Mud-Motor Characterization
Joint-Industry Project Proposal
September 1st, 2016
© 2016 Leader Drilling International
Previous Joint-Industry Projects
© 2016 Leader Drilling International
Conoco Consortium SPE Paper 22735
Objectives
Improved Motor Quality Assurance
Consistent Performance
Longer Motor, MWD & Bit Life
Realistic Models for Automation
Higher Performing Motor Designs
End-of-Run Motor-Grading
Motor Specification Guidelines
© 2016 Leader Drilling International
Rubber Meets the Rock
© 2016 Leader Drilling International
Quasi-Steady State
~ Power-Section Wear
~ Lithology Changes
Dynamics
~ Micro-Stalling
~ Transmission Wear
0 0
rev
/ ga
l
Time
New
Worn
Differential Pressure (psi)
Torq
ue
(ft-
lbf)
Bending Force
Instrumented Dynamometer
© 2016 Leader Drilling International
Output Flow Rate, Pressure & Temperature
Input Flow Rate, Pressure & Temperature
Rotation Speed & Torque
Rotor Dynamics & Temperature BHA Dynamics Bit Dynamics
Stator Temperatures & Pressure
Damped Constraint
Rigid Support
Primary Work-Scope
© 2016 Leader Drilling International
a. 6 ¾” * Conventional Dynamic Performance vs. Fit
b. 6 ¾” Conventional Rotor vs. Wear Rate
c. 6 ¾” Conventional Transmission Dysfunctions
d. 6 ¾” Conventional Downhole Technique
e. 6 ¾” Even-Wall Dynamic Performance vs. Fit
f. 6 ¾” Even-Wall Rotor vs. Wear Rate
g. 6 ¾” Even-Wall Downhole Technique
* 6 ¾” are 7:8 motors with 5.0 and 3.3 Stages
d. Downhole Technique
© 2016 Leader Drilling International
Pre-Drill X-mission Inspection + Rotor & Stator Mapping
Pre-Drill Instrumented Dynamometer Performance Test
Pre-Drill Downhole Performance Matrix Test
Drill Using Lessons Learned & Occasional Matrix Tests
Pre-Trip Downhole Performance Matrix Test
Post-Drill Instrumented Dynamometer Performance Test
Post-Drill X-mission Inspection + Rotor & Stator Mapping
1.
2.
3.
4.
5.
6.
7.
Secondary Priorities
© 2016 Leader Drilling International
h. 6 ¾” Fit, Polymer & Profile
i. Conventional 6 ¾” Work per Stage vs. Dogleg
j. Even-Wall 6 ¾” Work per Stage vs. Dogleg
k. Conventional 8” * Dynamic Performance vs. Fit
l. Conventional 8” Wear Rate
m. Conventional 8” Downhole Technique
n. Conventional 6 ¾” Shelf-Life & Re-Run Criteria
* 8” is a 7:8 motor with 4.0 Stages
© 2016 Leader Drilling International
h. Fit, Polymer & Profile
Measure Snug Rotor & Stator Profiles * before Testing
Perform Conventional Soft Dynamic Performance Tests
Perform Even-Wall Soft Dynamic Performance Tests
Measure Stator & Rotor Profiles after Testing
Repeat with a Looser Rotor-Stator Fit
Measure Stator & Rotor Profiles after Testing
1.
2.
3.
4.
5.
6. * Nominally the same motors from different manufacturers
i. Work per Stage vs. Dogleg
© 2016 Leader Drilling International
Measure Snug Rotor & Stator Profiles before Testing
Insert Pressure & Temperature Probes into Stator
Insert Temperature & Vibration Probes into Rotor
Measure Dynamic Performance while Applying Bending
Measure Rotor & Stator Profiles after Testing
1.
2.
3.
4.
5.
Possible Investigations
© 2016 Leader Drilling International
o. 5” * Even-Wall Performance vs. Fit
p. 5” Even-Wall Wear Rate
q. 5” Even-Wall Downhole Technique
r. 5” Work per Stage vs. Pitch & Dogleg
s. 6 ¾” Conventional 4:5 / 7.0 Performance vs. Fit
t. 6 ¾” Conventional 4:5 / 7.0 Wear Rate
u. 6 ¾” Conventional 4:5 / 7.0 Downhole Technique
* 5” are 7:8 motors with 5.0 Stages
Summary of the Science
© 2016 Leader Drilling International
Measure Fit, Wear & Roughness using Downhole Sensors
Optimize Downhole Performance from Lessons Learned
Assess the Effects of Polymers, Profiles & Shelf Life
Measure the Effect of Doglegs on Motor Stages
Improve our Understanding of Data Uncertainties
Develop More Realistic Models for Drilling Automation
Project Timeline
© 2016 Leader Drilling International
I. Initial Proposal (7/16 - 8/16)
II. Refine Scope-of-Work (9/16)
III. Participants’ Review (10/16)
$ Subscription (1/17)
V. Acquisition of Data (2/17 - 6/17)
VI. Data Distribution (7/17)
VII. Publish Generic SPE Report (9/17)
$$
Participants ( ~ US$ 80k)
© 2016 Leader Drilling International
Oil Companies
Science Committee
Motors
Dynamometer & Sensor Rental
Witnessing Tests
Motor Manufacturers (in-kind)
Science Committee
Motors
Service Companies (in-kind)
Sensors & Motors
3rd Parties (in-kind) & Universities
Data Analyses & Models
Deliverables
© 2016 Leader Drilling International
Qualified Dynamometer Data
Recommended Dynamometer Procedures
Quantified Motor Performance
Procedures to Extend Motor, MWD & Bit Life
More Realistic Motor Models
Data Quality Audits & Data Analyses
SPE Paper Documenting the Project