08.TBT1-Downhole Motors

Introduction to Drilling Technology
Dr. Javier Holzmann
SS 2018
Introduction to Drilling Technology
Introduction to Rotary-Drilling Technology
Drilling a Well, Drilling Methods
Rock Mechanics, Well Stability, Overbalance vs. Underbalance
Borehole Hydraulics
Drilling Mud: Functions, Properties, Rheology
Drilling Bits, Bit Selection Criteria
Drilling Optimization Concepts
Drill String Basics
Downhole Motors
Special Drilling Systems (Drilling Hammer, Coring)
Formation Pressure, Frac Gradient
Measuring Drilling Parameters
Dr. Javier Holzmann

Institut für Erdöl- und Erdgastechnik TBT I_SS 2018 2
Learning Objectives
 Downhole motors
- Application, classification & types
 Positive Displacement Motor (PDM)

- Construction
- Principle including laws of Moineau principle
- Geometry
- Characteristics including RPM and Torque dependency
on Gear Number
- Stator Failure Mechanisms
Dr. Javier Holzmann

Learning Objectives
 Turbine
- Construction
- Bearing Assembly
- Principle (Rotor, Stator) & Theory
- Characteristics
 Comparison of Moineau Motor and Turbine
Dr. Javier Holzmann

Downhole Motor
 Special tool mounted in the bottom hole assembly

(BHA) to drive the bit without rotating the drill string
from surface
 http://torotools.com/html/about_motors.html
Dr. Javier Holzmann

Downhole Motor Applications
 Straight hole drilling processes

- To provide additional RPM downhole
 Horizontal, highly inclined & directional processes
 Extended reach (extremely deep) drilling processes
 Slim hole drilling processes
Dr. Javier Holzmann

Downhole Motors Classification
Bit direct drive

(Downhole motors)
Hydro-mechanical
Electromotor
Motor
Hydrodynamic Hydrostatic
Motor Motor
Blade- Moineau- Peristaltic

Turbine
Motor Motor Motor
Dr. Javier Holzmann
Institut für Erdöl- und Erdgastechnik Source: Teodoriu, C.: Script Tbt 1, 2014 TBT I_SS 2018 7
Downhole Motor Types
Moineau Garrison
Vane motor
motor motor
3/4 Baker
motor
Source: Teodoriu, C.: Script Tbt 1, 2014

Dr. Javier Holzmann
Downhole Motor Types
Moineau Allegheny- Christensen/Shell

motor Ludium motor motor
5/6 Schlumberger
motor

Dr. Javier Holzmann
Positive Displacement Motor (PDM)
 Hydraulically driven downhole motor

 Uses the Moineau principle to rotate bit (independent
from DS rotation)
 Spiral rotor is forced to rotate within a rubber sleeved

stator by pumping mud through the tool
Dr. Javier Holzmann

 Consists of several sections:

- By-pass valve
- Power/Motor section
- Helical-shaped rotor and stator
- Universal joint or connecting rod section
- Bearing section with drive sub
 Power section converts hydraulic energy of high

pressure drilling fluid to mechanical energy in form of
torque output for the bit
Dr. Javier Holzmann

By-pass Valve
Power Unit
Moineau Motor Construction (Rotor and Stator)
 Conventional motor design

Transmission
Unit
Bearing
Tubular Housings
and Stabilizer
Dr. Javier Holzmann

Institut für Erdöl- und Erdgastechnik Source: Heriot-Watt University, Institute of Petroleum Engineering TBT I_SS 2018 12
Moineau Motor Construction
 New motor design
Source: http://www.nap.edu/openbook/0309050766/xhtml/images/img00018.jpg
Dr. Javier Holzmann
Motor Section
Stator
Rotor
Rubber Sleeve
Seal cavity
Source: http://www.roschengroup.com/14-2-down-hole-motor.html
Dr. Javier Holzmann
Motor Section

Dr. Javier Holzmann
Principle of a By-pass Valve
 Used in tripping operations

 PDM divides DS into two
zones:
- above and under the motor

Dr. Javier Holzmann
VertiTrak Components Pulser
Assembly
Pulser-
Control
Sub
Electronics,
Turbine Sensors,
Hydraulics
Source: Dr. Matthias Reich (X-tremeBaker Hughes INTEQ): TU Clausthal presentation 12/17/2004
Dr. Javier Holzmann
VertiTrak Components
Flow Rate (l/min)
Pressure (bar)
Torque (Nm)
Power
Section
Bit Speed (RPM)

Speed (1/min)
Source: Dr. Matthias Reich (X-tremeBaker Hughes INTEQ): TU Clausthal presentation 12/17/2004
Dr. Javier Holzmann
 Characteristics
- Torque is directly proportional to the motor’s differential
pressure  easy to operate.
- RPM is directly proportional to flow rate, though
somewhat affected by torque resistance
∆𝒑∙𝑸
- Hydraulic horsepower consumed: 𝑷HP =
𝟏𝟕𝟏𝟒
Where 𝑷HP = Power in [HP]

∆𝑝 = pressure drop across the motor in [psi]
Q = flow rate in [gpm]
Dr. Javier Holzmann

The First Law of Moineau Motors
 Prime mover (transmission means) mainly consists of
two helical members
 Two helical members are disposed within another
 Outer member has one helical thread (also helical

tooth) more than inner member
 Every thread of inner member constructed to constantly

contact outer member
Dr. Javier Holzmann

Typical PDM Lobe Profiles
1/2 3/4 4/5 5/6 7/8 8/9 9/10
Source: Heriot-Watt University, Institute of Petroleum Engineering

Dr. Javier Holzmann
Rotor Pitch
360° = 1 entire helical rotation HR

Verdrehungswinkel
360°
360° Verdrehungswinkel
360°

Dr. Javier Holzmann
Rotor Pitch
Source: http://www.scoutindustry360.com/web/wp-content/uploads/2014/04/netzsch-nemo-by-.jpg
Dr. Javier Holzmann
The Second Law of Moineau Motors
 “The pitches of the helices of the two members are in

the same ratio as the numbers of teeth or threads.”
𝐻𝑅 𝑘
=
𝐻𝑆 𝑘+1

Dr. Javier Holzmann
3D Animation of Rotor and Stator (5/6 Motor)
 https://www.youtube.com/watch?v=XMa8Wkq4Jo0
Dr. Javier Holzmann

Principle of a 1/2 Drilling Motor
 𝑀 =𝐹∙𝑒
 𝑀 = 𝑐𝑜𝑛𝑠𝑡1 ∙ 𝑝1 − 𝑝2 ∙ 𝑒
= 𝑐𝑜𝑛𝑠𝑡1 ∙ ∆𝑝 ∙ 𝑒
 𝑀 = 𝑐𝑜𝑛𝑠𝑡2 ∙ ∆𝑝

Dr. Javier Holzmann
Geometry of a 1/2 Moineau Motor
 O1: Center of rotor

O1
cross section e
O2
e
O3
 O2: Rotor axis
 O3: Stator Axis

Dr. Javier Holzmann
Geometry of a 1/2 Moineau Motor
 O1: Center of rotor

cross section
O2 O1
 O2: Rotor axis
 O3: Stator Axis

Dr. Javier Holzmann
The Third Law of Moineau Motors
1
 𝜔1 = −
𝑘
∙ 𝜔2
 𝜔2 = Rotational speed 2
of rotor around its
O3
stator axis
O2
 𝜔1 = Rotational speed 1 O1
of rotor around its
own axis

Dr. Javier Holzmann
Kinematic of a 5/6 Moineau Motor
Axis turns -90° Axis turns -180°
Rotor turns Rotor turns
1 90° 90° 180° 180°

𝜔1 = − ∙ 𝜔2 = = 18° = = 36°
𝑘 𝑘 5 𝑘 5
Dr. Javier Holzmann
Theoretical Flow Through a Moineau Motor
𝐻𝑠
 𝑉= 0
∆𝐴 ∙ 𝑑𝑙
 𝑄𝑡ℎ = 𝑘 ∙ ∆𝐴 ∙ 𝐻𝑠 ∙ 𝑛𝑅
 𝑛𝑅 = Number of revolutions [RPM]

∆𝐴

Dr. Javier Holzmann
Multi Gear Motor – Basic Profile Development
(k+1) e
ke

Dr. Javier Holzmann

Dr. Javier Holzmann
 Cycloids
Cycloid
Prolate
cycloid
Short
cycloid

Dr. Javier Holzmann
 Stator profile development
 Basic circle: R = (k+1)∙e
(k+1) e  Roll off circle: r = e
 A normal hypocycloide
e
r=e with “(k+1)-peaks” is
created
Dr. Javier Holzmann
 Rotor profile development
 Basic circle: R = k∙e

ke
 Roll off circle: r = e
 A hypocycloide with
er=e
“k-peaks” is created

Dr. Javier Holzmann
 Final rotor profile development
 Imagine:
- A circle with radius e rolls off
on hypocycloid
- Look on perpendicular points
on the way or the equidistant
extension of the hypocicloide
e
to the outside

Dr. Javier Holzmann
 Basic profile of rotor and stator
(k+1) e
ke

Dr. Javier Holzmann
Theoretical Characteristics of Moineau Motors
Efficiency
RPM Power
Torque
∆𝑃
Dr. Javier Holzmann
Moineau Motor Characteristics

Dr. Javier Holzmann
Characteristics of a 3/4 Motor
200 50
3 3/4" Navi-Drill M1C

03.08.1999, mk
180 45
Q=325 l/min
160 40
140 35
Q=250 l/min
Efficiency [%]
120 30
Torque [Nm]
efficiency h [%]
RPM[Nm]
Q=200 l/min
RPM
100 25
torque
80 Q=150 l/min 20
60 15
40 10
20 5
0 0
5 7 9 11 13 15 17 19
∆pp[bar]
[bar]

Dr. Javier Holzmann
Dependency of RPM and Torque from Gear Number
Dr. Javier Holzmann

Source: Teodoriu, C.: Script Tbt 1, 2014 TBT I_SS 2018
Institut für Erdöl- und Erdgastechnik 42
Qualitative Comparison of Different Motor Types
16000 1/2 gängig 600 5/6 gängig 9/10 gängig

16000 9/10 600
1/2 gängig 16000 5/6 gängig 600 gängig
16000 600 16000 600 16000 600
14000 1/2 14000
5/6 14000 9/10
14000 500 14000 500 14000 500
12000 500 500 12000 500
Drehmoment [Nm]
Drehmoment [Nm]
12000
Drehmoment [Nm]
Drehzahl [min ]
Drehzahl [min ]
Drehzahl [min ]
12000 12000
Torque [Nm]
Rpm [min ]-1

Torque [Nm]
Rpm [min ]-1
12000
Torque [Nm]
Rpm [min ]-1

400 400 400
-1
-1
10000 10000
-1
400 10000 400 400
10000 10000 10000
Drehmoment
Drehmoment
Drehmoment
8000 300 8000 300 8000 300
Drehzahl
8000 300
Drehzahl
8000 300
Drehzahl
8000 300
6000 6000 6000
200 200 200
6000 6000 6000
4000 200 4000 200 4000 200
4000 100 4000 100 4000 100
2000 2000 2000
100 100 100
2000 0 0 2000 0 2000 0 0
1 1
0 1
0 1
0 0 1
0 0 1
0

Dr. Javier Holzmann
Source: http://petrowiki.org/Directional_deviation_tools
Dr. Javier Holzmann
1:2 PDM Multilobe PDM
High speed Lower speed
Low torque Higher torque
High flow rate Lower flow rate
No rotor by-pass nozzle Rotor by-pass nozzle
- Low performance motor - Higher performance motor
- Low performance bit - Higher performance bit
Low WOB limit Higher WOB limit
High-speed bit usually needed Can use journal bearing
Relatively easy to orient More difficult to orient
Use with bent sub or basis for
Use mainly with bent sub
steerable PDM
Dr. Javier Holzmann
Stator Failure Mechanisms
 Mechanical failures and fatigue
 Thermal and hysteresis failures
 Chemical failures
Dr. Javier Holzmann

 Mechanical failure of the stator elastomer

- If elastomer is overloaded beyond its stress and strain limits
 Failure source:
- Excessive pressure & flow rate
- Repeated stalling
- Too much rotor-stator compression
 Overstrain stator elastomer

 Fatigue induced cracks
Dr. Javier Holzmann
Modern Moineau Motor with Uniform Elastomer
Coating
Elastomer in
Elastomer
gleichmäßiger
with
uniform
Wandstärke wall thickness
Steel stator
Statorkörper aus Stahl
 Improved heat transfer  higher effectivity

 smaller tolerance between  improved durability
rotor and stator properties
Dr. Javier Holzmann
 Failed stator due to growing fatigue crack
Fatigue cracks at
bottom of lobes
Dr. Javier Holzmann
 Thermal and hysteresis failures

- If stator elastomer temperature exceeds rated temperature
for certain time
 Failure source:
- High elastomer temperatures due to high downhole
temperatures, hysteresis heat, or both
- Physical properties of stator elastomer usually weaken as

temperature increases
 Weakening results in shortened stator life

Dr. Javier Holzmann
 Heat failure of stator elastomer

Dr. Javier Holzmann
 Hysteresis heat
build-up within
stator elastomer

Dr. Javier Holzmann
 Chemical failures of stator elastomer
 Failure source:
- Drilling fluids
- Aromatics/synthetic oils
 Weakening of molecular rubber chain

 Volume reduction or shrinkage
Dr. Javier Holzmann

Modern PDM – Cut Off View

Dr. Javier Holzmann
Rotor With Uniform Wall Thickness
Inner Pipe
Rotorwall

Dr. Javier Holzmann
Drilling Turbine
Source: http://baummags.a.cdnify.io/files/slides/locale_image/medium/
0075/18637_en_c43b3_4904_halliburton-turbopower.jpg …....
Dr. Javier Holzmann
Drilling Turbine

Dr. Javier Holzmann
Drilling Turbine – Bearing Assembly

Dr. Javier Holzmann
Drilling Turbine – Axial Bearing Assembly

Dr. Javier Holzmann
Turbine – Stator & Rotor
Source: http://cdn.pesn.com/wiki/we8l5l7tuoe2rframs0rlahzmx0fe6x1.gif
https://upload.wikimedia.org/wikipedia/commons/c/ca/Axial_compressor.gif
Dr. Javier Holzmann
Turbine – Stator & Rotor

Dr. Javier Holzmann
Drilling Turbine - Principle
Mud Flow
Rotary-
Force
Axial-
Force
Dr. Javier Holzmann
Drilling Turbine - Theory
Turbine Shaft
Stator Blade
Rotor Blade
Housing
Rotor
movement
Longitudinal cut
Longitudinal through stator
cut through rotor section
turbine section

Dr. Javier Holzmann
Entry edge
Exit edge
Entry edge
Exit edge
Entry angle and exit angle at the bucket profile of a drilling turbine

Dr. Javier Holzmann
Drilling Turbine Theory
Source: http://patentimages.storage.googleapis.com/US7204326B2/US07204326-20070417-D00000.png
Dr. Javier Holzmann
Rotor entry Rotor exit
 𝛽1 = rotor entry angle
 𝛽2 = rotor exit angle
 𝛽1 ≠ 𝛽2

Dr. Javier Holzmann
 𝑥 = width of gap
 𝑏 = width of rotor & stator
 𝐷𝑚 = average rotor diameter
 𝑚𝑔𝑒𝑠 = total mass flow
 𝑚𝑠𝑝 𝐿𝑎𝑢𝑓
= rotor gap losses
 𝑚𝑠𝑝 𝐿𝑒𝑖𝑡
= stator gap losses

Dr. Javier Holzmann
n in min-1
Friction coefficient f
n=0
n=100
n=300
n=500
n=700
n=900
n=1100
n=1300
Specific bearing load in [bar]
Bearing load in [kN]

Dr. Javier Holzmann
Drilling Turbine – Theoretical Characteristics

Dr. Javier Holzmann
Moineau Motor vs Turbine (after Tiraspolsky)
 Moineau Motor
- Low RPM
- High performance
- Very robust
- Hydrostatic principle
 Turbine
- High RPM, RPM depends on torque
- High durability, made of steel
- Very complicated starting procedure (qualified personal
necessary)
- Hydrodynamic principle
Dr. Javier Holzmann
Moineau Motor vs Turbine
Source: http://3.bp.blogspot.com/-zyuc8DyA29E/Vr3h0NB_uQI/AAAAAAAAFsQ/eIkIt2s6ln8/s1600/dcbisducn.png
Dr. Javier Holzmann
Comparison of Hydrodynamic and Hydrostatic
Drilling Motor Characteristics
6 ¾" Turbine (Hydrodynamic) 7 ¾” Moineau (Hydrostatic)
50 stages – 1600 l/min 3 Stages – 1600 l/min

Dr. Javier Holzmann
What we have done today:
 Downhole motors
- Application, classification & types
 Positive Displacement Motor (PDM)

- Construction
- Principle including laws of Moineau principle
- Geometry
- Characteristics including RPM and Torque dependency
on Gear Number
- Stator Failure Mechanisms
Dr. Javier Holzmann

What we have done today:
 Turbine
- Construction
- Bearing Assembly
- Principle (Rotor, Stator) & Theory
- Characteristics
 Comparison of Moineau Motor and Turbine
Dr. Javier Holzmann


08.TBT1-Downhole Motors

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08.TBT1-Downhole Motors

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Introduction to Drilling Technology

Dr. Javier Holzmann

Dr. Javier Holzmann

 Positive Displacement Motor (PDM)

Dr. Javier Holzmann

 Comparison of Moineau Motor and Turbine

Dr. Javier Holzmann

 Special tool mounted in the bottom hole assembly

Dr. Javier Holzmann

 Straight hole drilling processes

 Horizontal, highly inclined & directional processes

 Extended reach (extremely deep) drilling processes

 Slim hole drilling processes

Dr. Javier Holzmann

Bit direct drive

Blade- Moineau- Peristaltic

Source: Teodoriu, C.: Script Tbt 1, 2014

Moineau Allegheny- Christensen/Shell

Source: Teodoriu, C.: Script Tbt 1, 2014

 Hydraulically driven downhole motor

 Spiral rotor is forced to rotate within a rubber sleeved

Dr. Javier Holzmann

 Consists of several sections:

 Power section converts hydraulic energy of high

Dr. Javier Holzmann

 Conventional motor design

Dr. Javier Holzmann

 New motor design

Source: Teodoriu, C.: Script Tbt 1, 2014

 Used in tripping operations

Source: Teodoriu, C.: Script Tbt 1, 2014

Bit Speed (RPM)

Where 𝑷HP = Power in [HP]

Dr. Javier Holzmann

 Two helical members are disposed within another

 Outer member has one helical thread (also helical

 Every thread of inner member constructed to constantly

Dr. Javier Holzmann

1/2 3/4 4/5 5/6 7/8 8/9 9/10

Source: Heriot-Watt University, Institute of Petroleum Engineering

360° = 1 entire helical rotation HR

Source: Teodoriu, C.: Script Tbt 1, 2014

 “The pitches of the helices of the two members are in

Source: Teodoriu, C.: Script Tbt 1, 2014

Dr. Javier Holzmann

Source: Teodoriu, C.: Script Tbt 1, 2014

 O1: Center of rotor

 O3: Stator Axis

Source: Teodoriu, C.: Script Tbt 1, 2014

 O1: Center of rotor

 O3: Stator Axis

Source: Teodoriu, C.: Script Tbt 1, 2014

Source: Teodoriu, C.: Script Tbt 1, 2014

Rotor turns Rotor turns

1 90° 90° 180° 180°

 𝑛𝑅 = Number of revolutions [RPM]

Source: Teodoriu, C.: Script Tbt 1, 2014

Source: Teodoriu, C.: Script Tbt 1, 2014

Source: Teodoriu, C.: Script Tbt 1, 2014

Source: Teodoriu, C.: Script Tbt 1, 2014

 Stator profile development

 Basic circle: R = (k+1)∙e

(k+1) e  Roll off circle: r = e