Positive Displacement Drilling Motors

Positive Displacement Drilling Motors:
A Current Industry Status Report
© 1996 Baker Hughes Incorporated

All rights reserved.
Positive Displacement Motors (PDM) are used in drilling both

directional and vertical well profiles. Their application in directional
drilling is to provide bit rotation in a “sliding”mode, (no surface
rotation) and in terms of performance drilling (straight hole drilling),
they utilize the higher rotation speeds at the bit, i.e., motor rotation
plus surface rotation
The fundamental design criterion of positive displacement motors,
pumps, and compressors derives from the work of the French
engineer and inventor Rene Moineau (“Moineau progressive cavity
principle”) who during the period of 1930 to 1948 patented numerous
variants of the “capsular”devices (as he called them).
The late 50’s saw the advent of the BENT SUB used above a
downhole motor (either turbine or PDM) to deviate the borehole in a
smooth, continuous curve.
During the last decade there has been a quantum leap in both
directional drilling and borehole surveying techniques. Once used only
during kick-off of a directional well, PDM motors/steerable systems
are now employed extensively in all types of applications: straight hole
drilling, slim hole drilling, short and medium radius horizontal drilling
and extended reach drilling. In many cases this advanced downhole
technology has made drilling with PDMs more cost effective than
conventional rotary drilling.
1
1
Introduction
n Technology Overview n Specialty Tools

n Deflection Methods –Dual Power Section
n Motor Type –New Generation
– Turbine –Re-entry
– Vane –Underbalanced
– Positive Displacement –Formation Evaluation
n PDM Components n Conclusions

All rights reserved. Positive Displacement Motors
2
2
Drilling Technology Overview
Build Rate (deg./100’, deg/30m) 3 6 12 18 24 30 60 90 120 150
Curvature Long Medium Short

Conv Rotary Specialty Motors
Tool Type Conventional Drilling Motors

Articulated Motors
Collar
MWD Type (Secondary Application) Probe (Primary Application)
(Secondary Application) Flexible (Primary Application)
Conventional - No Limit Composites
Pipe Rotation Premium - Limited Rotation
Slide Drill - No Rotation
Conventional - No Restrictions
Completions Special
Project Specific
Radius (ft.) 2000 1000 600 300 200 100 60 40

NTS
Radius (m) 600 300 180 90 60 30 18 12

This overview of the present Drilling, MWD, Pipe Rotation, and

Completions technologies showing where the tool types are in
relation to a given curvature range.
The chart can be used as an indicator for areas of concern or interest
pertaining to specific product types and/or projects as related to a
given build-up-rate (BUR).
3
3
Drilling Tools - Deflection Methods
Positive Displacement Motors

All steerable motor assemblies are engineered as “three point”curve

drilling assemblies. This diagram provides a simple basis for
understanding how an oriented, steerable motor establishes wellbore
curvatures.
THREE POINTS OF STABILIZATION - at the bit gauge, bearing
housing stabilizer, and at the motor top end string stabilizer -
approximate an arc which defines the wellpath.
The curvature of this arc is determined by the deflection device tilt
angle and the distance from the bit gauge surface to the blade
surfaces of the stabilizers (L1 + L2).
4
4
Bent Sub & Motor Kick Off Sub (KOS) Double Kick Off (DKO)
Motor Motor
1/2° - 3°/100ft (30m) Bent ≤6°/100ft (30m)
Sub
Large BOS Large BOS
No Surface Rotation No Surface Rotation
1/2° - 3°/100ft (30m)

Smaller BOS
No Surface Rotation Double Kick-Off
Sub
Kick-Off Sub
BOS BOS
BOS

Directional drilling methods guide the wellpath along a prescribed

trajectory. The principal means whereby the wellpath is caused to
change direction - inclination - and/or azimuth, include those which
either 1) Create a side force, or at the bit
2) Create a change in bit attitude (tilt) [Bit off-set (BOS) is the
effect of bit tilt.
Both are the result of tool curvature, as noted on the previous slide.
Motor configurations for directional drilling would include motors with
bent subs (always unstabilized) and bent u-joint housings of several
types.
Typical applications for these PDM configurations would include kick-
offs, sidetracks, and simple course corrections.
5
5
Fixed Angle Build Double Tilt Universal

(FAB) Motor (DTU) Motor
Flex Bent Sub

≤ 20°/100ft (30m)
Large BOS
No Surface Rotation
≤6°/100ft (30m)
Small BOS
Surface Rotation
Bent Sub
Double Tilt
Housing
Tilted Drive Sub

BOS

The fixed angle build motor is configured as a non-rotatable directional

drilling motor for applications requiring uniform high curvature
wellpaths. In these applications the tool face of the motor is oriented
in the hole to the heading which will produce the desired course
change or correction. The rotary table is usually locked and the motor
is used to drill ahead in a sliding mode.
Steerable tools that are configured with a double tilted universal joint
(DTU) allows effective use of the motor in several drilling techniques,
including long and medium radius horizontal drilling, slim hole,
underbalanced, and performance drilling.
With the DTU, the motor configuration can be used for drilling both
tangent (rotary) sections and building angle (oriented sliding sections).
6
6
Adjustable Kick Double Alignment Kick Off

Off (AKO) Motor (DAM) Motor
≤12°/100ft (30m)
≤20°/100ft (30m)
Moderate BOS
Large BOS
Surface Rotation
up No Surface
to 8°/100ft (30m) Rotation
Alignment
Bent Sub
Adjustable Kick-Off Sub
BOS

Steerable tools that are configured with an adjustable kick-off sub

(AKO) are rig floor adjustable. This allows effective use of the motor in
several drilling techniques, including long and medium radius
horizontal drilling, slim hole, underbalanced, and performance drilling.
With specific AKO settings, the motor configuration can be used for
drilling both tangent (rotary) sections and building angle (oriented
sliding sections).
The addition of an alignment bent sub enables the AKO motor to
increase the build up rates of the assembly; in effect, it becomes an
adjustable angle building motor assembly. However in this
configuration surface rotation is not possible.
7
7
Motor Types
n Turbine
n Vane
n Positive Displacement

Downhole drilling motors can be driven by several types of power

modules, all of which extract hydraulic power from the drilling
fluid.
The turbine (1930’s) and positive displacement motor (1950’s)
are well established today, as the means of producing a
directionally accurate wellbore. Both have pros and cons in given
applications.
The PDM has gained the reputation of being the work horse and
is expected to remain well positioned for the future, especially in
some of the specialized applications (Re-entry, Slimhole, Short
and Medium Radius, etc.).
The turbine may see increased usage in hot hole applications
(geothermal, etc.), although PDM stator elastomer compounds
are continually pushing the temperature envelope.
The vane motor has a limited track record, and is not considered
a commercially available tool.
In that the PDM has been and is expected to be the drilling motor
design by choice, this presentation is therefore focused on the
Positive Displacement Motor (PDM).
8
8
Overview
Bearing Deflection Stator By-Pass

Assembly Device Valve
Drive Sub
1 Stage a) Mono Lobe
(Bit Box) b) Multi Lobe
Drive Sub Universal Joint Rotor

Assembly

The positive displacement (PDM) downhole motor is powered by the

circulating fluid to provide rotation and torque to the bit without the
need for rotation of the drill string. It is a simple and rugged drilling
tool.
The PDM consists of four basic components:
* By-Pass Valve
* Power module, (rotor and stator)
* Universal joint assembly/Deflection device (transmission element)
* Bearing assembly with drive sub
PDMs operate effectively with all types of drilling mediums at any mud
weight, including water, salt water, oil-base, oil emulsion, fluids with
high viscosity or which contain lost circulation material and
compressible fluids.
The motor design is modular in construction. PDM systems differ
mainly in the power module. Depending on the required application,
the various modular assemblies can be modified or replaced enabling
motor geometry to be configured for specific applications.
9
9
By-Pass Valve
Open Closed
Drilling Fluid
Flow
Piston
Sleeve
Stator
Housing

The By-Pass valve is designed to allow the drilling fluid to by-pass the
motor assembly, thereby filling the drill string while it is tripped into the
hole, and draining the pipe while the drill string is being connected.
With no circulation or with low circulation, a spring holds a piston in the
upper position. The ports are open and allow the mud to flow into or out of
the drill string. The piston is actuated by the flow rate. At about 30% of
maximum recommended pump rate the piston is forced down against a
seat, thus closing the ports. The drilling fluid is now directed through the
motor. When the pumps are shut down, the spring forces the piston to the
upper position again, thus opening the ports.
10
10
Fluid Flow Path
Stator
(Elastomer)
Rotor
Direction
Of
Rotation
Fluid Flow
Universal
Joint

All rights reserved. Power Modules
A PDM power module consists of an elastomer molded stator with a

spiral shaped chamber and a helicoidal profile steel rotor coated with
a special hardfacing to reduce wear and avoid corrosion.
A continuous seal is formed between the elastomer of the stator and
the coated surface of the rotor.
As the drilling fluid is pumped through the motor, it fills the cavities
between the dissimilar shapes of the rotor and stator, displacing the
rotor. The resulting motion is transferred through the bearing
assembly to the drive sub, delivering rotation and torque at the bit.
The rotational SPEED (angular velocity) of the rotor is proportional to
the drilling fluid FLOW rate through the motor cavities.
The TORQUE generated is proportional to the drilling fluid
PRESSURE DROP across the power module, and is typically a
function of the weight on bit (WOB).
Increasing weight on bit causes more torque and thereby increases
differential pressure across the power module until the motor stalls, so
an increase in WOB usually causes an increase in pump pressure.
By adjusting the bit speed and torque to changing downhole
conditions, the driller can enhance bit life and optimize penetration
rates.
11
11
Lobe Configurations
1/2 2/3 3/4
5/6 7/8 9/10

Power Modules
The characteristics of a PDM are a function of the design of the

stator/rotor geometry.
The available torque and rotational speed depend on the pitch angle
and the number of lobes in the stator and rotor. The original PDM
design was the 1/2 lobe, which worked well with natural and synthetic
diamond bits, but rotated too fast for roller cone bits.
As a result , low speed, high performance PDMs were developed with
multi-lobe configurations. With a multi-lobe system, the relationship
between speed and torque is changed with the number of lobes.
The stator/rotor geometry dictates that a helicoidal steel rotor with one
or more lobes is placed inside an elastomer stator having one more
lobe than the rotor. The rotor/stator configuration is written with a
slash between the two numbers: 1/2, 3/4, 5/6, 7/8 or 9/10
HP created = T xN where: HP is horsepower
5252 T is torque in ft-lbs
N is bit speed in rpm
HHP consumed = P x Q where: P is pressure drop
1714 Q is flow rate in gpm
EFFICIENCY = HP created
HHP consumed
12
12
How Motor Geometry Affects Efficiency
100
80
Efficiency %
60
40
20
0
1/2 3/4 5/6 9/1
0
Number Of Lobes (Rotor/Stator)

Power Modules
From previous testing and experience it has been found that the 1/2
lobe system operates with the best efficiency, and when the
rotor/stator lobe configurations increase the motor efficiency drops.
This drop is caused mainly by the loss in volumetric efficiency
because of a longer seal line between rotor and stator. The multi-lobe
PDM operates at its highest efficiency at relatively low speeds,
between 60 and 200 rpm.
13
13
Elastomer
Performance Limitations
Definition
ELASTOMER = ELAST IC POLY MER
Primary Characteristic
Ability to deform substantially under application of a force
and snap back to original shape when force is removed

Power Modules
Elastomers - Synthetic rubbers, often referred to as “rubbers”are

hydrocarbon, polymeric materials similar in structure to plastic resins.
The difference between plastics and elastomers is largely one of
definition based on the property of extensibility, or stretching. The
American Society for Testing and Materials defines an elastomer as;
“A polymeric material which at room temperature can be
stretched to at least twice its original length and upon immediate
release of the stress will return quickly to approximately its
original length.”
14
14
Elastomer
General Fluid Resistance
Non-Oil Resistance Elastomer Oil Resistance

Water Resistance Non - Water Resistance
Non Polar
Polar
unsat. slightly unsat. saturated unsat. slightly unsat. saturated
- NR - IIR - EPM - NBR - HNBR - ACM - FMQ

- IR - BIIR - EPDM - CR - AEM - ECO
- SBR - CIIR - FPM - AU/EU
- BR - FFKM
- TFEP
- Nitrile Type Elastomer
- VMQ
- Viton Type Elastomer

Power Modules
Non Polar - water resistant (Hydrophobic) Polar - Non water resistant

(Hydrophillic)
NR - Natural Rubber NBR - Acrylonitrile Butalene Rubber

IR - Isoprene Rubber (closest synthetic) CR - Chloroprene Rubber
SBR - Styrene Butadiene Rubber HNBR - Hydrogenated Acrylonitrile
BR - Butadiene Rubber Butalene Rubber
IIIR - Isobutadine Isoprene Rubber ACM - Polyacrylate Methylene
BIIR - Bromo Isobutadine Isoprene Rubber AEM - Ethylene Acrylate
CIIR - Chloro Isobutadine Isoprene Rubber FPM - Flourocarbon
EPM - Ethylene Propylene Uethylene FFKM - Per Flourocarbon (Kalrez)
EPDM - Ethylene Propylene Diene Uethylene TFEP - Tetra Flouro Ethylene Propylene
(Aflas)
VMQ - Silicone Rubber Methylene
Group
FMQ - Silicone Rubber Methylene with /
Flourine Group
(NBR, HNBR - Nitrile type elastomers) ECO - Epychloronydrin
15
AU/EU - Polyester Urethane / Polyether 15
(FFKM, TFEP - Viton type elastomers) Urethane
Elastomer
Specific Elastomer Types

Designation Application Comments
Type 1 Oil/Water Based Mud Systems Standard Temp.* < 130°C (265°F)
Type 2 Oil Based Mud Systems High Temp.* <180°C (360°F)
Type 3 Oil/Water Based Mud Systems Standard Temp.* <130°C (265°F)
Improved Wear Resistance
Type 4 Oil/Water Based Mud Systems Temp.* <160°C (320°F)
High Chemical Resistance
* Stated is Circulating Temperature
© 1996 Baker Hughes Incorporated Positive Displacement Motors

Power Modules
Elastomers currently available, are tabulated here, with temperatures

and special attributes. These temperatures are circulating
temperatures, a combination of static and operating temperatures.
16
16
Elastomer
Failure
Mode
Break Outs Hardening Swell Water

“CHUNKING”
Cracks

Power Modules
The PDM module that converts the hydraulic power (from the drilling
fluid) into mechanical power is the rotor/stator power module. The
power module, due to its construction and materials, is also the
section of the motor that has to take the most abuse; therefore the
majority of motor failures is either directly or indirectly related to the
performance of the rotor or stator.
The rotor, being manufactured from steel, has only a few failure
modes, OD wear, connection damage, and fatigue, and is very rarely
effected by the drilling fluid. The stator though, apart from its
mechanical failure modes, (steel stator tube), also has failure modes
associated with the operating conditions on the stator elastomer and
bonding agent (both physical and chemical). These failure modes
can be seen on the slide.
17
17
Elastomer
Failure
Mode

“CHUNKING”
l Heat Build-Up, Temp. l Drilling Fluids

l Bond Failure Cracks – Reactive Additives
l Strength, Elasticity – Oil Base
l Rotor/Stator Fit l Static Temperature
l Heat Build-Up

Po wer Modules
CHUNKING:
Heat Build-Up, Temperature - causes the stator to swell, wear, and
breakdown
Bond Failure (elastomer glue) - stator comes away from the housing
Strength, Elasticity - stator is too brittle and breaks up or too elastic
and does not maintain its form
Rotor/Stator Fit - too loose and fluid squeezes past the rotor, too tight
and there is insufficient HHP to turn rotor or friction is generated
SWELL:
Drilling Fluids - Reactive Additives, on next slides
- Oil Base Mud, on next slides
Temperature - excessive temperature tends to cause the elastomer to
swell, ID decreases, reducing rotor/stator fit, this causes premature
wear of the stator, also can cause the bonding agent to fail
Heat Build-Up - can be the start of localized bond failure or stator
swell
18
18
Elastomer
n Reactive Additives
– Corrosion Inhibitor
– Defoamer
– Emulsifier
– Scale Inhibitor
– Wetting Agent
– Torque Reducer

Power Modules
Reactive Additions:
•Corrosion Inhibitor
•Defoamer
•Emulsifier
•Scale Inhibitor
•Wetting Agent
•Torque Reducer
All of the above additives can, depending upon the amount, have an
adverse chemical reaction with the stator elastomer. Depending on
what the reaction is the stator can have various reactions, all of which
either cause premature stator failure or shortens the effective drilling
life of the PDM.
19
19
Elastomer
Oil Base Fluids - Aniline Point

l Definition
Aniline Point is the temperature at which a homogeneous mixture of oil
(oil based mud) and aniline separates into two phases when cooled:
phase 1: oil (oil based mud)
phase 2: aniline
Correlation between Aromatic Hydrocarbons (readily soluble in aniline)
and Swelling of an elastomer
l Consequence
Aniline Point is a measure of the solubility of the oil (oil based mud) in
aniline

Power Modules
Oil base Mud

By far, oil base mud has the greatest effect on stator elastomers. A
relationship of, temperature, aromatic hydrocarbons, and aniline point
can reduce an elastomer stator to a soft spongy rubber in a very short
time.
20
20
Elastomer
Oil Base Fluids - Aniline Point
Standard Fluids with Aniline Points

l ASTM - Oil #1: AP = 255°F +/- 2°F (124°C)
slight swelling or shrinkage
l ASTM - Oil #2: AP = 200°F +/- 6°F (93°C)

intermediate swelling
l ASTM - Oil #3: AP = 158 +/- 2°F (70°C)

high swelling

Power Modules
Oil base drilling fluids usually have a fuel oil base, the maximum
recommended fuel oil base is #2, but this can depend upon the
downhole temperature, operating and static.
All service companies with motors provide a drilling fluid compatibility
service where the known drilling fluid samples are tested, under
specified pressure and temperature, on elastomer samples and the
results indicate the types of elastomer deterioration that can be
expected. This indicates the drilling life expectancy of the PDM.
21
21
Elastomer
Failure
Mode

“CHUNKING”
Cracks
l Heat Build-Up
l Drilling Fluid
l Strength, Elasticity
l Temperature

Power Modules
Hardening, Cracks -
Hardening of the elastomer leads to cracking and eventual failure by
the mechanical compression of the rotor
Heat Build-Up - localized heat can “cook”or harden the elastomer
Drilling Fluid - when cracks are present in elastomer the fluid flow will
wash or erode the elastomer
Strength, Elasticity - hardened elastomer will have lost its elastic

capabilities and damage leading to failure will occur
Temperature - consistent heat beyond the elastomer design will start

to “cook”and harden the elastomer
22
22
Elastomer
Failure
Mode

“CHUNKING”
l Sand/Solids
Cracks l Temperature
l DrillingFluid
– Reactive Additives
– Oil Base
l Rotor/Stator Fit
l Service Conditions

Power Modules
Wear:
Sand/Solids - the composition of the drilling fluid can be very abrasive,

at PDM operating flow rates and pressures. The stator can wear very
quickly, reducing the stator life.
Temperature - high downhole temperatures can cause the stator to

swell, the swelling reduces rotor/stator operating tolerances resulting
in premature stator wear.
Drilling Fluid
Reactive Additives - additives can cause stator swelling, build
up on rotors (resulting in damage to stator), elastomer
degradation
Oil base - correct oil base drilling fluid is required to ensure
minimum stator wear.
Rotor/Stator Fit - when the rotor/stator fit (tolerance) is compromised

from wear, drilling fluid is allowed to bypass the rotor resulting in loss
of power.
Service Conditions - a good rotor/stator fit ( interference tolerance) is

required to ensure that the full amount of power can be delivered by
the drilling fluid. Poor maintenance causes premature stator failure.
23
23
Multi-part, Universal-
Joint Shafts
Drilling Fluid
Flow Path U-Joint
Drive Sub Rotor
Housing
Rotor
Universal Joint
Assembly

Drive Line Components
Universal Joint Assembly/Flexible Shaft

The lower end of the rotor and the upper end of the drive sub are
connected by a universal joint assembly or flexible shaft to transmit
the power generated by the power module via the drive sub to the bit.
Also, the universal joint assembly/flexible shaft translates the eccentric
motion of the rotor into concentric rotation for the bearing assembly.
24
24
Flexible Shafts
Drilling Fluid
Flow Path
U-Joint Housing Drive Sub Rotor
Rotor
Flexible Shaft
Assembly

One piece flexible shaft usually manufactured from high strength

materials, both ferrous and non-ferrous (steel, & titanium, beryllium
copper, etc.).
The outer housing (u-joint housing) connects the bearing assembly
with the power module. Depending on the job requirement, the u-joint
housing can be straight (performance drilling) or configured with a
single bend (oriented drilling), adjustable bend assembly, or double tilt
(steerable drilling - oriented and rotary applications).
25
25
Bearing Assemblies
Mud Lubricated
Drilling Fluid
Pin Connection To
Flow Path
Universal Joint
Assembly
Upper Radial Bearing Lower Radial Bearing

Assembly Assembly Drive Sub
Axial (Thrust) Bearing (Bit Box)
Assembly
Screw-On Stabilizer Sleeve
Bearing Housing

The bearing supported drive sub transmits rotation and torque

developed by the power module to the bit.
Axial loading of the drive sub is supported by specially designed ball
bearing stack - axial(thrust) bearings, while journal radial bearings
provide lateral support above and below the axial bearings.
The radial bearings are designed to restrict drilling fluid flow such that
a small percentage of the total circulation enters the bearings, for
cooling and lubrication, prior to exiting the lower radial bearing
clearance to the annulus.
The percentage bypassed through the bearings will depend upon
operation parameters such as bit pressure drop, drilling fluid
properties, and radial bearing clearance.
The major portion of the fluid circulation rate enters the drive sub
through ports on the universal joint assembly, above the upper radial
bearing, and exits through the drill bit nozzles.
26
26
Bearing Assemblies -
Sealed Oil Bath
Pin Connection
To Drilling Fluid
Universal Joint Sealed Oil Flow Path
Assembly Reservoir
Marine Bearing Upper Rotary Thrust Bearing Lower Rotary

Face Seal Assembly Face Seal
Compensating Drive Sub
Assembly (Bit Box)
Upper Radial Lower Radial

bearing bearing

The prepressured and pressure compensated bearing section

supports the weight on the bit and provides rigid lateral stability to the
drive shaft. Heavy duty roller thrust and radial bearings operating in
synthetic oil permit high bit loads and long bearing life.
Usually the oil system is filled under pressure to charge the oil
reservoir and a calculated amount is bled off to compensate for
downhole operating conditions. The oil reservoir also contains a
floating piston that allows equalization of the oil pressure with wellbore
hydrostatic pressure.
27
27
Sleeve Stabilizer
Blade Type: Blade Matrix:
l Straight l Tungsten Carbide
l Spiral l Insert
l Tight Spiral
Blade Number: Blade Direction:

l 3 blades to l Left Hand
6 blades
l Right Hand
Integral Stabilizer
Blade Profile:
l Angle of Leading/Trailing Edge
l Area of Wall Contact (Blade Surface)

Sleeve Stabilizer:
The sleeve stabilizer is usually a cast/forged component with the
blade type, number, and direction established prior to initial
manufacture, the profile and matrix can be selected at final
manufacture to suit the project and or expected drilling conditions. The
condition of the sleeve after use is determined by the gauge size and
blade wear, it is not usually repairable. They allow the same PDM to
be adapted to fit various hole sizes, and by careful sizing
(gauge/under-gauge) can be used by the driller in steerable motor
applications for maintaining specific well profiles.
Integral Stabilizer:
The upper bearing housing (UBH) with the integral stabilizer is usually
forged but can be machined from a forged billet. As with the sleeve
stabilizer, the blade type, number and direction have to be established
prior to initial manufacture, the profile and matrix can be selected at
final manufacture to suit the project and or expected drilling
conditions. Usually the integral stabilizer on the UBH can be repaired,
i.e. built-up and re-hardfaced.
Once the integral stabilizer on the UBH is worn to the point where it is
affecting motor steerability or borehole inclination/azimuth the motor
has to be laid down. 28
28
Outline
n Technology Overview n Specialty Tools

n Deflection Types – Performance Tools
n Motor Type n Dual Power Section
– Turbine n New Generation
– Positive Displacement – Re-entry

– Vane – Underbalanced
n PDM Components – Formation Evaluation
n Conclusions

The first section of the presentation looked at the mechanics of the

PDM -how it works, component configuration, etc.
The second section of the presentation looks at “specialty tools”,
reviews the present and future PDM specifications showing how the
new generations of PDMs outperform current PDMs.
29
29
Dual Power Section Motors
Functional Issues
n Complexity
– Twin rotors and stators
– Match fitting or rotors and stators
– Connection housing
– Double connection lower rotor
– Center connection rod
– Phase timing coupling /adjustment
– Upper stator failure leads to lockup or lower stator failure
– Increases connection prone to back-off

Specialty Tools
DPS PDMs are basically two separate PDMs connected together.

Although it appears straight forward to connect them, it imposes quite
complex technical problems and a considerable amount of re-
engineering.
30
30
Functional Issues (con’t)
n Limits
– Rotor phase timing, vibration problems
– Lower drive line torque limits
– BUR and steerability
– Mid-motor stabilization
– Doubles high dollar inventory
– Operating cost per hour
n Maybe lower in easy drilling
n Will be higher when pushed to limit

Specialty Tools
Apart from the engineering requirements there are also operational

concerns relating to motor geometry and drilling parameters
31
31
Functional Issues (con’t)
n Handling
– May exceed trucking lengths, large motors
– May require special support during rig floor pick-up
– Complex to change stabilization
– Some BOP safety concerns

Specialty Tools
Due to the nearly doubling of the motor length, handling of the DPS
motors can create problems with shipping logistics and rig handling.
32
32
Performance Characteristics
Generic 6-3/4” Drilling Motors
FLOW and SPEED

FLOW RATE RANGE SPEED RELATIONSHIPS
UPPER and LOWER FLOW RATES, gpm
700 600
600 500
MOTOR SPEED, rpm

500 400
400 300
300 200
200 100
100 0
1-27-8 2-3XL 5-6XL 1-27-8 2-3XL 5-6XL
5-6 5-6DPS 5-6 5-6DPS
MOTOR LOBE CONFIGURATION MOTOR LOBE CONFIGURATIONS

Specialty Tools
Flow Rate/Speed:
As can be observed, the “standard PDM”with mono or multi-lobe
configurations show conventional flow rate curves that reflect industry
requirements and standard design:
Mono-lobe - high speed/low torque
Multi-lobe - low speed/high torque
The new multi-lobe extra long (XL) PDMs need to operate at the same
flow rates, with relatively the same bit speeds, but produce higher and
broader power values for improved ROPs.
33
33
SPEED and TORQUE

SPEED RELATIONSHIPS TORQUE RELATIONSHIPS
600 10,000
500
PRODUCED TORQUE, ft-#

8,000
MOTOR SPEED, rpm
400
6,000
300
4,000
200
2,000
100
0 0
1-2 7-8 2-3XL 5-6XL 1-27-8 2-3XL 5-6XL
5-6 5-6DPS 5-6 5-6DPS
MOTOR LOBE CONFIGURATIONS MOTOR LOBE CONFIGURATIONS

Specialty Tools
As previously explained, multi-lobe configurations reduce speed and

increase torque, hence they produce a steady increase in torque.
The DPS and XL have increased torque values due to the increase in
motor length (increase in number of stages - rotor displacement is
increased)
34
34
SPEED and POWER

SPEED RELATIONSHIPS RESULTING POWER OUTPUT
600 250
PRODUCED HORSEPOWER RANGE

500
MOTOR SPEED , rpm
200
400
300 150
200
100
100
0 50
1-27-8 2-3XL 5-6XL 1-2 7-8 2-3XL 5-6XL
5-6 5-6DPS 5-6 5-6DPS
MOTOR LOBE CONFIGURATION MOTOR LOBE CONFIGURATION

Specialty Tools
The “standard PDM” with mono or multi-lobe configurations and the

XL/DPS motors have conventional speed curves, reflecting industry
and design standards.
Mono lobe - high speed/low torque
Multi lobe - low speed/high torque
However, the power produced by the PDM configurations show the
broader and higher power bands produced by the “new”motors.
With the XL PDMs, having a higher power output than the DPS PDMs.
35
35
Re-Entry
Short Radius Tool
Orientatio n Sub
Adjustable Kick-off
Motor (AKO) By-Pass Valve
K nuc kle Jo in ts
Motor
By -Pas s Valve Section
AKO/DTU
M oto r S ectio n Housing
DT U
AK O
Bearing
Assembly

Specialty Tools
The heart of the short radius drilling system is the articulated motor which
has specially designed motor components, engineered for high build rates.
The motor can be described from right to left as follows:
The bottom section (blue) is referred to as the steering section. Within the
steering section, the three points of contact that control the radius of
curvature are contained. They are the bit, the near bit stabilizer, and the
knuckle joint stabilizer.
The power section (yellow) is connected to the steering section by external
articulations (knuckle joint) and internal universal joints.
The knuckle joints allow the motor to pass through the curvature produced
by the steering section without any bending load being induced.
The top section (blue) includes the orientation sub for the guidance system.
It may also include a bypass valve or float valve if required.
The same concept applies to both the curve (AB) motor and the horizontal
(AH) motor.
There are a variety of deflection devices being used including both fixed and
adjustable bends along with different length of steering sections to allow for
the flexibility and the numerous configurations.
(Description of non articulated motor as in first section of presentation)
36
36
Slide Drill Systems
n 40 to 70 foot build curve radii

n 3-7/8” to 6” hole size
n Articulated and flexible tooling
n Packaged tool system
n MWD and steering tool for control/survey
n Up to 750 foot laterals
n Limited drilling efficiency
n Well bore placement control is a challenge
n Limited specialty completions

Specialty Tools
Slide drill systems - drilling and finishing the well using no surface
rotation due to tight build curve radius. (see next slide for specification
chart)
In the range of 40 to 70 ft (12 to 21m) build curve radius limits the
string rotation. This reduces the drillable lateral, drilling efficiency
(less hole cleaning), and wellbore placement control.
37
37
Short Radius
Tool/Hole Size Matrix Configuration
MOTOR SPECIFICATIONS 3-1/8" Short Radius 3-3/4" Short Radius 4-3/4" Short Radius 4-3/4" 30m Radius 6-1/2" Short Radius
System R18 System R12 System R12 System R30 System R30
Tool Size (inches) 3-1/8 3-3/4 4-3/4 4-3/4 6-1/2
Motor OD (inches / mm) 3-1/8 / 79.4 3-3/4 / 95.3 4-3/4 / 120.7 4-3/4 / 120.7 6-1/2 / 165.10
Curve Radius (feet / meters) 60 - 143 / 18-44 40 - 85 / 12-26 40 - 100 / 12-30 80 - 180 / 24.5-55 85 - 190 / 26-58
Curve BUR (°/100 ft.) 40 - 100 67 -146 58 -146 32 -71 30 - 67
Hole Size Drilled (inches) 3-7/8 4-1/2, 4-3/4 5-7/8, 6 5-7/8, 6 8-3/8
Motor Length (ft. / m) 14 / 4.3 12 - 17 / 3.5-5.2 12 - 17 / 3.5-5.2 12 - 17 / 3.5-5.2 15-17 / 4.7-5.3
Motor Weight (lbs / kg) 330 / 150 400 / 180 650 / 295 700 / 320 660 / 330
Minimum Hole Size Above
KOP - (1/8"over bit size, inches) 4 4-5/8, 4-7/8 6, 6-1/8 6, 6-1/8 8-1/2
Minimum Casing Size Above 5-1/2" 20#, 4-1/2" bit 7" 29#, 5-7/8" bit 7" 26#-32#, 5-7/8" bit
KOP - ( inches) 4-1/2" 11.6# 5-1/2" 17#, 4-3/4" bit 7" 26#, 6" bit 7" 23# - 29#, 6" bit 9-5/8" 36#, 8-3/8" bit
Max. Op. Temp. (°F / °C) 260 / 127 260 / 127 260 / 127 260 / 127 260 / 127
MOTOR SPECIFICATIONS 3-1/8" Short Radius 3-3/4" Short Radius 4-3/4" Short Radius 4-3/4" 30m Radius 6-1/2" Short Radius
Flow Rate (GPM / l/min) 80-160 / 300-600 133-185 / 500-700 132-230 / 500-850 132-230 / 500-850 265-480 / 1000-1800
Bit Speed (RPM) 182-365 260-370 150-255 150-255 110-200
Max. Diff. Press. (psi / bar) 613 / 40 683 / 48 341 / 24 512 / 36 430 / 30
Op. Torque (ft-lbs / Nm) 440 / 600 679 / 920 605 / 820 1048 / 1420 2150 / 2900
Box Up 3" CDP Pin 2-7/8" Hydril PH6 2-7/8" Hydril PH6 NC 38 NC 38
Make Up Torque (ft-lbs / Nm) 2655 / 3600 3500 / 4747 3500 / 4747 12800 / 17360 12800 / 17360

Specialty Tools
This table shows the range of short radius tools available.
38
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Rotary Systems
n 70 to 300 foot build curve radii

n 3-7/8” to 8-3/8” hole size
n Articulated and flexible tooling
n “Steerable” MR drilling concept
n Fatigue damage to drill pipe may occur
n MWD for control and survey
n Up to 2000 foot laterals
n Rotary mode drilling efficiency
n Excellent well bore placement control
n More conventional completions

Specialty Tools
Rotary systems - being able, if required, to rotate from the surface

during drilling and finishing the well through the build curve radius.
The range of 70 to 300ft (21 to 30m) build curve radius allows the
drillstring to be both rotated and oriented from the surface. The
surface rotation permits up to 2000ft laterals (cutting agitation), which
increases drilling efficiency and wellbore placement control.
39
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Underbalanced Drilling Motor
Compressible Fluid Systems
Stator Compressible Fluid:

(Elastomer) • Flow rate changes with pressure
• Low lifting capacity, AV’s greater than mud
• Higher air volumes exceed flow rates of mud
Rotor
motors
Direction • Air volume to clean hole is 3x greater than
Of flow rate for mud motor
Rotation
Air Motor Advantages:

• Power section design, enlarged chamber
Fluid Flow volume
• Low ∆ P is only required to operate air motor
• Air motor uses expansion work of the
compressiblefluid
• Over speeding of motor is less likely when
pulling
off bottom
Universal • Can be run on dry air
Joint • When run on fluid, high torque - (s)low speed

Specialty Tools
High angle and horizontal wells are drilled using steerable downhole
mud motors to build inclination and to drill the horizontal sections,
however, mud motors have been identified as having many economic
limitations when using a compressible drilling fluid.
Compressible fluids require annular velocities much greater than
drilling mud however, the higher air volumes exceed the
recommended flow rates for mud motors, often causing premature
failure.
Mud motors are hydrostatic, they can use only the displacement work,
and not the expansion work, of the compressed fluid.
The drill pipe represents a cylinder for pressure storage, so rotating of
the bottom leads to an expansion of the compressible drilling fluid with
a dramatic increase in motor speed. The effect of over speeding the
motor causes motor “run away”, resulting in possible motor and bit
damage.
The air motor with its optimized power module chambers utilizes the
expanding compressible fluid and as a result allows higher flow to
maintain hole cleaning.
40
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Compressible Fluid Systems
Size Flow Rate Speed Differential Pressure Operating Torque Power Output Eff. Lobe
6-3/4" Gall/Min Ltr/Min RPM PSI Bar ft/lbs. Nm HP kW
Low Speed/High Torque 185-475 700-1800 100-260 725 50 2800 3800 53-139 40-103 69% 5/6
Low Speed/Higher Torque 264-485 1000-1800 110-200 870 60 4300 5800 90-164 67-122 68% 7/8
Low Speed/Higher Torque-Flow 345-610 1300-2300 100-180 725 50 4800 6500 91-165 68-123 60% 7/8
XL Medium Speed/High Torque-Flow 264-660 1000-2500 88-220 955 65 5480 7400 91-228 68-170 62% 5/6
Medium Speed/Moderate Torque 185-530 700-2000 190-550 725 50 1840 2500 67-193 50-144 86% 1/2
Medium Speed/Low Torque 160-475 600-1800 190-580 580 40 1240 1680 45-137 33-102 85% 1/2
AD Mud (S)Low Speed/Higer Torque-Flow 345-610 1300-2300 53-94 350 24 4280 5800 43-76 32-57 62% 7/8
AD Compressible Fluid 2100 scfm 60 nm³/min 110-323 240 16.5 3170 4300 44-66 34-49 - 7/8

Specialty Tools
Chart showing comparison of various 6-3/4”motor configurations

including the air motor in air and the air motor using standard drilling
fluid
(AD Mud)
41
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ADM Motor Specifications
Size 3-1/8" 4-3/4" 6-3/4" 8" 9-1/2"

Pump Rate
[l/min] 300 - 600 600 -1200 1300 - 2300 2000 - 3400 2500 - 4200
[gpm] 80 - 160 160 - 320 345 - 610 530 - 900 660 - 1110
Speed Range
[rpm] 63 - 126 55 - 110 53-94 48-81 41 - 68
Oper. Diff. Pressure
[bar] 20 20 24 24 24
[psi] 290 290 350 350 350
Oper. Torque
[Nm] 960 2200 5800 10100 15000
[ft-lbs] 710 1620 4280 7450 11060
Max. Torque
[Nm] 1540 3520 9280 16160 24000
[ft-lbs] 1140 2590 6840 11910 17690
No Load Pressure
[bar] 14 10 14 14 12
[psi] 200 145 200 200 175
HP Range
[kW] 6-12 13-25 32-57 51-86 64-107
[HP] 8-16 17-34 43-76 68-115 86-143

Specialty Tools
The specification chart shows the size range of ADM motors, flow
rates, torques and low speed (compare to standard motor speeds)
* Note low differential pressure.
42
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Formation Navigation Definition
n GEOSTEERING - Using FEMWD sensors in conjunction with

directional data in horizontal wells to maintain the stratigraphic
position of the drilling assembly and to effectively steer the drilling
assembly into the target horizon.
n A further refinement in this technique uses advanced FEMWD sensors

to navigate the drilling assembly within the specified boundaries of
the reservoir. This is "Reservoir Navigation".

Specialty Tools
By integrating the directional drilling and formation evaluation

technologies, the new drilling systems allow drillers to detect bed
boundaries sooner and keep their horizontal wells within tighter zones
for extended intervals.
These new tools combine a steerable PDM with advanced MWD
sensors for geosteering and formation evaluation. The sensor array
can include inclinometers, azimuthal gamma ray scintillators, and a
multi-frequency, multi-depth of investigation resisivity sensor.
43
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Formation Navigation
Inclination
Measurement
Neutron Resistivity
Gamma Ray
Density
n Multiple depths of investigation for quantitative determination of

formation resistivity (Rt)
n Early bed boundary detection
n A near bit inclinometer, enabling quick response to inclination changes
n A steerable motor system, permitting variable build rates for up to 15°/100ft
n Resistivity measurements available in either oil base or water base muds
n Dual azimuthal gamma ray sensors 180° apart, providing high and low
side measurements

Specialty Tools
Operator benefits: (as above)
44
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Optional Modular Sensors
Drill Collar MWD Drill

Converter Collar
NaviGator ™ Tool
Modular Drilling
Modular Density Modular Neutron Dynamics (MDD)
Lithology (MDL) Porosity (MNP)

All rights reserved. Specialty Tools
The modular system permits the addition of other modular logging

sensors into the drilling system. This provides a comprehensive
geosteering/logging capability. This becomes important when there is
no follow up wireline logging and/or gas/oil contacts need to be
identified and avoided while drilling!!
45
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Application
n Ensure optimal entry into the reservoir
n Navigate within the bounds of the reservoir
n Predict exit from the reservoir
n Position a quantitative resistivity device close to the bit

All rights reserved. Specialty Tools
Drillers can now navigate in the target zone with greater precision
using these types of tools. With near bit dual resistivities, detection of
critical boundaries is permitted and allows the driller to make well path
corrections earlier than conventional propagation tools positioned
above the PDM.
46
46
Conclusions

A recap of the PDM, including future direction of the various drilling

systems.
47
47
Special Considerations
n High Circulation Rates

– Rotor nozzling
n Reactive Torque
– Motor characteristics
– Weight on bit
– Inclination of hole
– Type and length of DC’s, and HWDP
– If used, the number and placement of stabilizers
– Formation type, drillability
– Type of bit
– Flow rate
Conclusions
High Circulation Rates:

Multi-lobe PDMs have a maximum allowable drilling fluid flow. If higher
drilling fluid discharges are required, hole/bit cleaning, etc., the multi-
lobe PDM allows a bypass flow through the center of the rotor. This
bypass can be controlled by a nozzle - nozzle holder on the top of the
rotor. With a rotor nozzle installed, circulation rates in excess of the
nominal maximum values should be used only with the bit on bottom.
Excess flow off bottom would be only partly bypassed, and can cause
severe damage to the PDM and bit by over speeding.
By using a rotor nozzle, the PDM characteristics will be altered and the
PDM can not deliver its full power even with higher flow rates.
Determination of Reactive Torque:
The PDM produces a clockwise rotation at the bit box. An equal and
opposite reaction, which equals the torque consumed by the bit, is
therefore created and transmitted to the stator housing. This opposite
reaction is called “reactive torque”.
Reactive torque can be controlled by the operator by controlling WOB.
Because it tends to force the drillstring to the left, this reactive torque
must be taken into consideration in order to maintain correct directional
orientation during directional drilling.
48
48
Special Considerations
n LCM Concentration
– Grain size
– Quantity/bbl
– Mixing preparation

Conclusions
PDMs of all sizes have been used with loss circulation material (LCM)
(usually the LCM is “Walnut Hulls” or “Cellophane Flakes”). If the following
criteria are observed, there should be no problems encountered when
using LCM through a PDM. The 3 important things to remember are:
1) Grain Size, 2) Quantity/bbl, 3) Mixing preparation
1) Grain Size
This should not be larger than 6mm (1/4”) in diameter, and no smaller than
medium (40 mesh) to fine (80 mesh). The influence of LCM abrasiveness
on the stator elastomer should also be taken into account.
2) Quantity/bbl
There is no definitive answer to this, but in general a mix of 18 lb/bbl is
considered to be maximum and 13 lb/bbl normal. As long as the LCM fluid
can be pumped with a centrifugal pump, no problems are expected for the
PDM.
3) Mixing Preparation
Careful mixing of LCM is essential to avoid clogging the by-pass valve,
bearing assembly and possibly plugging the bit nozzles or fluid ways.
Never “dump”LCM into the mud pits at the pump intake, always use a
premix tank for mixing LCM.
49
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Drilling Technology Overview
Build Rate (deg./100’, deg/30m) 3 6 12 18 24 30 60 90 120 150
Curvature Long Medium Short

Conv Rotary Specialty Motors
Tool Type Conventional Drilling Motors

Articulated Motors
Collar
MWD Type (Secondary Application) Probe (Primary Application)
(Secondary Application) Flexible (Primary Application)
Conventional - No Limit Composites
Pipe Rotation Premium - Limited Rotation
Slide Drill - No Rotation
Conventional - No Restrictions
Completions Special
Project Specific
Radius (ft.) 2000 1000 600 300 200 100 60 40

NTS
Radius (m) 600 300 180 90 60 30 18 12

Conclusions
An overview of the present Drilling, MWD, Pipe Rotation, and

Completions technologies, showing where the tool types are in
relation to a given curvature range.
The chart can be used as an indicator for areas of concern or interest
pertaining to specific product types and/or projects as related to a
given build-up-rate (BUR).
50
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Future Direction Drilling Systems
n Few if any quantum leaps

– R&D funding limitations
– Semi-mature product line
– Future generation of motors
– Market direction remains flexible
n Re-entry applications
n Multi-lateral applications
n Extended reach applications
n Focus on system (multi product line) integration
– Drilling and survey
– Drilling and formation evaluation
– Drilling and completions
– Drilling and core recovery
Conclusions
Quantum Leaps?
Limited financial resource: money put where best returns are.
Large existing motor fleets: tweaking present configurations.
Future motors - establish future requirement, hi-temp, new
materials, etc.
Drilling systems, which way to go with limited funds
Focus Systems?
New hi-tech survey systems (laser gyros, etc.)
FE - one tool for all - drilling and evaluation
“Bottoms Up”concept, drill the well so all aspects are taken into
consideration
Formation information is invaluable in helping to plan for the
various drilling applications.
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Future Direction
Drilling Systems
n Focus on Enhancing Existing Products
– Improve effective ROP
n Improve instantaneous ROP
n Increase on bottom time of rock bits
n Increase on bottom time for battery systems
– Improve MTBF (Mean Time Between Failures)
– Improve tool / product interrelations
– Improve data quality
– Improve data transmission rates
– Reduce and improve tool connections

Conclusions
Focus -Products
52
52

Positive Displacement Drilling Motors

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Positive Displacement Drilling Motors

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Positive Displacement Drilling Motors:

A Current Industry Status Report

© 1996 Baker Hughes Incorporated

Positive Displacement Motors (PDM) are used in drilling both

n Technology Overview n Specialty Tools

© 1996 Baker Hughes Incorporated

Build Rate (deg./100’, deg/30m) 3 6 12 18 24 30 60 90 120 150

Curvature Long Medium Short

Tool Type Conventional Drilling Motors

MWD Type (Secondary Application) Probe (Primary Application)

(Secondary Application) Flexible (Primary Application)

Conventional - No Limit Composites

Pipe Rotation Premium - Limited Rotation

Slide Drill - No Rotation

Radius (ft.) 2000 1000 600 300 200 100 60 40

© 1996 Baker Hughes Incorporated

This overview of the present Drilling, MWD, Pipe Rotation, and

Positive Displacement Motors

All steerable motor assemblies are engineered as “three point”curve

1/2° - 3°/100ft (30m)

© 1996 Baker Hughes Incorporated

Directional drilling methods guide the wellpath along a prescribed

Fixed Angle Build Double Tilt Universal

Flex Bent Sub

Tilted Drive Sub

© 1996 Baker Hughes Incorporated

The fixed angle build motor is configured as a non-rotatable directional

Adjustable Kick Double Alignment Kick Off

Adjustable Kick-Off Sub

© 1996 Baker Hughes Incorporated

Steerable tools that are configured with an adjustable kick-off sub

© 1996 Baker Hughes Incorporated

Downhole drilling motors can be driven by several types of power

Bearing Deflection Stator By-Pass

Drive Sub Universal Joint Rotor

© 1996 Baker Hughes Incorporated

The positive displacement (PDM) downhole motor is powered by the

© 1996 Baker Hughes Incorporated

Positive Displacement Motors

A PDM power module consists of an elastomer molded stator with a

1/2 2/3 3/4

5/6 7/8 9/10

© 1996 Baker Hughes Incorporated

The characteristics of a PDM are a function of the design of the

© 1996 Baker Hughes Incorporated

ELASTOMER = ELAST IC POLY MER

© 1996 Baker Hughes Incorporated

Elastomers - Synthetic rubbers, often referred to as “rubbers”are

Non-Oil Resistance Elastomer Oil Resistance

- NR - IIR - EPM - NBR - HNBR - ACM - FMQ

© 1996 Baker Hughes Incorporated

Non Polar - water resistant (Hydrophobic) Polar - Non water resistant

NR - Natural Rubber NBR - Acrylonitrile Butalene Rubber

Specific Elastomer Types

* Stated is Circulating Temperature

© 1996 Baker Hughes Incorporated Positive Displacement Motors

Elastomers currently available, are tabulated here, with temperatures

Break Outs Hardening Swell Water

© 1996 Baker Hughes Incorporated Positive Displacement Motors

Break Outs Hardening Swell Water

l Heat Build-Up, Temp. l Drilling Fluids

© 1996 Baker Hughes Incorporated Positive Displacement Motors

© 1996 Baker Hughes Incorporated Positive Displacement Motors

Oil Base Fluids - Aniline Point