05b Down Hole Motors 2005

Quartz School for Well Site Supervisors
Module – 8
Directional Drilling
•Schlumberger Private
Section – 5b
Down Hole Motors
Outline
Mud Motor Principles
– hydraulic Vs. mechanical power
PowerPak motors
– Basic design, Bearings, Power sections
– Power curves
– Hydraulics issues
– Operational Considerations
2
Mud Motor Principles
Hydraulic Power (Hp) = Flow rate (GPM) x Pressure drop (psi) / 1714
Mechanical Power (Hp) = RPM x Torque (ft.lbs) / 5252
Motor Efficiency % = 32.64xRPMxTorque (ft.lbs) / ( Flow rate (GPM)xPressure drop (psi) )
3
PowerPak Overview
89 models from 2 1/8 in. to 11 1/4 in.
4
Basic Motor Types
M-series(Mud-lubricated bearings,54 models,any size)
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)
5
PowerPak XC & XF Short Radius Motors
• XC - High bit offset - excellent directional control
• XF - Low bit offset - 40ft Radius capability

6
PowerPak Basic Design
Top Sub
Power section
Transmission assembly
Surface Adjustable bend
Bearing section
Drive shaft
7
Selecting Motor Configuration
• Top Sub requirement

• Power Section configuration
• Bend Housing configuration
• Bearing Section configuration
• Expected drilling conditions
You also need to summarize configuration

parameters and confirm that the motor was built
to specification.
8
Top Subs
Require a crossover between the Stator and the rest of the BHA
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
9
Dump Valve
Spring operated sleeve - flow activated
Allows fluid to enter and exit string whilst
tripping.
High maintenance costs
10
Power
Power Section
Section Basics
Basics
11
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.
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
12
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
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
13
POWER SECTION CONFIGURATIONS
1:2 3:4 4:5 7:8
14
CONFIGURATION AND
NOMENCLATURE
ELASTOMER
STATOR TUBE INSERT
ROTOR
FLOW
ENTRANCE CAVITIES
REGION STATOR CONTOUR
(CUTBACK)
15
POWER SECTION BACKGROUND
LOBE
CAVITIES
16
WHEN THE ROTOR AND STATOR ARE ASSEMBLED A SERIES OF CAVITES ARE
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
17
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
WHEN THE ROTOR TURNS INSIDE THE STATOR ITS CENTER MOVES IN A CIRCULAR
MOTION ABOUT THE CENTER OF THE STATOR
18
ROTOR WITH LOBE A FULLY ROTOR POSITION ROTATED 20
INSERTED IN STATOR LOBE DEGREES FROM PREVIOUS
POSITION
19
Power
Power Section
Section Basics
Basics
20
DURING DRILLING HIGH PRESSURE FLUID PUMPED INTO THE TOP END OF THE
POWER SECTION FILLS THE FIRST SET OF OPEN CAVATIES
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
21
22
TYPICAL POWER SECTION
RPM/TORQUE CURVES
23
TYPICAL POWER SECTION
RPM/TORQUE CURVES
500 2000
6.75”, 1/2 LOBE, 4 STAGE
450 1800
400 1600
SLIP
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

100
MAX PRESS 400
50 USEFUL 200
LOSSES 0 DELTA P 0
0 100 200 300 400 500 600 700
DIFFERENTIAL PRESSURE (PSI)
24 100.0 80
THEORY SUMMARY
MORE LOBES = MORE TORQUE
MORE LOBES = LESS RPM
MORE STAGES = MORE TORQUE
MORE STAGES = MORE AVAILABLE PRESSURE
TIGHTER FIT = HIGHER SPEED / LESS SLIP
EXCESS PRESSURE = REDUCED RUBBER LIFE
25
Surface Adjustable Bent Housing
0 to 2 Degrees
O TO 3 Degrees or straight housing
0 to 4 Degrees for XC motor
26
Measuring the Bearing Gap
27
28
DUMMY BIT
– NEVER pump on mud

lubricated bearings
without proper pressure
drop at the bit
– Use a Dummy Bit when
surface testing with a bit
is not allowed
29
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
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.
30
Rotor Manufacturing
Gun Bore
Machine Threaded Connections
Contour
Buff
Plate
Polish
Inspect
31
ROTOR BEING CONTOURED
32
ROTOR SEMI FINISHED
33
ROTOR POLISHING
34
ROTORS WAITING TO BE CHROMED
35
Rotor Coatings
Coating Advantages Considerations
Chrome Plated Inexpensive, easy to recoat Not suitable for high chloride
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
36
Stator Manufacturing
Burn and Remove Old Rubber
Blast Tube ID
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
37
STATOR BURN
38
STATOR BLAST
39
CORES
40
CORE INJECTION END
41
RUBBER BEFORE INJECTION
42
STATOR INJECTION GUN
43
STATOR THREADING
44
STATOR BORE GAUGE
45
Stator
Elastomer bonded into stator housing
Re-line possible
Stator housing very thin walled - connections susceptible to
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
46
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
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)
47
GENERAL ELASTOMER
INFORMATION
TYPICAL STATOR RUBBER COMPOUNDS CONSISTS OF A NITRILE BASE POLYMER,
REINFORCING MATERIALS, CURATIVES, ACCELERATORS, AND PLASTICIZERS.
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.
48
GENERAL ELASTOMER
INFORMATION
HNBRS WITH 90 PERCENT OR HIGHER HYDROGENATION ARE SOMETIMES
REFERRED TO AS HIGHLY SATURATED NITRILES OR HSN.
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.
49
Interference fit
• Correct operating interference +0.020”
• Elastomer swell with temp and fluid
absorption
• Elastomer compression from pressure
• PowerFit software to calculate set up

under shop conditions
50
POWER SECTION OPERATION
RUNNING A POWER SECTION AT OR BELOW RECOMMENDED PRESSURE IS THE
PRIMARY OPERATIONAL CONSIDERATION TO MAXIMUM STATOR LIFE
POWER SECTIONS ARE RATED FOR OPTIONAL POWER AND OPTIONAL LIFE
EXCEEDING POWER SECTION MAXIMUM PRESSURE RECOMMENDATIONS WILL

INCREASE POWER AND REDUCE LIFE
51
STALLING THE POWER SECTION WILL HAVE THE GREATEST EFFECT ON STATOR
LIFE
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
52
POWER SECTION SPEED CAN ALSO EFFECT STATOR LIFE
250
MAX ∆ P
200 LINE
ROTOR SPEED
INCREASING
150 FLOWRATE
(RPM)
100
50
0
0 100 200 300 400 500
DIFFERENTIAL PRESSURE (PSI)
53
Stator Failure Mechanisms
Failure due to fatigue crack growth
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
54
Stator mechanical failure
Chunked stator due to overpressure
Stator lobes strained beyond their

mechanical limits
55
Aromatics or synthetic oils weaken
elastomer
Reaction causes Shrinkage or swelling
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
56
Stator Chunking - Symptoms
Chunking is the tearing of
stator lobe elastomer.
In a chunking failure
elastomer can still seen
bonding to the stator tube
wall.
57
Stator Chunking - Symptoms
Cracks appear along the
stator lobes
Note the elastomer is visibly
bonded to the stator tube
58
Hysteresis heat build up within the

stator
Hysteresis heat generation is due to
repeated flexing of the stator lobes
Heating increases with speed, pressure
differential and compression fit
Causes reduced physical properties
and expansion of the elastomer
59
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)
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
60
Stator De-bonding -Symptoms
Clear separation of elastomer

from tube
No elastomer remains attached
to the stator tube wall
De-bonding is extremely rare
61
Stator De-bonding -Causes
Failure of bonding agents to glue elastomer to stator tube
– Mud incompatibility with bonding agents
– Manufacturing defect
Remember:
De-bonding is extremely rare
Any sign of rubber on the
tube means it is NOT de-
bonding
62
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
Flaking of chrome coating
63
Rotor pitting - Causes
Fluid Erosion
Rotor / Stator seal is longitudinal
along the crest of the lobes
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
64
Stator Elastomer
Typical life of 100-400hrs
Typical failure modes
– Fatigue
– Heat build-up
(Hysteresis)
– Chemical degradation
65
Elastomer Tip
Stators fail due to high mechanical loading, fatigue,
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
66
PowerEdge vs Conventional Stator
Contoured
Ribbed
Stator Elastomer Stator Tube
Elastomer
Tube
PowerEdge Conventional
67
EVEN WALL STATOR
68
Rotor Nozzle
69
Rotor Nozzle
GPM 2 × MW
TFA = P ×10850
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.
70
Transmission Section Design
Universal-joint system
transmits Torque &
Thrust
High strength materials
& optimized design for
maximum fatigue life.
71
Bearing Assembly
Mud lubricated Bearings
Oil Sealed Bearings
72
Bearing Section
Design
Mud-Lubricated radial
& axial bearings
Single-piece forged
drive shaft
Optimized design for
minimum erosion &
pressure drop
73
MOTOR STABILIZATION OPTIONS
74
PowerPak Motor Assembly
75
76
77
High Performance Motors
12 new designs to establish PowerPak as most
versatile range of motors available in the industry.
High Performance drilling
– 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)
78
High Speed Motors
2:3 lobe PDM > 2x efficiency PowerPak 9.62”, 2:3 High
of multi-stage turbines speed + Diamond Impreg
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
79
Summary
PowerPak operated for >400k hrs p.a. with
MTBF>2500hrs
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.
80

05b Down Hole Motors 2005

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Quartz School for Well Site Supervisors

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

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

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

• XF - Low bit offset - 40ft Radius capability

Surface Adjustable bend

• Top Sub requirement

You also need to summarize configuration

Simple Crossover - Recommended for most drilling applications

Flex Subs - For tough drilling conditions

Float Sub - Incorporate commercially available floats

Dump Valve - Not recommended

Spring operated sleeve - flow activated

High maintenance costs

The Power section converts hydraulic energy of

The rotor has one less lobe than the stator

Number of stator lobes = number of rotor lobes + 1

EACH CAVITY IS SEALED FROM ADJACENT CAVITIES BY SEAL LINES

POWER SECTION FILLS THE FIRST SET OF OPEN CAVATIES

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

TORQUE OF A POWER SECTION IS PROPORTIONAL TO CAVITY VOLUME AND

DIFFERENTIAL PRESSURE ACROSS THE POWER SECTION

150 Torque at 500 GPM 600

MORE LOBES = LESS RPM

MORE STAGES = MORE AVAILABLE PRESSURE

TIGHTER FIT = HIGHER SPEED / LESS SLIP

EXCESS PRESSURE = REDUCED RUBBER LIFE

0 to 4 Degrees for XC motor

– NEVER pump on mud

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

•Solids control equipment.

•Adequate rotary torque to drill.

Machine Threaded Connections

Un plated Inexpensive, adaptable for Corrodes and erodes

Ceramic coated Chrome Suitable for HTHP Expensive, Difficult to fish

Prep and Add Adhesive

Assemble onto Core

Cure Rubber in Autoclave

Disassemble Core from Stator Tube

Flash Ends and Measure

Elastomer bonded into stator housing

oRM100 – the standard NBR compound used in most PowerPak

HNBR - HYDROGENATED NITRILE RUBBER - HYDROGEN IS INTRODUCED INTO THE

REFERRED TO AS HIGHLY SATURATED NITRILES OR HSN.

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

• Correct operating interference +0.020”

• Elastomer compression from pressure

• PowerFit software to calculate set up

EXCEEDING POWER SECTION MAXIMUM PRESSURE RECOMMENDATIONS WILL

POWER SECTION SPEED CAN ALSO EFFECT STATOR LIFE

Failure due to fatigue crack growth

As the no. of lobes increase fatigue life

Stator mechanical failure

Stator lobes strained beyond their

Reaction causes Shrinkage or swelling

Aniline point is the temperature at which

Aniline point < 180 F some deterioration

Chunking is the tearing of

Hysteresis heat build up within the

Clear separation of elastomer

Stators fail due to high mechanical loading, fatigue,

To increase stator life, lower pressures, avoid stalls,

Mud lubricated Bearings

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