Lecture 4: Down Hole Motors

BY
DR. A.K.PATHAK

DEPARTMENT OF PETROLEUM ENGINEERING

INDIAN SCHOOL OF MINES, DHANBAD

E-mail: [email protected]
 Down Hole Motor
• In search of alternative to conventional
rotary drilling where the entire drill string is
rotated from surface, various types of
down-hole motors have been proposed.
• Drill string rotation can be eliminated, by
having a motor placed down hole to drive
the bit by hydraulic power
 DOWN HOLE MOTORS
• 1. Positive Displacement Motors

• 2. Turbodrills
 POSITIVE DISPLACEMENT MOTORS

• It is basically consisted of a steel spiral shaft, which rotated with a

rubber sleeve stator.
• As mud was pumped between the spiral shaft and the stator the
shaft rotated clock wise and turned the bit.
• The hydraulic power of the mud in terms of pressure and flow
rate was converted to mechanical power at the bit in terms of
rotational speed and torque.
• The PDM provides faster RPM at the bit then conventional rotary
methods.
• Both single and multi lobe models are being used now a days for
straight hole drilling, Kick offs, side tracking and coring purpose.
POSITIVE DISPLACEMENT
MOTORS
 Motor Description

• Dump Valve
• Motor Section
- Stator
- Rotor
• Universal Joint
• Bearing Assembly
DUMP VALVE
To prevent the motor
rotating while running
in to the hole or
pulling out of the hole,
a by-pass valve or
dump valve is
installed at the upper
end of the motor.
 DUMP VALVE
• This valve has radial ports those remain
open when pump is shut during tripping.
• During drilling the increased mud pressure,
a piston pushes a sleeve down to cover and
seal off the ports.
• Whenever the limps are shut off a spring
forces the sleeve upward, opening the ports
again.
MOTOR SECTION
• The motor section
of a PDM consists
of –
• - Stator
• - Rotor
 ROTOR

• The rotor is a steel shaft of spiral form. For

a single lobe the cross section of the shaft is
circular.
• It is free at the top but attached to the
universal joint at the bottom
 STATOR
• The stator is moulded rubber sleeve, which forms a spiral
passage way to accommodate the rotor.
• The rubber sleeve is fixed to the steel body of the motor.
• When the rotor is fixed inside the stator the difference in
geometry between two components create a series of
cavities, when mud requires a path between the rotor and
stator.
• In doing so the mud displaces the shaft forcing it to rotate
clock wise as the mud continues to flow through the
passage way.
LOBE CONFIGURATION OF
PDM
• The cavity between
stator and rotor
required to freely
rotate the rotor is
called Lobe of
PDM
 LOBE CONFIGURATION OF
PDM
• In a single lobe motor the flow area is relatively large,
allowing a faster flow and hence a faster speed of rotation.
• In a multi-lobe motor, there can be up to 10 cavities in the
stator and 9 lobes on rotor.
• Thus flow area is reduced and hence speed of rotation is
also reduced.
• Torque developed at the bit however is quite high. PDMs
are available of ½ , ¾ , 5/6 , 9/10 lobes configurations.
DIFFERNET LOBES OF PDM
 Stages of PDM
• To increase the power and torque delivered
by PDM the number of PDM stages can be
increased.
• There are normally 3 stage in the motor
section but by welding two rotors together
this can be increased up to 6 stages.
• To achieve more power out put the overall
length of the PDM must be increased.
UNIVERSAL JOINT
• This joint converts the
eccentric motion to the co-
centric motion which is
transmitted to the bit.
Various type of flexible
joints can be used but a
simplest joint is a ball
joint lubricated by grease.
A rubber sleeve, around
the joint prevents mud
contamination.
 Bearing Assembly
Connecting
rod

Upper thrust
bearing
flow
restricior

Lower thrust
bearing

Rotating bit sub

Bi
t
 Bearaing Assembly of PDM
• The durability of bearing determines the operating
life of the motor.
• The bearing assembly fulfils two functions.
• (a) It transmits the axial load to the bit. This is
achieved through thrust bearing of several sets.
• (b) It maintains central position of the drive shaft
to ensure smooth rotation. This is achieved by
radial bearing which are of sleeve type made of
elastomer material.
Pitch of a PDM
 PERFORMANCE OF A PDM
• Performance Characteristics:
The energy supplied by the drilling
fluid is used to rotate the helical
shaft, which in turn rotates the bit.
The speed of rotation n can be
determined from:
 PERFORMANCE OFA PDM
• .n = Q/ A.L
• A = (π dr2 /4) + 2 e.dr - (π dr2 /4)
• A = 2 e.dr
• .n = Q / 2 e.dr . L = 123 Q / 2 x 7.48 e.dr.L
• .n = 115.5 Q / (e.dr.L)
• Q = flow rate in GPM e = eccentricity in inch.
• .dr = shaft diameter in inch L length of stages inch.
• A = available flow area between stator and rotor
 PERFORMANCE OF A PDM
• The in put power developed can be calculated from:
• Pi = Q . ΔP / 1714
• ΔP = Pressure drop per stage in psi.
• The out put power developed can be calculated by:
• Po = (1.904 x 10-4 ) T . n
• The torque developed is:
• T = 2.653 X 10-2 e. dr. L. ΔP
 EFFIECIENCY OF PDM
• The efficiency of the motor is the ratio of out
put power to the in put power of the motor. This
factor include
• (a) the internal fluid leaks along with the contact
surfaces, which increase due to wear.
• (b) frictional-losses in the bearing and universal
joint and
• (c) entry and exit losses.
 DRILLING WITH A PDM
• The pre tested motor is run along with BHA
in the hole with a bent sub above the motor
for providing build up rate.
• Once on bottom the motor should be picked
up 1 – 2 ft. up before starting the pump. The
off bottom circulation pressure should be
noted. The motor is then lowered and the
drilling can be commenced.
 Drilling with PDM
• As WOB is applied, the surface pressure will
increase. WOB and pump pressure should not
exceed then the manufacturer’s specification. If
too much WOB is used the pump pressure
reaches at maximum at which motor stalls and
stops drilling. In this condition the motor must
be picked up off the bottom and the surface
pressure should return to the original circulating
pressure.
 DRILLING WITH PDM
• During drilling, if the flow rate and pump
pressure are kept constant, the torque and
RPM should also be constant unless there is
formation change.
• A gradual lowering of the surface pressure
indicates that more WOB should be used.
 WARNING SIGN OF PDM
• A sudden rise in surface pressure usually indicates stalling condition
of motor.
• If the motor is kept in stalled condition serious damage will occur in
stator preventing a proper seal between the stator and rotor.
• If this happens, first keeping increased pressure circulation in off
bottom condition obstruction may be cleared else the motor have to be
tripped out of the hole and repaired.
• Increased surface pressure may also caused by mud clogging and
jamming the bearings.
• Bit wear may be indicated by repeated stalling of the motor. A
plugged nozzle will cause a more gradual increase in surface pressure.
• As the stator bearings become worn the pressure drop through the
motor decreases. This can be detected by observing a reduction in
surface pressure at which the motor stalls.
 TURBODRILLS
• The turbodrill could develop more power than the
rotary system.
• The turbine could produce much faster speed.
• Since the drill string did not have to rotate there
was less wear on the drill pipe and casing.
• The turbo drills can be used for both straight wells
and deviated wells.
• The major application of the turbodrill is to drill
long tangential section of the directional wells.
TURBODRILL
MOTOR SECTION OF TURBODRILL

• The turbine-motor,
consist of a series of
rotors and stators. The
rotors are blades
mounted on a vertical
shaft while stators are
fixed on the body of
the turbodrill. Each
rotor and stator pair is
called a stage
 MOTOR SECTION
• The number of the stages may be 25 to 250
depending up on application. The pressure
drop through each stage should be constant.
The number of stages is therefore, limited
by the total head available. Each stage also
contributes an equal share of the total
torque and total power developed by the
turbine.
WORKING OF TURBODRILL
 WORKING OF TURBODRILL
• As the mud is pumped through the turbine,
the stator deflects the flow of the mud
against the rotors forcing them to turn
clockwise direction.
• The upper end of the shaft is free while the
lower end is connected to the bit.
• The turbine blades are made of the Carbon
steel having small percentage of Chromium
alloy.
WORKING OF PDM
 WORKING OF TURBODRILL
• The blades may be positioned within an
inner and outer ring to form a wheel. The
profile of the blades has an important affect
on the pressure drop through the tool and
over all performance of turbine.
 WORKING OF PDM
• The minimum clearance of the turbine between
rotor and stator is of the order of mill meters.
• Any solid particle in the mud could easily cause
clogging of the motor.
• A sand content of 2 % or more could also cause
excessive wear of the turbine blades.
• Lost circulating materials cannot be allowed
through the turbine and must be diverted through a
circulating sub installed above the turbine for the
purpose
BEARING SECTION
• There are two type
of bearings.
• Thrust bearings are
used to with stand
the axial loads.
• radial bearings
centre the shaft
during rotation.
 THRUST BEARING
• These resists the axial load exerted on the
turbine.
• The simplest type of thrust bearing consists
of metal discs which slides on a bearing
surface of elastomer or synthetic rubber.
• The metal disc is attached to the shaft
while elastomer is fixed to the bearing
supports on the onside of the body tool.
 THRUST BEARINGS
• There are also channels through which the drilling
fluid lubricates the bearing.
• The resisting torque developed in the thrust
bearing is the function of the axial load and
coefficient of friction..
• Thrust bearing can be located between the motor
section and the bit, thus isolating turbine blades
from vibration and shock loads.
• In multi stage turbines thrust bearing may be
installed within each section
 RADIAL BEARINGS
• Radial bearings centralise the drive shaft.
Elastomer pads on both inside of the
bearing support and a metal sleeve on the
shaft are fitted such that a small clearance
0.5 mm exists between them. This type of
bearing is also lubricated by mud
 LOWER BEARINGS
• Lower Bearing: The function of lower
bearing is to centralise the lower part of the
drive shaft and to resist the bending stresses
exerted on the turbine while drilling.
 PRFORMANCE OF TURBODRILL

• The turbodrill is an axial flow machine

where fluid energy is transferred to the rotor
shaft. There is no appreciable radial flow
since the radius remains constant through
out the operation.
PERFORMANCE OF TURBODRILLS
PERFORMANCE OF
TURBODRILL
• The absolute velocity of
the fluid as it passes
through the turbine can be
diverted in to two
components:
• (a) parallel to the axis YY
is denoted by Vy, and
• (b) tangential component
IS Vt.
PERFORMANCE OF
TURBODRILLS
PERFORMANCE OF
TURBODRILL
• It is only tangential
component that does the
useful work of turning the
rotor. As the mud enters
the turbine, it is deflected
by the stator. Although
there is a change in
direction but no work is
done by the fluid on the
stator because the stator is
fixed
 PERFORMANCE OF
TURBODRILL
• Let Vt denote the initial velocity as the fluid
strikes the rotor. The angle at which V 1 acts
with respects to the direction of rotor
movement is α1. Similarly the final velocity
of the fluid be V2 acting at angle α2. From
the vector diagram it can be seen that
• Vt1 = Vy1 Cot α1 and
• Vt2 = Vy2 Cot α2
 PERFORMANCE OF
TURBODRILL
• Since Vy1 = Vy2 = Vy for the continuity of axial flow the
turbine the change in velocity can be written as:
• Vt2 - Vt1 = Vy (Cot α2 - Cot α1)
• The torque (T) produced by this force is given by:
• F . = ρ . Q . (Vt2 - Vt1)
• T = F . r = ρ . Q . r . (Vt2 - Vt1)
• Power (P) can be determined from
• P=T.ω
• Where ω is angular velocity in radians per seconds.
 PEFORMANCE OF
TURBODRILL
• The tangential velocity of rotor blade is Ut that can be –
• Ut = ω . r
• P = ρ . Q . (Ut2 . Vt2 - Ut1 . Vt1)
• To obtain pressure drop through turbine (ΔP) the power is divided by
mass flow rate giving –
• ΔP = ρ . (Ut2 . Vt2 - Ut1 . Vt1)
• Since r is constant Ut = Ut1 = Ut2 and the equations for torque, power and
pressure drop becomes as follows:
• T = ρ . Q . r . (Vt2 - Vt1)
• P = ρ . Q . Ut (Vt2 - Vt1)
• ΔP = Ut. ρ (Vt2 - Vt1)
 PERFORMANCE OF
TURBODRILL
• T , P and ΔP are directly proportional to the mud
density (ρ) therefore –
• T α Q2 , P α Q3 and ΔP α Q2. These relations can
be used to calculate the new performance under
altered parameters in field at the time of use -
•
• T2 = T1 ( Q2 / Q1)2 . (ρ2 / ρ1)
• P2 = P1 ( Q2 / Q1)3 . (ρ2 / ρ1)
• ΔP2 = ΔP1 ( Q2 / Q1)2 . (ρ2 / ρ1)
 PERFORMANCE OF
TURBODRILL
• The maximum rotational speed occurs when there
is no resistance to the flow of fluid through the
turbine.
• This is known as “runaway speed” and
corresponds to zero resisting torque.
• At the other extreme the turbine stalls when the
rotors are prevented from turning.
• This is called Stalling torque
• The resisting torque therefore reaches a maximum
between torque and speed is approximately linear.
PERFORMANCE OF
TURBODRILL
 PERFORMANCE OF
TURBODRILL
• The equation of this straight line can be expressed as-
• T=mn+c
• Stalling torque (TS)
• Where gradient m = - [-----------------------------------]
• Runaway speed (nR)
•
• And the intercept (c) is Stalling torque
 PERFROMANCE OF
TURBODRILL
• c = Ts
• The torque (T) can be given as –
• T = - (Ts / nR) + Ts
• T = Ts [ 1 – (n / nR) ]
• The power (P) developed by the turbine is –
• P=T.ω
• ω = (2π / 60) . n
• P = T . π . n / 30
 PERFORMANCE OF
TURBODRILL
• Substituting for T gives
• π.n n
• P = [-----------] . [Ts - (1 - ---------)]
• 30 nR
•
•
 PERFORMANCE OF
TURBODRILL
π . Ts π . Ts
• P = [-----------] . n - [----------] . n 2
• 30 30 nR
• π . Ts 2 . π . Ts . n
• (dP/dn) = [-----------] - [-----------------------] = 0
• 30 30 nR
• The optimum rotational speed (n o) can be
• no = n R / 2
• The maximum power is therefore obtain when the rotational
speed is exactly half of the runaway speed
PERFORMANCE OF
TURBODRILL
 PERFORMANCE OF
TURBODRILL
• T = TS {1 – (n / nR)}
• P = (π . n / 30) TS {1 – (n / nR)}
• nO = nR / 2
• PI = Q . ΔP / 1714
• PO = T.n / 5252
•
 Problem 1
PDM
• In a single lobe PDM the motor dis 2.5 inch, the
eccentricity 1.1.25 inch and the length of one
motor section is 48 inch. At a flow rate of 550
GPM the total pressure drop through motor is
480 psi. If the motor efficiency is 80%
Calculate the rotational speed, the torque
developed by the motor and the power output
of the motor.
 Solution 1PDM
• n = 115.5 Q / e . dr . L
• n = 115.5 x 550 / 1.125 x 2.5 x 48 = 470.56 = 471 rpm
• T = 2.653 X 10-2 e . dr . L . ΔP . E
• T = 2.653 X 10-2 x 1.125 x 2.5 x 48 x 480 x 0.8 = 1375 ft-lbf
• P = Q . ΔP E / 1714 = 550 X 480 X 0.8 / 1714 = 123.22 hP.
 Problem 2 PDM
• From the manufacturer specification a 3
stage single lobe PDM has a rotor
diameter of 4.555 inch, eccentricity 1.5
inch and a rotor pitch of 62 inch. The
available torque is 5666 ft-lbf, calculate
the pressure drop per stage in the motor.
 Solution 2 PDM
• ΔP = T / 2.653 X 10-2 e . dr . L
• ΔP = 5666 / 2.653 X 10-2 X 1.5 X 4.555 X 62 X 2
• ΔP = 252 psi for 3 stage
• ΔP = 84 psi per stage
 Problem 3 PDM
• While drilling with a PDM at a flow rate
of 200 GPM the maximum pressure drop
from the manufacturer table is 360 psi
using an MWD tool the actual downhole
measurements are obtained as follows –
• Torque = 460 ft-lbf, speed = 380 rpm.
Calculate the efficiency of motor.
 Solution 3 PDM
• Po = T N / 5252 = 460 X 380 / 5252 = 33.28 hP
• Pi = Q . ΔP / 1714 = 200 X 360 / 1714 = 42.01
• E = PO / Pi = 33.28 x 100 / 42.01 = 79.22%
 Problem 4 PDM
• For a 9 ½ inch single lobe PDM whose
rotor diameter is 2.5 inch, length of one
stage is 50 inch and eccentricity is 1.125
inch plot power versus pressure drop for
200 – 400 psi for a range of speed 100 –
200
 Solution 4 PDM
• Pi = Q . ΔP / 1714 = (e . dr . L . n / 115.5) . (ΔP / 1714)
• Pi = [1.125 x 2.5 x 50 / (115.5 x 1714)] n . ΔP
• Pi = 7.1034 x 10-4 n . ΔP
• ΔP = 200 – 250 – 300 – 350 – 400
• n = 100 – 150 – 200
 Comparison Table
ΔP psi n = 100 n = 150 n = 200
P P P
200 14.21 21.31 28.4
250 17.15 26.64 35.52
300 21.31 32.20 42.6
350 24.86 37.29 49.72
400 28.41 42.60 56.8
 Problem 5 PDM
• In planning a kick off the operator has selected the following
parameters-
• Flow rate = 550 GPM, Bit speed = 150 rpm, ΔPb = 900 psi.
• Drill string + annulus pressure drop = 1800 psi
• Maximum surface pressure = 3000 psi
• The down hole motors which are available select the motor which
fots these requirements and calculate the power output.
 Solution 5 PDM
• n = 115.5 Q / e . dr . L
• e . dr . L = 115.5 x 550 / 150 = 523.5
• available pressure = 3000 – 1800 – 900 = 300 psi
• ΔP = 300 psi
• P = Q . ΔP / 1714 = 550 X 300 / 1714 = 96.27 hP
 Problem 1 Turbodrill
• At a flow rate of 600 GPM a turbodrill
produces a torque of 3589 ft-lbf of 665
rpm. Calculate power output and total
pressure drop if efficiency is 70%.
 Solution 1 Turbodrill
• Po = T . n / 5252 = 3589 x 665 / 5252 = 454.43 hP
• Pi = Q . ΔP / 1714
• E = Po / P i
• 0.70 = 454.43 x 1714 / 600 x ΔP
• ΔP = 454.43 x 1714 / 600 x 0.7 = 1854.51 psi
 Problem 2 Turbodrill
• Specifications of a Turbodrill
• ρ1 = 10 ppg Q1 = 500 GPM P1 = 263 Hp ΔP1 = 1285 psi
• T1 = 2492 ft.-lbf n1 = 554 rpm
• Calculate new performance with ρ2 = 12 ppg Q2 = 700 GPM
 Solution 2 Turbodrill
• T2 = T1 (ρ2 / ρ1) (Q2 / Q1)2 = 5861.2 ft-lbf
• P2 = P1 (ρ2 / ρ1) (Q2 / Q1)3 = 866 HP
• ΔP2 = ΔP1 (ρ2 / ρ1) (Q2 / Q1)2 = 3029.4 psi
• P = T . n / 5252
• n = 5252 x P / T = 5252 X 866 / 5861.2 = 776 RPM
 Problem 3 Turbodrill
• During a lab test a turbodrill has the
stalling torque 1800 ft-lbf and the
runaway speed 1500 rpm. Plot the T Vs n
and P Vs n curves and determine the
optimum speed and maximum power out
put.
 Solution 3 Turbodrill

no = nr / 2 = 1500 / 2 = 750 rpm

n T = TS {1 – (n / nR) P = T . n / 5252
0 1800 0
50 1740 16.57
100 1680 31.99
150 1620 42.27
200 1560 59.41
250 1500 71.49
300 1440 82.25
350 1380 91.97
400 1320 100.53
450 1260 107.96
500 1200 114.24
550 1140 119.38
600 1080 123.38
650 1020 126.23
700 960 127.95
750 900 128.52
 Solution 3 Turbodrill

no = nr / 2 = 1500 / 2 = 750 rpm

n T = TS {1 – (n / nR) P = T . n / 5252
750 900 128.52
800 840 127.95
850 780 126.23
900 720 123.38
950 660 119.38
1000 600 114.24
1050 540 107.96
1100 480 100.53
1150 420 91.97
1200 360 82.25
1250 300 71.49
1300 240 59.41
1350 180 42.27
1400 120 31.99
1450 60 16.57
1500 0 0
THANKS