lADC/SPE 47791 Optimization of Drilling Parameters with the Performance of Multilobe Positive Displacement Motor (PDM)

G. Robello Samuel*, EnerTech-Landmark Graphics, Stefan Miska, University of Tulsa

. * . m
Society of Petroleum Engineers Asia Pacific Driffing

* SPE Member
Copwght 19S8, lADC/SPE Asia Pacific Drilling Tefinology This paper was ~psred fw presentaticm at the 1998 lADC/SPE ConferenM held in Jakarta, Indowsia, 7-9 Septembr 1998.

This paper was selasted fw presentation by an lADC/SPE Program Committee following review of infoimatim untained in m abstract submittad by the author(s). Contents of the paper, as presented, have not been reviewed by the International Association of Drilling Ccfdfactws or the Society of Petroleum Engineers and are subject to Wedicm by ths author(s). The material, as presented, does not necessarily reflect any position of the IADC or SPE, their ofti~rs, w members. Papers psented at the lADC/SPE meetings are subjest to publication review by Editorial Committees of the IADC and SPE. Electronic reprodudfon, disbibution, or slorage of any part of this papar for commercial purposes without the written cnnsent of the Society of Petroleum Engineers is prohibited, Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not bs copied. The abstrad must cQntain Cnnsplcuous acknowledgment of wbre and by whom the paper was presentd write Librarian, SPE, PO. Box 833836, Richardson, TX 75083-3836, U. S.A., fsx 01-972-9S3-9435.

maximum rock destructive ability nor maximum horsepower of the motor. The optimization is carried out with the objective function of maximum ROP and a constraint of net thrust on the motor bearing, Common equations are derived for the net thrust acting on the motor bearing. This optimization not only result in increased rate of penetration but also increased life of the motor bearing and thus increasing the downhole operating hours of the motor. It also enables us to calculate the optimal flowrate and optimal horsepower of the motor.
Roller Cone Bits

Abstract

The average rate of penetration as a function of eight on bit and bit rotational speed is given by

Recent increase in application of coiled tubing for horizontal wells and in particular underbalanced drilling triggered the necessity of a powefil downhole motor. More often downhole motor stalling and motor replacement is a problem when using with coiled tubing drilling system. To enhance the technology and make the system effective, optimization of drilling parameters is essentially required. The frequent motor replacement during the operation incrementally increases the operating cost despite deriving potential benefits from coiled tubing drilling. The key to improved coiled tubing drilling system is a unified system approach that encompasses motor and bit. This paper presents an analytical study on the optimization of motor performance and drilling parameters. A new simple test called wear-o~f test is defined to establish an operating window. The practical usefulness of the theory, backed by the fundamental and optimal analysis for roller cone and diamond bits, is demonstrated with numerical examples.
Introduction

RoP=K,(f)(&y.

(,)

The power required for drilling can be given by the following empirical relationship ~)
HPb=Kb~.V#b. (2)

The above equations are based on the following assumptions. G the formation is microscopically homogeneous G hole cleaning is adequate . hole drilled is vertical The power developed by the motor is calculated from the product of torque and angular velocity and is given by the following relation
T ~N HP. = 550 60

Combining the two equations and solving for torque T, the following relationship is achieved
T=KX Kh ~ di. (4)

()

(3)

Optimization of the downhole motor is very important to have a better trade off between premature bearing failures and downhole operating hours of the motor. The motor operation also has to be tuned and sized to achieve maximum rate of penetration (ROP). This helps not only to prevent downhole failures of motors but also frequent pulIing out of the coiled tubing. This optimization should result in accelerating the rate of penetration without worsening the health and operation of the motor. This objective imposes neither the condition of

However, the torque capability of the multilobe motor is given by the relation(2)
T= KyApK, D:phq. (5)

where
KY=O.O1 Ki = I

(2 -i~ Equating Eq. 4 and Eq. 5 the relationship between the pressure drop across the motor in terms of the \VOB can be obtained and is given by

()

l+i

(6)

Robello, Miska

IADCISPE 4779

(7)

FY=FX

where
K,,. = ~ [1KyKi

Substituting Eq. 11 in Eq. 12

()
Ph

rrDh .

(12)

Fy=8.9x105 A,p,[,, n, N2e~.

Ph

(13)

Figure 1 shows the variation of pressure drop for various weights on bit for different configurations of the motor. At a stall torque, pressure drop across the motor deforms the stator of the power section and breaks the seal lines. At this point maximum torque is produced while rpm is equal to zero. Equation 7 could be useful to calculate the stall WOB corresponding to stall pressure drop and vice versa.
Bearing Thrust
The bearing section of the motor is a critical part in the motor assembly, which transmits the drilling thrust and rotational power to the drill bit. The endurance of the thrust bearing has tremendous implication on the life of the motor besides the power section. ~erefore, the thrust on the bearing of the motor is an important consideration and constraint in the optimal operation of the motor, which dictates the optimal selection of WOB and speed of the motor. Generally, it gives one of the best criteria to be optimized not only to have better operatin conditions of the motor, but also for the system as a whole (3~ - . Figure 2 illustrates the forces acting on the bearing section. The axial thrust on the bearings is composed of the following three components: a. hydraulic thrust created by the pressure drop acting on the cross sectional area (hydraulic thrust - HTa) b. hydraulic thrust created due to the pressure drop across the bit (hydraulic thrust - HTb) c. thrust due to the radial force (mechanical thrust - Mn d. self-weight of the shafi and the U-joint. (weight thrust - W~. The hydraulic thrust can be approximately given as

thrust due to weight of the rotating elements including The transmission parts is given by
WT= (Ar/,, n,,pr + W,,). NT= HT+MT-t NT=(Ap+Ap~)Ac WT -(15) (14)

The net axial thrust (NT) on the bearing can be given as

+8.9x 10s A, I,n,epr N2 ~
Ph

n,p, + It~,, + (.4,1, 1 The pressure drop across the bit can be given as
Aph =

PQ2 (16) 10858A,~ Substituting Eq. 7 and Eq, 16 in Eq. 15, the net thrust on the bearing is modified as

A,l,,n,,eprN2~ + (.4r/,n,p,+ w,, ) + 8.9x 10-5

Ph

(17) In addition, the flow rate can be given by the followin equation(z) in terms of the configuration and power sectio dimensions as where
K,i = 0,0034.2

HTa=Apx

Ac,

(8)

Optimization The following optimization is carried out using the Lagrang

(9) HT= @x Ac+Aphx Ac. (lo) Unbalance exists due to the fact that the center of mass of the shafi does not coincide with the axis of the rotation. The unbalance force is more pronounced at the lower pair motor as compared to the higher pair motor due to the larger eccentricity. The unbalance is measured in terms of an equivalent mass of the shafi with the eccentricity of the shafi. This unbalance force has two components, axial FY and tangential F.. me axial component tends to impart thrust on the top bearings in addition to the HT and WT. The tangential force is given by(45)
HTb = Aph X Ac .

multiplier method with the objective function of ROP given b Eq. 1 and constraint of net thrust on the bearing given b Eq. 17. The objective function is Eq. 1

With the objective function of Eq. 19 and constraint of Eq. 17 the Lagrange functions are solved which yields. N fJp[ where
4.= :
=

()
@,c

(20)

9.

(11) The axial component can be calculated from the following equation considering Fig. 3
FX =4n2Arprl,, n,,N2e.

[
pm =

1 )[

AcKr, xd;W(,;t ~,q

h )

17,8x

1051,eprn,

Ar + P,D;P; 5429 A:

(K,, )2

47791

Optimization

of Drilling Parameters with the Performance

of Multilobe Positive Displacement

Motor (PDM)

The optimum speed is located in such a way that the weight on bit balances the net thrust load on the bearings so as to have extended bearing life and also maximum ROP. From Eq. 2 optimum weight thus calculated can be used to calculate the pressure drop across the motor. The relation between the optimum weight on bit and the pressure drop across the motor is given as
Wop,=

With the known optimum bit rotational speed and weight on bit, the average optimum rate of penetration can be calculated with the following equation. (22)

[1

H<)P,

KhNOP,d:

(21)

The stall weight is calculated from Eq. 7 and is found to be 12000 lbs., corresponding to the stall pressure drop of 550 psi in the power section. The optimum speed and optimum weight on bit are calculated iteratively and found to be N,,P,= 540 rpm W,,P,= 6600 lbs. The corresponding flowrate at the optimum operating speed is found tobe215 gpm. The pressure drop across the motor can be calculated as follows
Ap=K~

[1
y,,,xd; D;P,v

Illustration:

The following numerical example explains the importance of the calculations of the optimal drilling parameters. a, = 1.25, U2= 0.75, K~ = 4x1 0-5 Kf= 110 fph dh= 6% AP,e./l = 550 psi Motor details: Configuration = % Eccentricity = 0.397 in Number of stages= 4 Overall length = 143 in Diameter of the housing= 4.5 in Diameter of the shaft= 2.43 in =70% Efficiency Material = 4166 FM or 17-4 SS bar Maximum Horse power =40 hp Area of the cross section of the cavity can be calculated from the following equation(2);
Ac=

= 200 psi. ( 4.52 X35.75X.70 ) The pressure drop calculated is well below the stall pressure, which prevents frequent stalling of the motor as compared to the operation of the motor close to the stalling pressure. The average optimal rate of penetration is Ap = 63.08

6.615 X6.2525

and the corresponding horsepower is

Opfl=0(&)25 74fth

HP= (4x10-S)(6.6)15(540)(6.25)25 =36 hp.

n liz , 4(2-j~D

Substituting the respective values ~452 ~(2_05)2 .530i~2

Area of the cross section of the shaft is given by

~ = ;D,: = :2.432=

Figure 4 shows the plot of the weight on bit/net thrust load on the bearings versus the speed of the motor for the particular configuration of the motor selected. The optimum values of the WOB and speed are shown, Further calculations can be repeated for different configurations of the motor if the operating characteristics dictate a lower bit rotational speed. With the foregone calculations of optimum parameters such as optimum horsepower of the motor, optimum weight on bit, optimum bit rotational speed and optimum flow rate, it is observed that the horsepower requirement for optimum rate of penetration is only 30% of the maximum horsepower capability of the motor. This not only results in higher rate of penetration but also long downhole operating hours of the motor due to the proper balancing force at the bearings. In addition, it is evident that the calculations strongly depend on the drilling parameter exponents, which in turn rely on the formation characteristics under consideration.
Tuning of Downhole Motor

4.63 in2

K,C xKh [)KyKi

and Ki=z

where K,= 5252; Ky =0.01; Kh 4x105

I+i

()

= 0.333 0.001133

(2-i)2

so

i(l+i) i 00034 (2-i~ Kw = 63.08

The success of drilling with a downhole motor assembly largely depends on the tuning and adjustment of intake parameters as cited earlier. Figure 5 shows the plot of optimum rate of penetration versus pressure drop across the motor for various configurations of the motor. This shows that the lower pair motor achieves a higher optimum rate of penetration for the same pressure drop. Figure 5 shows the effect of optimum rotational speed of the motor and optimum ~veighton bit on the pressure drop across the motor whereas Fig. 6 shows the effect of optimum rate of penetration and optimum flow rate on the pressure drop across

Robello, Miska

lADC/SPE 47791

the motor. For the same pressure drop, the lower pair motor results in a higher speed coupled with the lower weight on bit, as compared to that of the higher pair motor. The decrease in rotational speed is more pronounced at the lower configuration motor than the higher pair motor, which obviously calls for higher optimum weight on bit. These calculations also depend on the rotational speed, weight exponents and formation factors, which vary for different formations. The formation factor for horsepower calculation ranges from 4x 10sfor very hard to 14x10-5for very sofi formations. So the calculations and results should be handled with due circumspection. The sensitivity of the change in eccentricity of the shaft on the rate of penetration is far less when compared to that of change in mud density and nozzle area.
Diamond Bits

L(Dr, Ph)= ROP(D, , P, ]+~T(D,

, P.)

(26)

Taking respective derivatives and solving yields

N,,.,

@t, + = () t ( P,, )

(27)

where
0,, =

[)

.4C Ki,d, W,,,,

1.5x D;7

P,te ~/;P: ~ p,, = 17.8x 10- lteprn,A, i 5429A() ,, The optimum speed is found in such a way that the weigh applied on bit balances the net thrtlst load acting on th bearings.
Illustration

Ruggedness and high rotational speed capability make diamond bits more attractive and preferable than roller cone bits to operate with the downhole motor. The motor operation was optimized for roller cone bits to achieve the maximum rate of penetration with the constraint of net thrust acting on the bearing of the motor. The same philosophy of optimization was carried out for diamond bits, In the case of diamond drilling, the restricted mud flow area results in a pressure gradient over surface of the bit face causing a force called the hydraulic [ifi G)or pump-off force as shown in Fig,7. This causes a reduction of effective weight on bit. Therefore, the pump-off force needs to be accounted for the calculations. The mechanical weight on bit is the difference between the applied weight and the pump-off force acting on the face of the bit. The average rate of penetration for a diamond bit T is further simplified and given as (23)

The following numerical example explains the importance o the calculations of the optimum drilling parameters. d~= 6 W 4P,,,,,,= 550 psi d, =0.19 in x.Y=3.5s=0.4p =0.12 Motor details: Same as in previous illustration Area of the cross section of the cavity

Area of the cross section of the shaft is given by .4, = ~ D? = 4.63 in2
K~ 8.34 The optimum bit rotational speed and weight on bit is found iteratively and found to be N,)P,=518 W,,p,= 10900 Ibs.

W=w. -wp
Wp=Aph Ah.

The power required for drilling can be given by the following empirical relationship
HPh = p ; nWNd, (24)

() The relationship between the pressure drop across the motor in terms of the WOB can be obtained and is given by
(25)

The corresponding flow rate is 240 gpm. The average optimal rate of penetrat ion is found to be ROP(,P,= 195 ftihr and the corresponding horsepower is calculated Hp= 0.12X10900 X5I8XZX4X6.25 =23 hp 60x12x3x.530x2
Analysis:

where
K K~ = ~ KVK, () Optimization .

Estimation of optimum parameters for roller cone an diamond bits by the above method calls for an importan analysis. Upon comparison of the parameters, it is seen tha the rate of penetration is lower for diamond bits than the rolle cone bits. On the other hand, the operating horsepower i lower for the diamond bits than the roller cone bits. The flow requirements have not changed much as compared to the othe parameters, The graphical representation of the optimum speed and weight are shown in Fig,8.
Wear-off Test

The optimization is carried out with the objective function of Eq. 23 and the constraint of net thrust. Therefore, the Lagrange function is formulated as below:

The evaluation of drilling parameters depends on wear an operating efficiency of the motor. The efficiency of the moto

47791

Optimization

of Drilling Parameters with the Performance of Multilobe Positive Displacement

Motor (PDM)

drops as the operating time of the motor increases. Accordingly, the optimum parameters estimated for the same motor also change. This necessitates establishing a method to estimate the efficiency of the motor while the motor is in operation. This will help to delineate the safe operating envelope so that maximum rate of penetration and operating life of motor is achieved. The Fig, 9 shows a typical plot representing the operating parameters for maximum rate of penetration rate. The operating efficiency of the motor relative to the new motor can be estimated in the field by conducting a simple test, called the wear-oJf test, by observing the hook load and the standpipe pressure. The equation 7 relates to the pressure drop across the motor and the efficiency of the motor. Whh the bit off bottom as shown in the first sketch of Fig. 10, the standpipe pressure, p~b~l~ is noted. Afier applying desired amount of weight on bit as seen in the second sketch of Fig. 10, the standpipe pressure, pWObfl) is noted. The difference between these standpipe pressures gives the pressure drop across the motor and is related by (28) @M(l)= ~(,b(l) ~w,,b(l) Afier drilling a certain number of hours, the above mentioned procedure is repeated for the same flow rate and weight on bit and is shown in the third and fourth sketch of Fig. 10. The difference between the standpipe pressures at this desired point gives the new pressure drop across the motor, and is given by (29) @m(2) = ~,,b(2) - ~!v,,b(2) . From Eq, 7 the operating efficiency is given by
(30)
( fiPm~) )

the cases gives the pressure drop across the motor,

Wear Estimation

It needs to be highlighted here that the ivear-oJJ test can also be helpful to monitor the wear on the motor to avoid sudden pernicious effect on the motor operation. The wear of the motor can be given as a finction of pressure drop across the motor and the cumulative operating time in hours(45).

WE= f (@, t). (31) The relative wear on the motor can be estimated using the following equation , \

Acknowledgment The authors wish to thank the U, S. Department of Energy for

permission to publish this paper. The sL~pportof TUDRP (Tulsa University Drilling Research Projects) member companies is also gratefully acknowledged. The authors would like to express their appreciation to EnerTechLandmark Graphics Corp., and The University of Tulsa for the opportunity to present this paper,
Summarv
G

The efficiency of a new motor for the particular configuration can be estimated either by the analytical equation presented in this paper or obtained from the bench test performance characteristic curves provided by the manufacturer. Using the ef~ciency of a new motor, subsequent change in the operating efficiency of the motor can be evaluated. Equation 29 also helps to monitor performance of the motor. me wear coefficient takes into consideration the change in the diameter and pitch due to wear. This coefficient can be avoided by measuring the pitch and diameter downhole so that realistic efficiency can be monitored in real time. The above procedure is valid for roller cone bits. For diamond bits the pump-off force changes as the bit wears out. To effectively isolate the pump-off effect, the procedure needs to be modified as follows. 1. Note down the off bottom stand pipe pressure. 2. Note down the drill-off standpipe pressure. 3. Apply the desired weight on bit and note down the on bottom stand pipe pressure and calculate the effective weight. 4. Repeat steps 1 and 2 at the desired depth. 5. Apply the same effective weight on bit taking it to account of the new pump-off force. 6. The difference in the standpipe pressures in both

The comprehensive optimization of PDM with the drilling parameters using roller cone and diamond bits presented is applicable for multilobe motors. Generalized optimal relations between bit rotational speed and weight on bit will help the user to prevent the operation of the motor beyond the capability of the motor, The theory presents a quantifiable basis for measuring effects of the operating parameters on different size and configurations of the motor under use. The wear off test gives an operating window of operation so that the driller-can stay with in-the operating ~vindow of operation and also gives an estimate of the wear of the power section of the motor while drilling.

Nomenclature al = WOB exponent,

a2 = speed exponent,
Ac= cross sectional area of the cavity, sq.in., A, = area of the cross section of the shaft, sq.in.,

,4. = total nozzle flow area, sq.in., AP= effective pump-off area, sq,in., D,,= diameter of the shaft, in., Dll= diameter of the housing, in,, db= diameter of the bit, in., e = eccentricity of the motor, in., F,= axial force, Ibf, Fy = tangential force, Ibf, HP= horsepower, hp, i = winding ratio, k!= housin~shafi wear coefficient,

Robello, Miska

lADC/SPE 47791

kz = material property coefficient, kj = housing, shaft, pitch wear coefficient, kq = coefficient, (9.48), k,= coefficient, (1.8x IOC), K= constant, K,= constant, (5252) Ky = con-, (0.01) K,= constant, (0.028) Kb = formation hardness, teeth, bearing, mud coeff., Kf = formation drillability factor, Wr,

Department of Energy -BDM -1998 5. G. Robello Samuel, TUDRP Advisory Board Meeting Reports, May, Nov. 1996, May, Nov. 1998 6. Winter W.J, Warren T.M., Determining the True Weight-on-bit for Diamond Bits SPE 11950 San Francisco 1983. 7. Peterson J.L., Diamond Drilling Model Verified in Field and Laboratory Tests SPE 5072, AIME: Houston, 1974.
Figures

Ki = winding ratio coefficient, Kij = winding ratio coefficient, 1,= length of the seal line of one cavity, in., n$ = number of stages, N= bit rotational speed per minute, rpm, Ph= pitch of the housing, in., P,= pitch of the shaft, in., Q = theoretical flow rate, cu.in, ROP =rate of penetration, ft/hr., s = diamond size (carats/stone), T= theoretical torque, ft-lb, w.= weight of the U-joints, lbs, W = weight on bit (WOB), lbs, WP=pump-offforce, lbs, xx= average density of face stones (carats/inz), x = exponent, (1.5) y = exponent, (2.5) &= pressure drop, psi, P,= density of the shafi, lbm/in3, q = overall efficiency, a = helix angle, deg., pm= density of mud, ppg, P = coefficient of friction
Subscript

o~1 3 5 7 9
11

winding number

Figure 1 IYOB and Pressure Drop Across the Motor

power semion

1,2 = condtion points, b = bit, d= diamond, f= final condition, i = initial condition, m = motor, ob = off-bottom, opt = optimum, rc = roller cone, stall = stall condition.
References

Imsmissionsection

I 1 1

Weight of rod

pressure dropacrossthe motor

Weight oftrnnsmissionshafi

bearing section

1. Report, Smith Tool, Technical Services, Irvine, CA 2. G. Robello Samuel, Stefan Miska, Len Volk Analytical Study of the Performance of Positive Displacement Motor (PDM): Modeling for Incompressible Fluid SPE 39026 LACPC, Brazil, 1997. 3. Lucia F.V., How to Optimize Downhole Motor Guidance System Performance Pet. Engineer, June 1992. 4. Miska S., Qui W., Robello G.S., Advanced Horizontal Coiled Tubing Drilling System Annual Report US.

I
+
bit WOB !? pressure dropacrossthebnt

Figure 2 Forces acting On the PDM Bearing Section with Roller Cone Bits

47791

Optimization

of Drilling Parameters with the Performance of Multilobe Positive Displacement

Motor (PDM)

@
Figure 3 Unbalance Force Components

Figure 6 The Effect of ROP (Opt), WOB(Opt), Pressure Drop

RPM(Opt)

on

pwr

section

1
wtion

Weight

ofrcd

dssion

Figure 4 Load (Weight on Biflhrust Load) For Various Bit Rotational Speeds

Weight of bnnsmission slmff

bearing sectim

bit

Figure 5 The Effect of ROP(Optimum) The Motor

on Pressure Drop Across

Robello, Miska

lADC/SPE 47791

r
/

...
w.

Figure 8 Load (Weight on Bit/Thrust Load) For Various Bit Rotational Speeds

._. _. -. -. -. I

... . . .

RPM

Figure 9 Load (Weight on Bit/Thrust Load) For Various Rotational Speeds and Operating Efficiencies

.,..

P-,,

. . .; .,. <.>.

rr. bo!l,,m

n.eight *ppli*d

I
Figure 10 Wear-oj~Test