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Why hasn’t the Mud Motor been replaced?Tim Barnard

Speaker Information

Tim Barnard

Drilling Advisor

November 1, 2018

Occidental Petroleum

Member of SPE & IADD

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Speaker Bio

Occidental Petroleum – 5 years– Drilling Engineering

– Primarily Delaware Basin Unconventional (Texas & New Mexico)

Schlumberger IPM – 7 years– Drilling Engineering, Wells Site Supervision, Project Management

– Deepwater, Conventional Land, Unconventional Land

RMIT University – B.Eng. (Aerospace) 2005

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Why hasn’t the Mud Motor been replaced?

Scenario 1– 12-1/4” Hole: Surface Drive RSS vs. Motor Assist RSS

Scenario 2- 6-3/4” Hole: Mud Motor once the “limiter” now the “enabler”

Scenario 3– 9-7/8” Hole: Mud motor contributes to step change in 24 hr. footage

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Rotary Steerable – Top Drive Only12-1/4” Hole

Offset Well Analysis

– Review UCS Logs & Parameter Logs

BHA Design Concepts

– Removed Mud Motor from BHA

– Refine stabilizer placement through modeling

– Identify Critical RPMs through modeling

– Hydraulics, Buckling, Neutral point

– Employed Roller Reamers to mitigate stick-slip

– S&V Reduction Tool

– RSS Tool Limitation (RPM)

– Bit Design (depth-of-cut management)

– Top Drive (performance envelope)

Established Parameter Roadmap

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Pre-Job Planning Phase Improved Lateral Vibrations

AddedPonyCollar

Rotary Steerable - Top Drive Only (Well A)12-1/4” Hole

Difficult to manage parameters inreal-time

Unable to mitigate by varying WOB

Periods of excessive MSE

High shock levels recorded

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Bit Trip

Bit Trip

Observations

Results

RSS ability to steer effected

Short run lengths

Unplanned bit trips and poor dulls

Rotary Steerable MM Assist – Selection12-1/4” Hole

Power Section: 8.00” 7:8 lobe 4.0 stage 0.169 rev/gal

Torque Slope: 16.5 ft-lbs. / psi

Max Torque: 14,930 ft-lbs.

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Provider Proposed Option Offset Well EDR Data Review

Proposed Mud Motor had insufficient torque and excessive speed for application

Reference: Dyna-Drill Power Section Catalog 2016 Edition

Torque Slope: 24.5 lbs. / psi

Torque Req’d: ~15,964 ft-lbs.

9/10 lobe 3.0 stg 0.11 rev/gal

DRPM: 170 (85 + 85)

Rotary Steerable MM Assist – Selection12-1/4” Hole

Model: 8.00” 7:8 3.4 0.089 rev/gal

Torque Slope: 28.04 lbs. / psi

Max Torque: 21,450 ft-lbs.

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BHA

Add Mud Motor to BHA

Source fit-for-purposeconfiguration

Hydraulic horsepowerQ > 800 GPM

Deliver sufficient torque to PDCbit to efficiently shear rock

Comply with RSS RPM Limits

Solution Power Section Specifications

Reference: Dyna-Drill Power Section Catalog 2016 Edition

Rotary Steerable MM Assist (Well B)12-1/4” Hole

Able to run consistent parameters

MSE corresponds with fm. changes

Consistent surface torque

Reduction in shock levels

RSS demonstrated excellentdirectional control

Run length improved to ~4,000 ft

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Results

Slim-hole Continuous Improvement

Philosophy of identifying and removing “limiters” Buckling preventing ↑ in WOB

‒ 6-1/8” hole to 6-3/4” hole

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Reference: IADC Drilling Manual 12th Edition

Mud Motor

‒ Consistently exceed maximum operating differential pressure‒ Increased stress on components below the motor due to stalls‒ Fatigue failure common

Connections

‒ NC38 connection ratings insufficient‒ Require double shoulder proprietary connections

Stabilization

‒ Lack of stabilization causing BHA to walk‒ RSS steering response compromised due to poor stabilization

Hydraulics (Rig Pump Pressure)

‒ 7,500 psi Stand Pipe required to run Mud Motor assist RSS BHAs on most wells

Torque (Rig Top-drive)

‒ As lateral lengths increase so do torque requirements

5” Mud Motor no longer the limiter in slim-hole

Mud motor initially removed from the BHA toto focus on other performance limiters

Systematically addressing these limitersallowed more powerful mud motor to beintroduced back in the BHA

– RSS + 475 7/8 3.8 delivered 1,500 fpd

– RSS Surface Drive delivered 3,000 fpd

– RSS + 500 7/8 8.4 delivering 5,500+ fpd

5” bottom-ends consistently delivering singlerun laterals

11 Reference: Dyna-Drill Power Section Catalog 2016 Edition

‒ 55% increase in Torque

‒ 78% increase in RPM

‒ 94% increase in horsepower

Mud Motor initially limiting 9-7/8” hole performance

9-7/8” Hole RSS BHA Performance Limiters– 6 3/4” 7/8 lobe 5.0 stage 0.28 rev/gal power section

– 6 3/4” bottom-end (bearings and driveline) exceed max. WOB and torque rating

– Rotary Steerable Limitations

• 8” motor not ideal due to RSS flow rate restriction

• Surface parameter limitations due to RSS RPM restriction

– Consistently running at or above max. diff. pressure rating

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Impact

– Only able to achieve ~3,500 ft in a 24 hour period

Directional & motor provider upgraded fleet

– 6-3/4” 7/8 5.0 7” 7/8 5.7 power sections

– 6-3/4” 7-1/4” transmissions and bearing sections

– 6-3/4” 7” stator tubes for added stiffness

– 0.28 rev/gal 0.24 rev/gal speed

– Chrome Carbide rotors

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Mud Motor configuration critical to success in 9-7/8”

Impact

– Flexible SRPM, WOB & torque operating envelope

– Improved run lengths and MTBF

– 62% increase in footage achieved in 24 hrs. ~5,700 ft

Reference: Dyna-Drill Power Section Catalog 2016 Edition

‒ 31% increase in Torque

‒ 16% reduction in RPM

‒ 10% increase in horsepower

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2000

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6000

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12000

14000

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0 200 400 600 800 1000 1200 1400

Torq

ue

(ft.

lbs)

Differential Pressure (psi)

Power Section Torque Comparison

Linear (700 7/8 5.7)

Linear (675 7/8 5.0)

Conclusion

Drilling performance in unconventional wells continues to rely heavily on Mud Motors

Mud motors are consistently used in the industry to de-couple or dampen torsional vibrations

Mud motor selection is critical to mission success. Employ holistic / systems engineeringapproach during selection process

Important to identify when the Mud Motor is limiting performance

5” Mud Motors no longer limiting performance in slim-hole

Performance envelope (Q, Tq., WOB) can be extended with correct mud motor selection

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