PDM Motor

Positive Displacement Drilling Motors:
A Current Industry Status Report
© 1997 Baker Hughes Incorporated 303-020 / 1

All rights reserved.
Introduction
z Technology Overview z Specialty Tools

z Deflection Methods – Dual Power Section
z Motor Type – New Generation
– Turbine – Re-entry
– Vane – Underbalanced
– Positive Displacement – Formation Evaluation
z PDM Components z Conclusions
© 1997 Baker Hughes Incorporated

Positive Displacement Motors 303-020 / 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
Premium - Limited Rotation

Pipe 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

Drilling Tools - Deflection Methods

Bent Sub & Motor Kick Off Sub (KOS) Double Kick Off (DKO)
Motor Motor
1/2° - 3°/100ft (30m) Bent Sub ≤ 6°/100ft (30m)
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

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

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

Motor Types
z Turbine
z Vane
z Positive Displacement

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

By-Pass Valve
Open Closed
Drilling Fluid
Flow
Piston
Sleeve
Stator
Housing

Fluid Flow Path
Stator
(Elastomer)
Rotor
Direction
Of
Rotation
Fluid Flow
Universal
Joint
Positive Displacement Motors

All rights reserved. Power Modules 303-020 / 11
Lobe Configurations
1/2 2/3 3/4
5/6 7/8 9/10

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)

All rights reserved. Power Modules
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

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

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

Elastomer
Failure
Mode
Break Outs Hardening Swell Water

“CHUNKING”
Cracks

Elastomer
Failure
Mode

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

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

Elastomer
z Reactive Additives
– Corrosion Inhibitor
– Defoamer
– Emulsifier
– Scale Inhibitor
– Wetting Agent
– Torque Reducer

Elastomer
Oil Base Fluids - Aniline Point

z 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
z Consequence
Aniline Point is a measure of the solubility of the oil (oil based mud) in
aniline

Elastomer
Oil Base Fluids - Aniline Point
Standard Fluids with Aniline Points

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

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

high swelling

Elastomer
Failure
Mode

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

Elastomer
Failure
Mode

“CHUNKING”
z Sand/Solids
Cracks z Temperature
z Drilling Fluid
– Reactive Additives
– Oil Base
z Rotor/Stator Fit
z Service Conditions

Multi-part, Universal-
Joint Shafts
Drilling Fluid
Flow Path
U-Joint Housing Drive Sub Rotor
Rotor
Universal Joint
Assembly

Drive Line Components
Flexible Shafts
Drilling Fluid
Flow Path Rotor
U-Joint Housing Drive Sub
Rotor
Flexible Shaft
Assembly

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
© 1997 Baker Hughes Incorporated Positive Displacement Motors 303-020 / 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
© 1997 Baker Hughes Incorporated Positive Displacement Motors 303-020 / 27

Sleeve Stabilizer
Blade Type: Blade Matrix:
z Straight z Tungsten Carbide
z Spiral z Insert
z Tight Spiral
Blade Number: Blade Direction:

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

All rights reserved. Drive Line Components
Outline
z Technology Overview z Specialty Tools

z Deflection Types – Performance Tools
z Motor Type • Dual Power Section
– Turbine • New Generation
– Positive Displacement – Re-entry
– Vane – Underbalanced
z PDM Components – Formation Evaluation
z Conclusions

Dual Power Section Motors
Functional Issues
z 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

All rights reserved. Specialty Tools
Functional Issues (con’t)
z 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
• Maybe lower in easy drilling
• Will be higher when pushed to limit

Functional Issues (con’t)
z Handling
– May exceed trucking lengths, large motors
– May require special support during rig floor pick-up
– Complex to change stabilization
– Some BOP safety concerns

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
1-2 7-8
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 303-020 / 33
SPEED and TORQUE

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

500
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

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
1-2 7-8
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

All rights reserved. Specialty Tools 303-020 / 35
Re-Entry
Short Radius Tool
O rien tation S ub
Adjustable Kick-off
Motor (AKO) By-Pass Valve
K nuckle Joints
Motor
B y-Pa ss Valve Section
AKO/DTU
M oto r Sectio n Housing
D TU
A KO
Bearing
Assembly

Slide Drill Systems
z 40 to 70 foot build curve radii

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

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

Rotary Systems
z 70 to 300 foot build curve radii

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

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 flow
Of rate for mud motor
Rotation
Air Motor Advantages:

• Power section design, enlarged chamber volume
Fluid Flow • 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
• Can be run on dry air
• When run on fluid, high torque - (s)low speed
Universal
Joint

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

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

Formation Navigation Definition
z 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.
z 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".

Formation Navigation
Inclination
Measurement
Neutron Resistivity
Gamma Ray
Density
z Multiple depths of investigation for quantitative determination of

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

Specialty Tools
Optional Modular Sensors
Drill Collar MWD Drill

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

Specialty Tools
Application
z Ensure optimal entry into the reservoir

z Navigate within the bounds of the reservoir
z Predict exit from the reservoir
z Position a quantitative resistivity device close to the bit

Conclusions
© 1997 Baker Hughes Incorporated 303-020 / 47

Special Considerations
z High Circulation Rates

– Rotor nozzling
z 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
Special Considerations
z LCM Concentration
– Grain size
– Quantity/bbl
– Mixing preparation

Conclusions
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
Premium - Limited Rotation

Pipe 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
Future Direction Drilling Systems
z Few if any quantum leaps
– R&D funding limitations
– Semi-mature product line
– Future generation of motors
– Market direction remains flexible
• Re-entry applications
• Multi-lateral applications
• Extended reach applications
z Focus on system (multi product line) integration
– Drilling and survey
– Drilling and formation evaluation
– Drilling and completions
– Drilling and core recovery

Conclusions
Future Direction
Drilling Systems
z Focus on Enhancing Existing Products
– Improve effective ROP
• Improve instantaneous ROP
• Increase on bottom time of rock bits
• 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

PDM Motor

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Positive Displacement Drilling Motors:

A Current Industry Status Report

© 1997 Baker Hughes Incorporated 303-020 / 1

z Technology Overview z Specialty Tools

© 1997 Baker Hughes Incorporated

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

Premium - Limited Rotation

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

© 1997 Baker Hughes Incorporated

© 1997 Baker Hughes Incorporated

1/2° - 3°/100ft (30m)

© 1997 Baker Hughes Incorporated

Fixed Angle Build Double Tilt Universal

Flex Bent Sub

Tilted Drive Sub

© 1997 Baker Hughes Incorporated

Adjustable Kick Double Alignment Kick Off

Adjustable Kick-Off Sub

© 1997 Baker Hughes Incorporated

© 1997 Baker Hughes Incorporated

Bearing Deflection Stator By-Pass

Drive Sub Universal Joint Rotor

© 1997 Baker Hughes Incorporated

© 1997 Baker Hughes Incorporated

Positive Displacement Motors

1/2 2/3 3/4

5/6 7/8 9/10

Positive Displacement Motors

© 1997 Baker Hughes Incorporated

ELASTOMER = ELAST IC POLY MER

© 1997 Baker Hughes Incorporated

Non-Oil Resistance Elastomer Oil Resistance

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

© 1997 Baker Hughes Incorporated

Specific Elastomer Types

* Stated is Circulating Temperature

Positive Displacement Motors

Break Outs Hardening Swell Water

Positive Displacement Motors

Break Outs Hardening Swell Water

z Heat Build-Up, Temp. z Drilling Fluids

Positive Displacement Motors

Positive Displacement Motors

Oil Base Fluids - Aniline Point

Positive Displacement Motors

Oil Base Fluids - Aniline Point

Standard Fluids with Aniline Points

z ASTM - Oil #2: AP = 200°F +/- 6°F (93°C)

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

Positive Displacement Motors

Break Outs Hardening Swell Water

Positive Displacement Motors

Break Outs Hardening Swell Water

Positive Displacement Motors

© 1997 Baker Hughes Incorporated

© 1997 Baker Hughes Incorporated

Upper Radial Bearing Lower Radial Bearing

© 1997 Baker Hughes Incorporated Positive Displacement Motors 303-020 / 26

Marine Bearing Upper Rotary Thrust Bearing Lower Rotary