxTorque (ft.lbs) / ( Flow rate (GPM)xPressure drop (psi) )

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 PowerPak Overview

89 models from 2 1/8 in. to 11 1/4 in.

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 Basic Motor Types

M-series(Mud-lubricated bearings,54 models,any size)

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S-series (Oil-sealed bearings,27 models,A675 & below)

XC Motor (Mud-lubricated, 5 models, A475&below,XH)

XF Motor (Mud-lubricated, 3 models, below A475)

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PowerPak XC & XF Short Radius Motors

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• XC - High bit offset - excellent directional control

• XF - Low bit offset - 40ft Radius capability

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 PowerPak Basic Design
Top Sub

Power section

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Transmission assembly

Surface Adjustable bend

Bearing section

Drive shaft
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 Selecting Motor Configuration

• Top Sub requirement

• Power Section configuration
• Bend Housing configuration

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• Bearing Section configuration
• Expected drilling conditions

You also need to summarize configuration

parameters and confirm that the motor was built
to specification.

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 Top Subs

Require a crossover between the Stator and the rest of the BHA

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Four standard options - Depends upon drilling conditions

Simple Crossover - Recommended for most drilling applications

Flex Subs - For tough drilling conditions

Float Sub - Incorporate commercially available floats

Dump Valve - Not recommended

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 Dump Valve

Spring operated sleeve - flow activated

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Allows fluid to enter and exit string whilst
tripping.

High maintenance costs

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 Power
Power Section
Section Basics
Basics

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 Power Section Design

The Power section converts hydraulic energy of

high pressure fluid to mechanical energy in the
form of torque output for the drill bit.

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The power section consists of a helical shaped
rotor and stator

The rotor has one less lobe than the stator

Number of stator lobes = number of rotor lobes + 1

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 Power Section

SP- Standard Power- Standard power section, available in different lobe and in any size

XP- Extra Power- 30% to 70% longer than standard power section therefore offering
higher torque output

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GT- Greater Torque power section, 30% longer XP therefore highest torque options

HS- High Speed power sections are extra long 2:3 lobe combinations offering very high
horse power due to the high bit speed

HF- High Flow power sections are available for the A500 and A700 model. These can
accommodate higher flow rates due to the longer pitch on the spiral

AD- Air Drilling, similar to HF. They have been designed to run slower for any given flow
rate by reducing the number of stages and increasing the pitch

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 POWER SECTION CONFIGURATIONS

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1:2 3:4 4:5 7:8

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 CONFIGURATION AND
NOMENCLATURE
ELASTOMER
STATOR TUBE INSERT
ROTOR

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FLOW

ENTRANCE CAVITIES
REGION STATOR CONTOUR
(CUTBACK)

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 POWER SECTION BACKGROUND

LOBE

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CAVITIES

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 POWER SECTION BACKGROUND

WHEN THE ROTOR AND STATOR ARE ASSEMBLED A SERIES OF CAVITES ARE

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FORMED ALONG THE HELICAL CURVE OF THE POWER SECTION

EACH CAVITY IS SEALED FROM ADJACENT CAVITIES BY SEAL LINES

SEAL LINES ARE FORMED ALONG THE CONTACT LINE BETWEEN THE ROTOR AND
STATOR AND ARE CRITICAL TO PERFORMANCE

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 POWER SECTION BACKGROUND

THE CENTERLINE OF THE ROTOR IS OFFSET FROM THE CENTER OF THE STATOR BY
A FIXED VALUE KNOWN AS THE ECCENTRICITY OF THE POWER SECTION

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WHEN THE ROTOR TURNS INSIDE THE STATOR ITS CENTER MOVES IN A CIRCULAR
MOTION ABOUT THE CENTER OF THE STATOR

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 POWER SECTION BACKGROUND

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ROTOR WITH LOBE A FULLY ROTOR POSITION ROTATED 20
INSERTED IN STATOR LOBE DEGREES FROM PREVIOUS
POSITION

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 Power
Power Section
Section Basics
Basics

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 POWER SECTION BACKGROUND

DURING DRILLING HIGH PRESSURE FLUID PUMPED INTO THE TOP END OF THE

POWER SECTION FILLS THE FIRST SET OF OPEN CAVATIES

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THE PRESSURE DIFFERENTIAL ACROSS TWO ADJACENT CAVITES FORCES THE

ROTOR TO TURN, AS THIS HAPPENS ADJACENT CAVATIES ARE OPENED ALLOWING

FLUID TO PROGRESS DOWN THE LENGTH OF THE POWER SECTION

TORQUE OF A POWER SECTION IS PROPORTIONAL TO CAVITY VOLUME AND

DIFFERENTIAL PRESSURE ACROSS THE POWER SECTION

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 TYPICAL POWER SECTION
RPM/TORQUE CURVES

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 TYPICAL POWER SECTION
RPM/TORQUE CURVES
500 2000
6.75”, 1/2 LOBE, 4 STAGE
450 1800
400 1600
SLIP

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350 1400

T O R Q U E (F T -L B )
300 1200
RPM at 350 GPM
R PM

250 1000
RPM at 500 GPM
200 800
Torque at 350 GPM

150 Torque at 500 GPM 600

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MAX PRESS 400
50 USEFUL 200
LOSSES 0 DELTA P 0
0 100 200 300 400 500 600 700
DIFFERENTIAL PRESSURE (PSI)

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 THEORY SUMMARY

MORE LOBES = MORE TORQUE

MORE LOBES = LESS RPM

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MORE STAGES = MORE TORQUE

MORE STAGES = MORE AVAILABLE PRESSURE

TIGHTER FIT = HIGHER SPEED / LESS SLIP

EXCESS PRESSURE = REDUCED RUBBER LIFE

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 Surface Adjustable Bent Housing

0 to 2 Degrees

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O TO 3 Degrees or straight housing

0 to 4 Degrees for XC motor

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 Measuring the Bearing Gap

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 DUMMY BIT

– NEVER pump on mud

lubricated bearings

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without proper pressure
drop at the bit
– Use a Dummy Bit when
surface testing with a bit
is not allowed

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 Rig Consideration For running
PowerPak*
•Pumps should be capable of flow rates and pressures expected for the
depth, drillstring and trajectory proposed

•Adequate rig instrumentation, including make up torque sensors, weight

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indicators, stroke counter, pressure gauges, torque gaugesand RPM
gauges.

•Solids control equipment.

•Rotary lock or other devices to lock drill string, for sliding mode.

•Adequate rotary torque to drill.

•Ensure that rotary table are sized big enough to accommodate larger
motors.
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 Rotor Manufacturing

Gun Bore

Machine Threaded Connections

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Contour

Buff

Plate

Polish

Inspect

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ROTOR BEING CONTOURED
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ROTOR SEMI FINISHED

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ROTOR POLISHING

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ROTORS WAITING TO BE CHROMED

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 Rotor Coatings
Coating Advantages Considerations
Chrome Plated Inexpensive, easy to recoat Not suitable for high chloride

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environment
Tungsten Carbide little corrosion or erosion Expensive, Difficult to fish

Un plated Inexpensive, adaptable for Corrodes and erodes

powerfit

Ceramic coated Chrome Suitable for HTHP Expensive, Difficult to fish

Carbide

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 Stator Manufacturing

Burn and Remove Old Rubber

Blast Tube ID

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Degrease Tube ID

Prep and Add Adhesive

Assemble onto Core

Inject Rubber

Cure Rubber in Autoclave

Disassemble Core from Stator Tube

Flash Ends and Measure

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STATOR BURN

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STATOR BLAST

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CORES

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CORE INJECTION END

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RUBBER BEFORE INJECTION
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STATOR INJECTION GUN

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STATOR THREADING

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STATOR BORE GAUGE
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 Stator

Elastomer bonded into stator housing

Re-line possible
Stator housing very thin walled - connections susceptible to

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corrosion

oRM100 – the standard NBR compound used in most PowerPak

motors. Will even perform well in OBM and up to 300F with proper fit
planning.
oRM145 – an HNBR compound suitable for OBM’s and/or high
temperatures above 260 to 300F. About twice the cost of RM100.
oHN234 – a reformulation of HN 89 that’s harder and bonds better,
more expensive and used where RM100/RM145 are not suitable

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 Stator Materials
RM100 – the standard NBR compound used in most PowerPak
motors. Will even perform well in OBM and up to 300F with
proper fit planning.
RM145 – an HNBR compound suitable for OBM’s and/or high

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temperatures above 260 to 300F. About twice the cost of RM100.
HN89 – an HNBR compound with good results in OBM, but
bonding problems in WBM. Currently in very limited usage.
HN234 – a reformulation of HN 89 that’s harder and bonds better,
more expensive and used where RM100/RM145 are not suitable
RM167 – an HNBR replacement for RM145, commercially
available but not currently used in Power Paks.
RM114 – shows promise as a harder version of RM100, under
field testing (9/04)
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 GENERAL ELASTOMER
INFORMATION

TYPICAL STATOR RUBBER COMPOUNDS CONSISTS OF A NITRILE BASE POLYMER,
REINFORCING MATERIALS, CURATIVES, ACCELERATORS, AND PLASTICIZERS.

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NBR - NITRILE RUBBER - GOOD PHYSCIAL PROPERTIES - OIL RESISTANT

HNBR - HYDROGENATED NITRILE RUBBER - HYDROGEN IS INTRODUCED INTO THE

RUBBER TO IMPROVE PHYSICAL PROPERTIES AND IMPROVE HEAT RESISTANCE.

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 GENERAL ELASTOMER
INFORMATION

HNBRS WITH 90 PERCENT OR HIGHER HYDROGENATION ARE SOMETIMES

REFERRED TO AS HIGHLY SATURATED NITRILES OR HSN.

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ALL NITRILE POLYMERS ARE PREPARED WITH VARYING RATIOS OF ACN.

THE AMOUNT OF OIL AND SOLVENT RESISTANCE IS BASED ON THE ACN CONTENT

OF THE POLYMER.

COMPOUNDS WITH 25 TO 35 PERCENT ACN CONTENT ARE “MEDIUM”, AND

COMPOUNDS WITH 35 TO 50 PERCENT ACN ARE KNOWN AS “HIGH” ACN
COMPOUNDS.

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 Interference fit

• Correct operating interference +0.020”

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• Elastomer swell with temp and fluid
absorption

• Elastomer compression from pressure

• PowerFit software to calculate set up

under shop conditions

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 POWER SECTION OPERATION

RUNNING A POWER SECTION AT OR BELOW RECOMMENDED PRESSURE IS THE
PRIMARY OPERATIONAL CONSIDERATION TO MAXIMUM STATOR LIFE

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POWER SECTIONS ARE RATED FOR OPTIONAL POWER AND OPTIONAL LIFE

EXCEEDING POWER SECTION MAXIMUM PRESSURE RECOMMENDATIONS WILL

INCREASE POWER AND REDUCE LIFE

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 POWER SECTION OPERATION

STALLING THE POWER SECTION WILL HAVE THE GREATEST EFFECT ON STATOR
LIFE

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STALLING OCCURS WHEN THE ROTOR RPM IS REDUCED TO ZERO WHILE
CONTINUNING TO PUMP FLUID THROUGH THE MOTOR.

STALLING FORCES FLUID PAST THE SEAL LINES CAUSING SEVERE RUBBER
DAMAGE AND CHUNKING OF THE RUBBER

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 POWER SECTION OPERATION

POWER SECTION SPEED CAN ALSO EFFECT STATOR LIFE

250

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MAX ∆ P
200 LINE
ROTOR SPEED

INCREASING
150 FLOWRATE
(RPM)

100

50

0
0 100 200 300 400 500
DIFFERENTIAL PRESSURE (PSI)

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 Stator Failure Mechanisms

Failure due to fatigue crack growth

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Fatigue failures are due to high cyclic
loading on the stator elastomer

As the no. of lobes increase fatigue life

decreases because loading frequency
increases

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 Stator Failure Mechanisms

Stator mechanical failure

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Chunked stator due to overpressure

Stator lobes strained beyond their

mechanical limits

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 Stator Failure Mechanisms
Aromatics or synthetic oils weaken
elastomer

Reaction causes Shrinkage or swelling

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of stator

Aniline point is the temperature at which

chemicals in the mud and elastomer can
mix easily

Aniline point < 180 F some deterioration

< 135 F rapid failure

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 Stator Chunking - Symptoms

 Chunking is the tearing of

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stator lobe elastomer.
 In a chunking failure
elastomer can still seen
bonding to the stator tube
wall.

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 Stator Chunking - Symptoms

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 Cracks appear along the
stator lobes
 Note the elastomer is visibly
bonded to the stator tube

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 Stator Failure Mechanisms

 Hysteresis heat build up within the

stator
 Hysteresis heat generation is due to

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repeated flexing of the stator lobes
 Heating increases with speed, pressure
differential and compression fit
 Causes reduced physical properties
and expansion of the elastomer

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 Stator Chunking - Causes
 High cyclic stress loading on lobe caused by
 Too high differential pressure applied to motor
 Too high interference fit run (Motor Build/Temp/Swell)

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 Reduced elastomer properties due to mud chemical effects (mud
elastomer compatibility issue)
 Repeated slippage / stalling of motor
 Severely pitted rotors can contribute to lobe stress and cut the
elastomer
 Shocks / Stick Slip / High RPM / high doglegs/ bend setting
 Fatigue or age and storage conditions

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 Stator De-bonding -Symptoms

 Clear separation of elastomer

from tube

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 No elastomer remains attached
to the stator tube wall
 De-bonding is extremely rare

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 Stator De-bonding -Causes
Failure of bonding agents to glue elastomer to stator tube
– Mud incompatibility with bonding agents

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– Manufacturing defect

Remember:
 De-bonding is extremely rare
 Any sign of rubber on the
tube means it is NOT de-
bonding

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 Rotor pitting - Symptoms
 Pits / Holes in rotor chrome coating
 Mud can pass through chrome to base material
 Mud can act below the chrome corroding base material

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 Flaking of chrome coating

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 Rotor pitting - Causes
 Fluid Erosion
 Rotor / Stator seal is longitudinal
along the crest of the lobes

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 High leakage flow (slip) erodes the
rotor and stator
 Seen as circumferential grooves
across the crest of the rotor and
stator lobes
 Caused by high differential pressure,
excessive solids, motor stalls or non-
chrome rotors used in high solid
contents
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 Stator Elastomer

Typical life of 100-400hrs

Typical failure modes

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– Fatigue
– Heat build-up
(Hysteresis)
– Chemical degradation

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 Elastomer Tip

Stators fail due to high mechanical loading, fatigue,

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drilling fluid incompatibility, and high temperature.

To increase stator life, lower pressures, avoid stalls,

use proper fits, and use the best elastomer match up
with the drilling fluid and temperature

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 PowerEdge vs Conventional Stator
Contoured
Ribbed
Stator Elastomer Stator Tube
Elastomer
Tube

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PowerEdge Conventional
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EVEN WALL STATOR

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Rotor Nozzle

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 Rotor Nozzle
GPM 2 × MW
TFA = P ×10850

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TFA = total flow area (nozzle size, in.²)
Q = amount of flow to bypass (gpm)
MW = mud weight (ppg)
P = expected differential pressure + friction
pressure (psi). Friction pressure is 125psi
for A475 and larger, 150psi for A350 and
smaller.

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 Transmission Section Design

Universal-joint system
transmits Torque &

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Thrust

High strength materials
& optimized design for
maximum fatigue life.

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 Bearing Assembly

Mud lubricated Bearings

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Oil Sealed Bearings

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 Bearing Section
Design

Mud-Lubricated radial
& axial bearings

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Single-piece forged
drive shaft

Optimized design for
minimum erosion &
pressure drop

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 MOTOR STABILIZATION OPTIONS

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 PowerPak Motor Assembly

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 High Performance Motors

12 new designs to establish PowerPak as most
versatile range of motors available in the industry.

High Performance drilling

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– High torque - PowerPak GT motors

4.75”, 5.00”, 7.00” & 9.62” (to 18kft.lbs)
– High Speed - PowerPak HS motors

4.75”, 6.75” & 9.62” (to 600 rpm)
– High flow - PowerPak HF motors
5.00” ( 400 gpm), 7.00” (1000gpm)

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 High Speed Motors

2:3 lobe PDM > 2x efficiency
PowerPak 9.62”, 2:3 High
of multi-stage turbines speed + Diamond Impreg

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Lower Pressure requirement Bits
per Hp output due to – Rocky Mountains - USA,
increased efficiency May 2000

Greater torque compared to – 244hrs at 3.14’/hr,
turbines and 1:2 lobe motors 275deg.F, 13ppg OBM
– 12.25”, Hycalog 444GUP7
Impreg Bit

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 Summary

PowerPak operated for >400k hrs p.a. with
MTBF>2500hrs

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PowerPak GT High torque tools provide record
breaking performance.

PowerPak HS tools provide maximized power for
Impreg Bit applications.

PowerPak HF tools designed for high flow with no
compromise in reliability.

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