Beruflich Dokumente
Kultur Dokumente
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Development of downhole drilling motors . . . . . . . . 3
1.2 PowerPak* design and tooling . . . . . . . . . . . . . . . . . . . . 5
1.3 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.0 PowerPak Description . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Top sub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Power section . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Transmission section . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Bearing section and drive shaft . . . . . . . . . . . . . . . 31
2.5 Housings and threads . . . . . . . . . . . . . . . . . . . . . . . 36
3.0 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 General specifications . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Dogleg severity limitation . . . . . . . . . . . . . . . . . . . 45
3.3 Job preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4 Running PowerPak motors . . . . . . . . . . . . . . . . . . 51
3.5 Fishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.0 Geosteering* Tool . . . . . . . . . . . . . . . . . . . . . . . . 65
5.0 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . 69
6.0 Drillers Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1
Introduction 1.1
3
1.1 Introduction
Dump valve
Power section
SAB
Surface-Adjustable
Bent housing
4
Introduction 1.2
5
1.2 Introduction
Dump valve
Power section
SAB
Surface-Adjustable
Bent housing
Transmission
assembly
Bearing section
Drive shaft
6
Introduction 1.2
7
1.3 Introduction
1.3 Applications
8
Introduction 1.3
9
2.0 PowerPak Description
10
PowerPak Description 2.1
Body
Piston
Spring
Port
Sleeve
Open Closed
11
2.1 PowerPak Description
Float sub
Float subs for PowerPak motors incorporate commer-
cially available float valves. They also act as crossovers
between conventional API-type threads and Anadrill
threads.
Flex sub
For tough drilling conditions, a flex sub can be run as
the top sub of a PowerPak motor. The flex sub acts as a
crossover sub, and it may include a float valve. The con-
ditions for which a flex sub should be used are
frequent motor stalling
rocking the BHA to help sliding
backreaming
high dogleg severity (more than 12 per 100 ft).
12
PowerPak Description 2.2
13
2.2 PowerPak Description
Ratio 5:6
Ratio 1:2
Housing
Rotor
Stator
14
PowerPak Description 2.2
15
2.2 PowerPak Description
700 6000
Speed
600 Torque
Output shaft speed (rpm)
5000
500
4000
Torque (ft/lbf)
400
3000
300
200 2000
100 1000
0 0
1:2 3:4 5:6 7:8
Rotor/stator ratio
16
PowerPak Description 2.2
Compression
of stator
Major
diameter
Minor
diameter Minor
diameter
Mean diameter
(valley to peak diameter)
17
2.2 PowerPak Description
n +1
rotor _ stages = stator _ stages,
n (2-2)
where
n = number of rotor stages
rotor_stages = number of stages (360 turns) on the
rotor
stator_stages = number of stages (360 turns) in the
stator/power section.
For example, for a PowerPak model A675 model motor
with a 4:5 lobe, 4.8-stage power section, the power
section and the individual stator each have 4.8 stages.
However, the rotor has more than 4.8 stages. The number
of stages on the rotor is
4 +1
rotor _ stages = ( 4.8) = 6.0.
4
18
PowerPak Description 2.2
Stage
length
Rotor
Rotor/stator fit
The interference fit of the rotor and stator is critical to
the performance and overall life of the elastomer in the
stator tube. A motor with too much interference (the
rotor is much bigger than the stator) runs with a high
differential pressure but will develop premature chunking
after only a few circulating hours (i.e., 68 hr). The
chunking may be uniform or follow a spiral path through
the motor.
A rotor/stator interference that is too loose produces a
weak motor that stalls at low differential pressure. Motor
stalling is the condition in which the torque required to
turn the bit is greater than the motor is capable of
producing.
When a motor stalls, the rotor is pushed to one side
of the stator and mud is pumped across the seal face on
the opposite side of the rotor. The lobe profile of the
stator must deform for the fluid to pass across the seal
face. This causes very high fluid velocity across the
deformed top of the stator lobes and leads to chunking.
Chunking caused by motor stalling when sliding (no
21
2.2 PowerPak Description
Mud temperature
The circulating temperature dictates the amount of inter-
ference in assembling the rotor/stator. The higher the
anticipated downhole temperature, the less compression
is required between a rotor and stator. The reduction in
interference during motor assembly compensates for the
swell downhole of the elastomer because of temperature
and mud properties. If there is too much interference
between the rotor and the stator at operating conditions,
then the stator will experience high shearing stresses,
resulting in fatigue damage. This fatigue leads to pre-
mature chunking failure.
Failure to compensate for stator swell resulting from
the anticipated downhole temperature is a leading cause
of motor failure.
Drilling fluids
PowerPak motors are designed to operate effectively
with all types of oil- and water-base drilling fluids, as
well as with oil-emulsion, high-viscosity and high-
density drilling fluids, air, mist and foam. Drilling fluids
can have many different additives, some of which have
a detrimental effect on the stator elastomer and stainless-
steel/chrome-plated rotor.
It is well known that oil-base muds (OBM) generally
cause stators to swell. If oil-base drilling fluids are used,
it is important to consider the effects of bottomhole
circulating temperature and the aniline point on the
PowerPak stator, which is made of nitrile rubber. Aro-
matics such as aniline can swell and deteriorate nitrile
rubber. The aniline point is the lowest temperature at
22
PowerPak Description 2.2
Differential pressure:
understanding motor performance curves
The difference between on-bottom and off-bottom
drilling pressure is defined as the differential pressure.
This pressure difference is generated by the rotor/stator
section of the motor. The larger the pressure difference,
the higher the torque output of the motor and the lower
the output shaft speed.
Motors that are run with too much differential pres-
sure experience premature chunking (within as few as
6 pumping hr) in a manner similar to stators that have
too much interference (compression) between the rotor
and stator. The chunking will follow a spiral path or be
uniform throughout the stator body. Running a motor at
23
2.2 PowerPak Description
24
PowerPak Description 2.2
Nozzled rotors
The PowerPak rotor is bored and can be fitted with a
nozzle that bypasses part of the flow to extend the
motors capacity and enhance flexibility in matching
motor performance to other hydraulic or downhole
conditions (Fig. 2-6). The amount of fluid bypassed is
determined by the nozzle, the pressure drop through the
power section and the fluid density.
25
2.2 PowerPak Description
Q 2 MWppg
TFA = ,
P 10, 858 (2-3)
where
TFA = total flow area (nozzle size, in.2)
Q = amount of flow to bypass (gpm)
MWppg = mud weight (lbm/gal)
P = expected differential drilling pressure +
friction pressure (psi). Friction pressure is
125 psi for A475 and larger motors or 150 psi
for A350 and smaller motors.
Table 2-1 lists the total flow area of common nozzle
sizes, and Table 2-2 shows the amount of fluid bypassed
for common mud weights at two nozzle sizes.
Table 2-1. PowerPak motor nozzle size and total flow area
Nozzle Size Total Flow Area Nozzle Size Total Flow Area
(in.) (in.2) (in.) (in.2)
26
Table 2-2. Rotor nozzle bypass flow at different pressure drops
Nozzle Mud Pressure Drop Across Power Section (psi [bar])
(in.) Weight 100 [7] 200 [14] 300 [21] 400 [28] 500 [35] 600 [42] 700 [49] 800 [56]
(ppg [kg/liter]) Bypass Flow Rate (gpm [liter/min])
7/32 8.34 [1.00] 14 [52] 19 [73] 23 [90] 27 [103] 30 [116] 33 [127] 36 [137] 38 [146]
10.00 [1.20] 12 [47] 18 [67] 21 [82] 25 [94] 28 [106] 30 [116] 33 [125] 35 [134]
12.00 [1.44] 11 [43] 16 [61] 20 [75] 23 [86] 25 [96] 28 [106] 30 [114] 32 [122]
14.00 [1.68] 10 [40] 15 [56] 18 [69] 21 [80] 23 [89] 26 [98] 28 [106] 30 [113]
9/32 8.34 [1.00] 22 [85] 32 [121] 39 [148] 45 [171] 50 [191] 55 [209] 59 [226] 63 [242]
10.00 [1.20] 20 [78] 29 [110] 35 [135] 41 [156] 46 [174] 50 [191] 54 [206] 58 [221]
12.00 [1.44] 19 [71] 26 [101] 32 [123] 37 [142] 42 [159] 46 [174] 49 [188] 53 [201]
PowerPak Description
14.00 [1.68] 17 [66] 24 [93] 30 [114] 35 [132] 39 [147] 42 [162] 46 [174] 49 [187]
12/32 8.34 [1.00] 40 [152] 56 [215] 69 [263] 80 [304] 89 [340] 98 [372] 105 [402] 113 [430]
10.00 [1.20] 36 [139] 51 [196] 63 [240] 73 [277] 81 [310] 89 [340] 96 [367] 103 [392]
12.00 [1.44] 33 [127] 47 [179] 58 [219] 66 [253] 74 [283] 81 [310] 88 [335] 94 [358]
14.00 [1.68] 31 [117] 43 [166] 53 [203] 62 [234] 69 [262] 75 [287] 81 [310] 87 [332]
14/32 8.34 [1.00] 54 [207] 77 [292] 94 [358] 108 [414] 121 [462] 133 [507] 144 [547] 153 [585]
10.00 [1.20] 50 [189] 70 [267] 86 [327] 99 [378] 111 [422] 121 [462] 131 [500] 140 [534]
12.00 [1.44] 45 [172] 64 [244] 78 [299] 90 [345] 101 [385] 111 [422] 120 [456] 128 [487]
14.00 [1.68] 42 [160] 59 [226] 73 [276] 84 [319] 94 [357] 103 [391] 111 [422] 118 [451]
16/32 8.34 [1.00] 71 [270] 100 [382] 123 [468] 142 [540] 158 [604] 174 [662] 187 [715] 200 [764]
10.00 [1.20] 65 [247] 91 [349] 112 [427] 129 [493] 145 [551] 158 [604] 171 [652] 183 [697]
12.00 [1.44] 59 [225] 84 [318] 102 [390] 118 [450] 132 [503] 145 [551] 156 [596] 167 [637]
14.00 [1.68] 55 [208] 77 [295] 95 [361] 109 [417] 122 [466] 134 [511] 145 [551] 155 [589]
18/32 8.34 [1.00] 90 [342] 127 [484] 155 [592] 179 [684] 200 [764] 220 [837] 237 [905] 254 [967]
10.00 [1.20] 82 [312] 116 [441] 142 [541] 164 [624] 183 [698] 201 [764] 217 [826] 232 [883]
12.00 [1.44] 75 [285] 106 [403] 129 [493] 150 [570] 167 [637] 183 [698] 198 [754] 211 [806]
27
2.2
14.00 [1.68] 69 [264] 98 [373] 120 [457] 138 [528] 155 [590] 170 [646] 183 [698] 196 [746]
2.2 PowerPak Description
Dogleg
Rotating a motor in a high-dogleg interval in a well can
damage the stator. The geometry of the wellbore causes
the motor to bend and flex, especially if the motor has a
bent housing. Because the stator housing is the weakest
portion of the motor, it bends the most. As the stator
housing bends, the elastomer pushes on the rotor and
bends it, which causes excessive compression on the
stator lobes and leads to chunking.
28
PowerPak Description 2.3
Thrust ball
Transmission shaft
Adjustable
bent housing
Drive balls
29
2.3 PowerPak Description
Stator adaptor
Stator adaptor
Adjusting ring
Offset housing
30
PowerPak Description 2.4
Housing
Drive shaft
Race
Bearing balls
Sleeve thread
protector
31
2.4 PowerPak Description
A962 and 12 8
1
Yes Yes 1058
A1125 13 8
3
No Yes 1112
14 8
5
No Yes 1178
1534 No Yes 1178
1578 No Yes 1178
1714 No Yes 1178
1738 No Yes 1178
21 8
7
No Yes 14
2534 No Yes 14
2734 No Yes 14
NA = not applicable
32
PowerPak Description 2.4
Bearing
housing Drive shaft
33
2.4 PowerPak Description
Weight on bit
The aggressive nature of PDC bits generally precludes
high bit weights. Tricone bits, however, are often run
with high bit weights that accelerate the wear of the balls
and races of the axial bearings.
The races in the mud-lubricated axial bearings are
case hardened. Their wear rate is not linear, because the
amount of wear increases once they have worn past the
hardened area. Just because a motor has only minor
wear after a long run does not mean that the bearings
are capable of repeating the same run time.
The WOB limits listed in Chapter 5, Performance
Data, are the rated maximum for the motors. Motors
with XP power sections do not have higher bit weight
limits than regular motors. The additional torque output
34
PowerPak Description 2.4
Mud solids
The bearing section is compatible with most mud sys-
tems. Highly abrasive mud systems can cause excessive
wear on the entire bearing pack (radial and axial).
Examples of highly abrasive muds include muds with
more than 2% sand and systems that use hematite or
similar substances for weighting material.
35
2.5 PowerPak Description
36
PowerPak Description 2.5
NR = not recommended
Corrosion
For the majority of applications, corrosion of the motor
housing and internal componentsexcept for the
rotoris not a problem. There are a few exceptions
where corrosion can cause problems, particularly in
the thread roots of the stator box threads. The stator box
connection is vulnerable because of its thin-wall design
and placement in the motor. Neither of these factors can
easily be changed.
Severe corrosion problems have occurred in salt-
saturated muds, apparently as a result of galvanic action
between the dissimilar metals of the PowerPak drill col-
lars and the conductive drilling mud. Sacrificial anodes
have been found to work well in the motors when this
type of corrosion is a problem. Using flex pup joints
above the motors also helps reduce the level of stress
on the connections when drilling where corrosion is
a problem.
37
2.5 PowerPak Description
Thread-locking compound
The use of Torq-Lok thread-locking compound is
recommended on
XP section motors
A475 and smaller motors
any PowerPak motor if tough drilling conditions
are expected:
backreaming
rotary speeds higher than 150 rpm
anything other than a standard bit below the output
shaft (cross-over, stabilizer, core barrel, etc.)
high vibration or shock.
Because thread-locking compounds have a higher
coefficient of friction than pipe dope, the makeup torque
on thread-locked connections should be 1.25 times the
normal torque to achieve the same shoulder compression.
38
Operations 3.0
39
3.1 Operations
Maximum WOB
The maximum weight on bit for a PowerPak motor is
determined by its bearing section and is independent
of the selected power section. These values are the
maximum loads that can be placed on a bit during
motor operation.
Working overpull
The working overpull is the maximum load that can
be placed on a stuck motor (pushing or pulling) with-
out crushing the axial bearing parts. The load must be
kept less than this amount to allow rerunning the
motor after it is unstuck.
Absolute overpull
Absolute overpull is the maximum load that can be
placed on a stuck motor (pushing or pulling) before
doing major damage to the motor and possibly leaving
a fish in the hole.
Bit pressure
To maintain a flow of cooling/lubricating fluid through
the bearing section, the bit used with a motor must
have a minimum amount of pressure drop. The bit
nozzle must be selected on the basis of bit hydraulics
calculations to provide the minimum pressure drop to
the bit. The maximum bit pressure drop should not be
exceeded for a relatively long time because the axial
and radial bearings of the motor could be washed out.
40
Table 3-1. PowerPak motor specifications (U.S. units)
Motor Lobes Stages Flow Flow Rate Rotating Hole Tool Tool Max. Working Absolute Bit
Rate with Bypass Speed Diameter Weight Length WOB Overpull Overpull Pressure
(gpm) (gpm) (rpm) (in.) (lbm) (ft) (lbf) (lbf) (lbf) (psi)
Min Max Min Max Min Max Min Max
A213 XP 5:6 6.0 20 50 180 640 2.38 3.50 80 10.5 3,200 15,000 19,000 250 1500
A238 M 5:6 2.5 20 50 100 380 2.88 3.50 80 8.45 5,000 22,000 28,000 250 1500
XP 5:6 5.2 20 50 100 400 120 12.52
A350 M 4:5 5.0 30 110 160 98 360 4.50 6.00 300 15.12 8,000 30,000 69,500 250 1500
M 7:8 3.0 30 110 160 48 176 310 15.12
Operations
M 4:5 3.5 100 250 350 105 262 620 16.62
XP 4:5 6.0 100 250 350 105 262 5.88 7.00 920 22.54 25,000 50,000 137,000 250 1500
M 7:8 2.2 100 250 350 56 140 640 16.62
XP 7:8 3.8 100 250 350 56 140 900 22.54
AD 7:8 2.0 300 700 100 230 800 20.12
41
3.1
3.1
42
Operations
Min Max Min Max Min Max Min Max
A1125 M 3:4 3.6 1000 1500 1700 115 170 17.50 26.00 6400 29.02 75,000 225,000 650,000 250 1500
Table 3-2. PowerPak motor specifications (SI units)
Motor Lobes Stages Flow Flow Rate Rotating Hole Tool Tool Max. Working Absolute Bit
Rate with Speed Diameter Weight Length WOB Overpull Overpull Pressure
(liter/min) Bypass (rpm) (mm) (kg) (m) (N) (N) (N) (bar)
Min Max (liter/min) Min Max Min Max Min Max
A213 XP 5:6 6.0 76 189 180 640 60.5 88.9 36.3 3.20 14,200 66,700 84,500 17.2 103.4
A238 M 5:6 2.5 76 189 100 380 73.2 88.9 36.3 2.58 22,200 97,900 124,600 17.2 103.4
XP 5:6 5.2 76 189 100 400 54.4 3.82
A350 M 4:5 5.0 114 416 606 98 360 114.3 152.4 136.1 4.61 35,600 133,400 309,200 17.2 103.4
M 7:8 3.0 114 416 606 48 176 140.6 4.61
Operations
M 4:5 3.5 379 946 1325 105 262 281.2 5.07
XP 4:5 6.0 379 946 1325 105 262 149.4 177.8 417.3 6.87 111,200 222,400 609,400 17.2 103.4
M 7:8 2.2 379 946 1325 56 140 290.3 5.07
XP 7:8 3.8 379 946 1325 56 140 408.2 6.87
AD 7:8 2.0 1136 2650 100 230 362.9 6.13
43
3.1
3.1
44
Operations
Min Max (liter/min) Min Max Min Max Min Max
A1125 M 3:4 3.6 3785 5678 6435 115 170 444.5 660.4 2903.0 8.85 333,600 1,000,800 2,891,300 17.2 103.4
Operations 3.2
45
3.2 Operations
46
Table 3-4. Buildup rate predictions
Motor Hole Fully Stabilized Bend Setting Bearing-Housing Stabilizer Only No Bearing-Housing Stabilizer (Slick)
Size (in.) 0.39 1.15 1.5 2.12 3.0 0.39 1.15 1.5 2.12 3.0 0.39 1.15 1.5 2.12 3.0
A475M 6 NA NA NA NA NA 2.26 7.11 9.37 13.36 18.99
A475M 634 2.07 9.07 12.33 18.08 26.20 2.76 7.61 9.87 13.85 19.48
A675M 812 1.81 6.96 9.35 13.58 20.46 1.59 4.71 6.17 8.73 12.36
A675M 978 1.81 6.96 9.35 13.57 19.55 1.96 5.09 6.54 9.1 12.73
A675M 1058 0.77 4.38 6.77 11 16.97 2.17 5.29 6.74 9.30 12.93
A800M 1058 0.71 3.85 5.97 10.70 17.49 1.68 4.59 5.59 8.34 11.72
A800M 1214 1.59 6.15 8.27 12.01 17.30 1.58 5.17 5.17 7.18 10.03
A962M 1214 1.57 5.64 7.53 10.86 15.58 1.62 4.32 5.58 7.80 10.83
A962M 15 1.57 5.64 7.53 10.86 15.57 2.21 4.91 6.17 8.38 11.52
A962M 1712 1.04 5.11 7 10.33 15.04 1.78 4.08 5.15 7.04 9.71
A1125M 15 1.44 5.15 6.88 9.93 14.23 1.38 3.93 5.11 7.19 10.14
A1125M 1712 0.96 4.67 6.40 9.44 13.75 1.42 3.61 4.62 6.41 8.95
A213XP 258 1.1 15 22.3 34.1 50.9
Operations
A238M 278 2.64 19.91 27.94 42.12 62.15
A238M 312 0 8.85 16.88 31.06 51.09
A287M 338 7.79 23.61 30.97 43.95 62.30
A287M 334 2.01 17.83 25.19 38.17 56.52
A350M 414 0.39 6.46 11.11 24.34 36.28
A350M 434 0 6.68 11.47 19.91 31.85
NA = not applicable
Typical field values are 25%40% less than these predicted optimum values.
47
3.2
A fully stabilized motor has a 18-in. undergauge bearing-housing stabilizer and a 18-in. undergauge string stabilizer above the motor.
For hole sized 1712 in. and larger, the stabilizers are 14-in. undergauge.
3.3 Operations
Motor selection
Hole diameter and flow rate usually dictate the tool
diameter. After the diameter has been chosen, the other
specifications can be selected.
Dump valve
The probability of plugging the dump valve can be
reduced by running a float valve above the motor. If a
float valve is run and plugging is still a potential prob-
lem, a crossover sub can be run instead of a dump valve.
Rotor/stator configuration
The rotor/stator configuration affects the bit speed (rpm)
at a given flow rate. The default standard is 4:5 (or 5:6
for PowerPak model A962M). Other configurations are
also available.
When OBM is used, the 4:5 ratio is preferred to 7:8
to minimize possible elastomer damage.
Rotor nozzle
A rotor nozzle should be specified if high flow rates
are anticipated.
Bent housing setting
The degree of bend depends on the anticipated maxi-
mum DLS in the hole section to be drilled. In deter-
mining this setting, use Table 3-4 with caution because
the calculations are based on idealized hole conditions
for a limited number of BHA configurations. Local
experience should be taken into consideration, even if
it has been obtained using different steerable motors,
because those actual figures provide a guideline for the
predictions obtained from the planning software.
The bend selection also depends on the diameter of
any stabilizers. The bend should be set at a reasonable
minimum to decrease possible stabilizer hanging.
Rotating the string to hold angle rather than continuing
48
Operations 3.3
49
3.3 Operations
Hydraulics calculations
Every PowerPak motor is designed to perform efficiently
within a range of fluid flow rates. The flow ranges are
listed in the general specifications on Tables 3-1 and 3-2
and the individual motor tables in Chapter 5, Perfor-
mance Data.
Variation above or below recommended volumes
and the related pressure drop across the bit may lead
to decreased motor efficiency and life. Anadrill uses a
specialized hydraulic program to verify that the pressure
drop at the bit remains within the specified range. The
250-psi minimum limit ensures proper cooling of the
bearing section. The 1000-psi maximum limit prevents
excessive erosion.
Drilling system pressure drop should be calculated
considering the stalling pressure of the motor (i.e.,
approximately 1.75 times the operating pressure). MWD
pressure drop should be accounted for in the calculation.
The total pressure drop should be compared with the
rig capacity, using the motor stalling pressure and the
highest mud weight planned for the run.
Mud weight and plastic viscosity affect the total sys-
tem pressure requirements. If the pressure required to
deliver the recommended volume of fluid to the
PowerPak motor is greater than what the pumps can
deliver, it may be necessary to reduce either the volume
or pressure drop through both the tool and the bit.
Pressure drop can be reduced by decreasing the number
of drill collars and/or other elements that affect WOB,
as well as by changing bit nozzle size or drilling fluid
characteristics.
Anadrill offers software programs for computing
the optimum hydraulics for a specific situation.
Surveying considerations
Anadrill uses a standard model to calculate the length
of nonmagnetic material required above the motor.
50
Operations 3.4
51
3.4 Operations
Visual checks
1. Check the PowerPak motor for any transportation
damage. Record the motors serial number.
2. Perform a surface functional test before anything is
added to the tool. A dog collar safety clamp should
be placed just below the top sub. If the surface func-
tional test includes an MWD system and the motor
has mud-lubricated bearings, install an Anadrill sub-
stitute bit on the bottom of the motor to provide the
bit pressure drop required to prevent the bearings
from running dry.
3. Before the bit is installed, check the bearing clearance
or axial play of the motor by measuring the distance
between the lower part of the bearing section and the
top of the bit sub. Measure the distance twice, first
with the motor hanging free in the elevators, then
repeated with the full weight of the motor sitting on
the rotary table (Fig. 3-1). The difference between the
two distances is the amount of axial bearing clear-
ance. Record the two measurements and compare
them with the figures shown in the documentation
supplied with the motor. Repeat this check after the
motor has been run to determine the amount of bear-
ing wear that occurred during the run. The maximum
allowable clearance for both the preinstallation check
and after running is shown in Table 3-6.
52
Operations 3.4
! !
0
A
Clearance = A B
53
3.4 Operations
Functional test
1. Lift the PowerPak motor with the appropriate lifting
sub, set it in the rotary slips and secure it by placing
a dog collar safety clamp just below the top sub.
2. Install a crossover sub if it is necessary between the
PowerPak motor and the kelly/top drive. Next, make
up the kelly to the PowerPak motor, remove the
safety clamp and lift the motor from the slips.
3. Open the blowout preventer (BOP) rams and lower
the PowerPak motor below the rotary table. If a dump
valve is used, ensure that the valve ports are below
the bell nipple, yet still visible. Use the rig tongs to
secure the motor and the kelly.
4. The pumps can now be turned on and the stroke
speed slowly increased. If mud is used, it should
squirt out of the ports on the dump valve until the
volume is sufficient to force the piston down and
close off the ports. When the ports close, pull up
the motor with the pumps on until the drive shaft is
visible. Record the flow rate when the dump valve
closes if a bit is in place.
5. Check the area at the bottom of the bearing housing
and the drive shaft to confirm mud flow from the
radial bearing. This discharge is designed to lubricate
and cool the bearing pack, and it should be about 4%
to 10% of the total mud flow rate. Depending on the
mud properties and whether the test is performed
before making up the bit to the motor, mud flow may
be insignificant or nonexistent as a result of insuffi-
cient backpressure across the motor. In this case, the
duration of the test should be as short as possible to
avoid damaging the bearing. If no bit or a dummy bit
is used to provide bit pressure drop, the test should
not exceed 1 min in duration.
6. Lower the motor back through the rotary table with
the pumps still running. (If the pumps are turned off
while the motor is above the table, the dump valve
can open and squirt mud on the rig floor.)
54
Operations 3.4
7. With the dump valve below the rotary table, turn the
pumps off. If the valve does not open, bleed off the
mud from the standpipe.
8. If the functional test is performed before installing
the stabilizer sleeve or drill bit, these should now be
made up at the correct torque, according to Table 3-5.
The bit can be screwed onto the drive shaft bit box
and torqued to specifications with a rig makeup tong.
! !
Stator adaptor
Adjustment ring
0 3 0 3
3 0 Offset 3 0
housing
0 3
Alignment
1 3 0 teeth 2
3
3
0 3
3 0 3 0
4 5
56
Operations 3.4
Running in hole
Caution is urged when tripping assemblies with large
bent sub angles. Special care should be exercised when
running through the BOP and wellhead equipment,
marine risers, stage cementing collars, casing packers,
liner hangers, etc.
When running a PowerPak motor in a deep or high-
temperature well or in mud systems that may be contam-
inated with cement or steel cuttings (i.e., after milling a
casing window), the trip should include stops to fill the
drillpipe and circulate for a few minutes.
Drilling
When bottom is reached, the motor should be held
a few feet off-bottom to circulate briefly until the
planned flow rate is reached. Motor speeds and circu-
lation rates above or below the specified general
ranges in Tables 3-1 and 3-2 should be avoided,
as they may result in increased wear on motor
components.
The off-bottom standpipe pressure and pump strokes
should be recorded. While lowering the assembly,
drilling is indicated by an increase in standpipe
57
3.4 Operations
58
Operations 3.4
59
3.4 Operations
Environmental constraints
There is no Material Safety Data Sheet (MSDS) risk
for the PowerPak system; no specific environmental
protection procedures need be applied when operating
the motors. However, any mud remaining in motors
returning from jobs must be safely collected for later
recycling or disposal. Anadrill bases are equipped with
zero-discharge systems to handle the disposal of all
drilling fluids.
Troubleshooting
By paying careful attention to variations in mud-flow
pressure, it is possible to detect many common down-
hole problems that may occur while drilling and take
corrective action before a costly trip becomes necessary.
Information to identify and correct problems is listed in
Table 3-8.
60
Table 3-8. Troubleshooting
Observation Secondary Observation Possible Explanation Remedial Action
ROP drops Unchanged flow rate Motor stalling Stop rotation immediately
Pressure surges Torque increases Pull off-bottom; shut down pumps
if pressure drop is not observed
Resume drilling carefully
Apply WOB gradually
ROP drops FLow rate drops Motor stalling Same as above; pump stroke forced
Constant pressure down by motor stalling
ROP decreases Normal WOB Bit balling Pull off-bottom; reciprocate string;
Pressure increases Torque decreases eventually increase flow rate
Normal WOB Stabilizers hanging or reaming Proceed with care
Torque increases When stabilizer hanging occurs while
sliding, drill a few feet in rotation
Eventually POOH to reduce bend
in SAB housing
ROP decreases Normal WOB Junk in hole Proceed carefully to wash junk away
Irregular pressure Irregular rotary torque Cone locking and/or POOH
Operations
ROP decreases Normal WOB Washout or dump valve failure Pull off-bottom
Pressure decreases Normal torque Look for trends on charts; POOH
Normal WOB Formation change Adapt parameters
ROP normal Normal WOB, torque String ID obstructed Recycle pumps with various flow
Pressure surges Flow rate unchanged rates; reciprocate string
ROP normal Normal WOB, torque Washout Look for trends on charts; POOH
Pressure decreases Flow rate unchanged
61
3.4
Abnormal mud return and pit levels Mud losses Follow lost circulation procedure
ROP increases Formation change Adapt parameters
3.5 Operations
3.5 Fishing
62
Table 3-9. Fishing dimensions (U.S. units)
Reference Description (in.) A213 A238 A287 A350 A475 A675 A800 A962 A1125
A Dump valve/top sub OD 2.13 2.38 3.06 3.75 4.75 6.75 8.00 9.63 11.25
B Stator/stator adaptor OD 2.13 2.38 1.88 3.50 4.75 6.75 8.25 9.63 11.25
C Adjusting ring OD (kick pad) 2.25 2.47 2.99 3.59 5.03 7.00 8.38 9.82 11.63
D Offset housing OD 2.13 2.38 2.90 3.50 4.75 6.75 8.25 9.63 11.25
E Stabilizer body maximum OD NA NA NA NA 5.38 7.50 9.25 11.00 13.38
F Bearing housing/nut OD 2.13 2.38 2.87 3.50 5.38 6.75 8.25 8.25 11.00
G Bit box OD 2.25 2.38 3.06 3.75 4.75 6.70 8.18 14.62 9.63
I Drive shaft OD 1.18 1.58 1.88 2.28 3.00 4.00 5.25 9.75 6.25
M Dump valve/top sub length 0.38 7.56 12.00 11.28 27.52 15.96 15.48 110.04 15.72
O Stator adaptor length 0.62 9.96 14.88 12.48 14.28 16.80 19.68 22.56 27.48
P Adjusting ring length 0.20 2.28 3.00 3.72 5.40 6.12 6.36 6.36 8.52
Q Offset housing length 0.99 12.60 16.56 19.56 22.08 30.48 32.6 38.40 43.80
R Bearing housing fishing neck 0.57 7.44 9.48 10.56 3.60 8.76 13.56 10.56 14.28
S Bearing housing bottom neck NA NA NA NA 11.04 11.40 11.04 14.52 14.52
T Drive shaft visible length 0.33 3.96 4.92 6.00 5.64 8.28 10.08 10.44 10.44
U Bend to bit box length 2.08 27.48 34.92 40.08 48.96 72.36 84.72 93.36 99.48
Introduction
V Stabilizer upset length NA NA NA NA 0.48 1.56 2.76 3.12 NA
Operations
X Sleeve length NA NA NA NA 5.50 7.00 8.00 12.00 12.00
A Dump valve/top sub ID 0.75 0.75 1.38 1.75 2.00 3.00 3.00 3.00 4.50
B Stator/stator adaptor ID 1.50 1.62 1.93 2.25 3.38 5.00 5.88 7.00 8.50
C Adjusting ring ID 1.56 1.87 2.20 2.70 3.70 5.14 6.18 7.31 8.53
D Offset housing ID 1.09 1.31 1.88 2.13 2.88 4.00 5.00 6.00 7.75
E Bearing housing/nut ID 1.33 1.50 1.79 2.15 3.06 4.44 5.13 6.19 6.19
F Drive shaft ID 0.50 0.50 0.75 0.82 1.13 1.50 2.00 2.38 2.38
63
3.5
NA = not applicable
Pipe connections A M
B N
W
H
B O
C P
D Q
V
R
E
U
X
S
F
I
G T
3.5
Table 3-10. Fishing dimensions (SI units)
64
Reference Description (cm) A213 A238 A287 A350 A475 A675 A800 A962 A1125
A Dump valve/top sub OD 5.41 6.05 7.77 9.53 12.07 17.15 20.32 24.46 28.58
Introduction
Operations
B Stator/stator adaptor OD 5.41 6.05 4.78 8.89 12..07 17.15 20.96 24.46 28.58
C Adjusting ring OD (kick pad) 5.72 6.27 7.59 9.12 12.78 17.78 21.29 24.94 29.54
D Offset housing OD 5.41 6.05 7.37 8.89 12.07 17.15 20.96 24.46 28.58
E Stabilizer body maximum OD NA NA NA NA 13.67 19.07 23.50 27.94 33.99
F Bearing housing/nut OD 5.41 6.05 7.29 8.89 13.67 17.15 20.96 20.96 27.94
G Bit box OD 5.72 6.05 7.77 9.53 12.07 17.02 20.78 37.13 24.46
I Drive shaft OD 3.00 4.01 4.78 5.79 7.62 10.16 13.34 24.77 15.88
M Dump valve/top sub length 0.97 19.20 30.48 28.65 44.50 40.54 39.32 279.50 39.93
O Stator adaptor length 1.57 25.30 37.80 31.70 36.27 42.67 49.99 57.30 69.80
P Adjusting ring length 0.51 5.79 7.62 9.45 13.72 15.54 16.15 16.15 21.64
Q Offset housing length 2.51 32.00 42.06 49.68 56.08 77.42 82.91 97.54 111.25
R Bearing housing fishing neck 1.45 18.90 24.08 26.82 9.14 22.25 34.44 26.82 36.27
S Bearing housing bottom neck NA NA NA NA 28.04 28.96 28.96 36.88 36.88
T Drive shaft visible length 0.84 10.06 12.50 15.24 14.33 21.03 25.60 26.52 26.52
U Bend to bit box length 5.28 69.80 88.70 101.80 124.36 183.79 215.19 237.13 252.68
V Stabilizer upset length NA NA NA NA 1.22 3.96 7.01 7.92 NA
X Sleeve length NA NA NA NA 13.97 17.78 20.32 30.48 30.48
A Dump valve/top sub ID 1.91 1.91 3.51 4.45 5.08 7.62 7.62 7.62 11.43
B Stator/stator adaptor ID 3.81 4.11 4.90 5.72 8.59 12.70 14.94 17.78 21.59
C Adjusting ring ID 3.96 4.75 5.59 6.86 9.40 13.06 15.70 18.57 21.67
D Offset housing ID 2.77 3.33 4.78 5.41 7.32 10.16 12.70 15.24 19.69
E Bearing housing/nut ID 3.38 3.81 4.55 5.46 7.77 11.28 13.03 15.72 15.72
F Drive shaft ID 1.27 1.27 1.91 2.08 2.87 3.81 5.08 6.05 6.05
NA = not applicable
GeoSteering Tool 4.0
LWD data
Bulk density
Rps resistivity
Rad resistivity
x200
x100
x300
x000
x500
x800
x400
x900
x65
x75
Oil-water contact
x80
Gamma ray in well path
x85
Drainhole sketch
True vertical depth
65
4.0 GeoSteering Tool
66
GeoSteering Tool 4.0
Dump valve
Power
section
Wireless SAB
telemetry Surface-Adjustable
Bent housing
Gamma ray
Azimuthal
Fixed bent housing
resistivity,
inclination
and rpm
Stabilizer
and bearings
Resistivity
at the bit
67
PPK5 (whole) 12/6/96 9:00 AM Page 69
PowerPak A213
218-in. OD
213
Adjustable bent housing
settings (03) 0.00 0.39
0.78 1.15
1.50 1.83
2.12 2.38
2.60 2.77
2.90 2.97
3.00
Ultimate WOB/overpull
(motor damage will occur) 19,000 lbf [85 kN]
69
PPK5 (whole) 12/6/96 9:00 AM Page 70
NA = not applicable
Performance
250
700 rpm at 50 gal/min Recommended max
operating pressure Torque
600 200
rpm at 40 gal/min
Torque (ft/lbf)
500
Speed (rpm)
150
400 rpm at 30 gal/min
300 100
200
50
100
0 0
0 200 400 600 800 1000 1200
Off-bottom pressure drop
135 psi at 30 gal/min
173 psi at 40 gal/min
222 psi at 50 gal/min
20
50 gal/min
15 40 gal/min
Power (hp)
30 gal/min
10
Recommended max
operating pressure
5
0
0 100 200 300 400 500 600 700 800 900 1000
On-bottom pressure off-bottom pressure (psi)
70
PPK5 (whole) 12/6/96 9:00 AM Page 71
PowerPak A238
238-in. OD
238
0.78 1.15
1.50 1.83
2.12 2.38
2.60 2.77
2.90 2.97
3.00
Ultimate WOB/overpull
(motor damage will occur) 28,000 lbf [125 kN]
71
PPK5 (whole) 12/6/96 9:00 AM Page 72
NA = not applicable
Performance
525 175
450 150
rpm at 50 gal/min Torque
375 125
Torque (ft/lbf)
Speed (rpm)
7
50 gal/min
6
5 35 gal/min
Power (hp)
4
3
20 gal/min
2
Recommended max
1 operating pressure
0
0 50 100 150 200 250 300 350 400 450
On-bottom pressure off-bottom pressure (psi)
72
PPK5 (whole) 12/6/96 9:00 AM Page 73
238
Standard flow rate 2050 gal/min [80190 liter/min]
Nozzle flow rate NA
Bit speed (free running) 100380 rpm
Revolutions per unit volume 7.8/gal [2.06/liter]
Max power 15.6 hp [11.6 kW]
NA = not applicable
Performance
700 350
Torque
600 300
500 250
Torque (ft/lbf)
Speed (rpm)
rpm at 50 gal/min
400 200
300 rpm at 35 gal/min 150
200 rpm at 20 gal/min
100
100 Recommended max 50
operating pressure
0 0
0 100 200 300 400 500 600 700 800 900 1000
Off-bottom pressure drop
91 psi at 20 gal/min
123 psi at 35 gal/min
173 psi at 50 gal/min
16
14 50 gal/min
12
Power (hp)
10
8 35 gal/min
6
4 20 gal/min
Recommended max
2 operating pressure
0
0 100 200 300 400 500 600 700 800 900 1000
On-bottom pressure off-bottom pressure (psi)
73
PPK5 (whole) 12/6/96 9:00 AM Page 75
PowerPak A287
278-in. OD
287
3.00
Ultimate WOB/overpull
(motor damage will occur) 39,500 lbf [176 kN]
75
PPK5 (whole) 12/6/96 9:00 AM Page 76
NA = not applicable
Performance
600 300
Torque
500 rpm at 80 gal/min 250 Torque (ft/lbf)
Speed (rpm)
400 200
200 100
rpm at 20 gal/min
100 50
Recommended max
operating pressure
0 0
0 100 200 300 400 500 600
Off-bottom pressure drop
53 psi at 20 gal/min
84 psi at 50 gal/min
140 psi at 80 gal/min
16
80 gal/min
14
12
Power (hp)
10
50 gal/min
8
6
4
2 Recommended max 20 gal/min
0 operating pressure
76
PPK5 (whole) 12/6/96 9:00 AM Page 77
287
Max power 34.9 hp [26 kW]
NA = not applicable
Performance
600 600
Torque
500 rpm at 80 gal/min 500
Torque (ft/lbf)
Speed (rpm)
400 400
300 rpm at 50 gal/min 300
200 200
rpm at 20 gal/min
100 100
Recommended max
operating pressure
0 0
0 200 400 600 800 1000 1200 1400
Off-bottom pressure drop
107 psi at 20 gal/min
137 psi at 50 gal/min
194 psi at 80 gal/min
35
80 gal/min
30
25
Power (hp)
20 50 gal/min
15
10
5 20 gal/min
Recommended max
0 operating pressure
77
PPK5 (whole) 12/6/96 9:00 AM Page 78
Performance
400 400
Torque
350 rpm at 90 gal/min 350
300 300
Torque (ft/lbf)
Speed (rpm)
rpm at 60 gal/min
250 250
200 200
150 rpm at 30 gal/min
150
100 100
50 Recommended max 50
operating pressure
0 0
0 100 200 300 400 500 600 700
Off-bottom pressure drop
62 psi at 30 gal/min
110 psi at 60 gal/min
191 psi at 90 gal/min
16
14 90 gal/min
12
Power (hp)
10
8 60 gal/min
6
4
30 gal/min
2 Recommended max
operating pressure
0
0 100 200 300 400 500 600 700
On-bottom pressure off-bottom pressure (psi)
78
PPK5 (whole) 12/6/96 9:00 AM Page 79
PowerPak A350
312-in. OD
350
Max overpull with flow
(no motor damage) 8000 lbf [36 kN]
Ultimate WOB/overpull
(motor damage will occur) 69,500 lbf [309 kN]
79
PPK5 (whole) 12/6/96 9:00 AM Page 80
NA = not applicable
350
Performance
400 800
rpm at 110 gal/min Torque
350 700
300 600
Torque (ft/lbf)
Speed (rpm)
35
30 110 gal/min
25
Power (hp)
20
70 gal/min
15
10
5 30 gal/min
Recommended max
operating pressure
0
0 100 200 300 400 500 600 700 800 900
On-bottom pressure off-bottom pressure (psi)
80
PPK5 (whole) 12/6/96 9:00 AM Page 81
350
Performance
250 1000
Torque
200 800
Torque (ft/lbf)
Speed (rpm)
20
110 gal/min
15
Power (hp)
70 gal/min
10
5
Recommended max 30 gal/min
operating pressure
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
81
PPK5 (whole) 12/6/96 9:00 AM Page 83
PowerPak A475
434-in. OD
Ultimate WOB/overpull
C
(motor damage will occur) 137,000 lbf [609 kN]
83
PPK5 (whole) 12/6/96 9:00 AM Page 84
NA = not applicable
Performance
600 600
Torque
500 500
rpm at 200 gal/min
Torque (ft/lbf)
Speed (rpm)
400 400
475
0 0
0 50 100 150 200 250 300 350 400 450
Off-bottom pressure drop
50 psi at 100 gal/min
58 psi at 150 gal/min
69 psi at 200 gal/min
35
30 200 gal/min
25
Power (hp)
20 150 gal/min
15
10 Recommended max
operating pressure 100 gal/min
5
0
0 50 100 150 200 250 300 350 400 450
On-bottom pressure off-bottom pressure (psi)
84
PPK5 (whole) 12/6/96 9:00 AM Page 85
Performance
400 1600
350 1400
Torque
300 1200
Torque (ft/lbf)
Speed (rpm)
60
250 gal/min
50
Power (hp)
40
175 gal/min
30
20
100 gal/min
10 Recommended max
operating pressure
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
85
PPK5 (whole) 12/6/96 9:00 AM Page 86
Performance
300 3000
rpm at 250 gal/min Torque
250 2500 Torque (ft/lbf)
Speed (rpm)
150 1500
rpm at 100 gal/min
100 1000
Recommended max
50 operating pressure 500
0 0
0 200 400 600 800 1000 1200
Off-bottom pressure drop
97 psi at 100 gal/min
118 psi at 175 gal/min
151 psi at 250 gal/min
100
250 gal/min
80
Power (hp)
60 175 gal/min
40
100 gal/min
20 Recommended max
operating pressure
0
0 200 400 600 800 1000 1200
On-bottom pressure off-bottom pressure (psi)
86
PPK5 (whole) 12/6/96 9:00 AM Page 87
Performance
200 2000
Torque
150 1500
Torque (ft/lbf)
Speed (rpm)
30
250 gal/min
25
175 gal/min
Power (hp)
20
15
10 100 gal/min
Recommended max
5 operating pressure
0
0 50 100 150 200 250 300 350 400 450
On-bottom pressure off-bottom pressure (psi)
87
PPK5 (whole) 12/6/96 9:00 AM Page 88
Performance
350 3500
300 Torque 3000
Torque (ft/lbf)
Speed (rpm)
200 2000
500 gal/min [2041 CFM]
150 1500
300 gal/min [2041 CFM]
100 1000
50 Recommended max 500
operating pressure
0 0
0 50 100 150 200 250 300 350 400 450
Off-bottom pressure drop
62 psi at 30 gal/min
110 psi at 60 gal/min
191 psi at 90 gal/min
120
700 gal/min
100 [2041 cfm]
Power (hp)
80 500 gal/min
[1458 cfm]
60
40 300 gal/min
[875 cfm]
Recommended max
20 operating pressure
0
0 50 100 150 200 250 300 350 400 450
Pressure drop (psi)
88
PPK5 (whole) 12/6/96 9:00 AM Page 89
PowerPak A675
634-in. OD
Ultimate WOB/overpull
C
(motor damage will occur) 255,000 lbf [1130 kN]
89
PPK5 (whole) 12/6/96 9:00 AM Page 90
Performance
500 2000
Torque
rpm at 500 gal/min
400 1600
Speed (rpm)
Torque (ft/lbf)
rpm at 350 gal/min
300 1200
0 0
675
120
500 gal/min
100
80
Power (hp)
350 gal/min
60
40
200 gal/min
20 Recommended max
operating pressure
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
90
PPK5 (whole) 12/6/96 9:00 AM Page 91
Performance
450 4500
Torque
400 4000
350 3500
Torque (ft/lbf)
Speed (rpm)
180
160 600 gal/min
140
Power (hp)
120
100 450 gal/min
80
60
Recommended max
40 operating pressure
300 gal/min
20
0
0 100 200 300 400 500 600 700 800 900
On-bottom pressure off-bottom pressure (psi)
91
PPK5 (whole) 12/6/96 9:00 AM Page 92
Performance
350 7000
Torque
300 rpm at 600 gal/min 6000
250 5000
Speed (rpm)
Torque (ft/lbf)
rpm at 450 gal/min
200 4000
150 rpm at 300 gal/min 3000
100 Recommended max 2000
operating pressure
50 1000
0 0
675
300
600 gal/min
250
Power (hp)
150
300 gal/min
100
Recommended max
50 operating pressure
0
0 200 400 600 800 1000 1200
On-bottom pressure off-bottom pressure (psi)
92
PPK5 (whole) 12/6/96 9:00 AM Page 93
Performance
300 6000
Torque
250 5000
Torque (ft/lbf)
Speed (rpm)
200 4000
rpm at 600 gal/min
150 3000
rpm at 450 gal/min
100 rpm at 300 gal/min 2000
100
600 gal/min
80
450 gal/min
Power (hp)
60
300 gal/min
40 Recommended max
operating pressure
20
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
93
PPK5 (whole) 12/6/96 9:00 AM Page 94
Performance
225 9000
Torque
200 8000
175 rpm at 600 gal/min 7000 Torque (ft/lbf)
Speed (rpm)
150 6000
rpm at 450 gal/min
125 5000
100 rpm at 300 gal/min
4000
75 3000
50 Recommended max 2000
operating pressure
25 1000
0 0
675
200
600 gal/min
150
Power (hp)
450 gal/min
100
50 Recommended max
300 gal/min
operating pressure
0
0 200 400 600 800 1000
On-bottom pressure off-bottom pressure (psi)
94
PPK5 (whole) 12/6/96 9:00 AM Page 95
Performance
160 8000
Torque
140 7000
120 rpm at 800 gal/min [2333 CFM] 6000
Torque (ft/lbf)
Speed (rpm)
100 5000
rpm at 60 gal/min [1749 CFM]
80 4000
60 rpm at 400 gal/min [1166 CFM] 3000
40 Recommended max 2000
operating pressure
20 1000
675
0 0
0 50 100 150 200 250 300 350 400 450
Off-bottom pressure drop
62# psi at 30 gal/min
110# psi at 60 gal/min
191# psi at 90 gal/min
140
800 gal/min [2333 CFM]
120
100
600 gal/min [1749 CFM]
Power (hp)
80
60 400 gal/min [1166 CFM]
40 Recommended max
operating pressure
20
0
0 50 100 150 200 250 300 350 400 450
On-bottom pressure off-bottom pressure (psi)
95
PPK5 (whole) 12/6/96 9:00 AM Page 97
PowerPak A800
8-in. OD
97
PPK5 (whole) 12/6/96 9:00 AM Page 98
Performance
500 2500
rpm at 600 gal/min
Torque
400 2000 Torque (ft/lbf)
Speed (rpm)
0 0
0 100 200 300 400 500 600
Off-bottom pressure drop
64 psi at 300 gal/min
72 psi at 450 gal/min
83 psi at 600 gal/min
800
140
600 gal/min
120
100
Power (hp)
80 450 gal/min
60
40 Recommended max
operating pressure 300 gal/min
20
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
98
PPK5 (whole) 12/6/96 9:00 AM Page 99
Performance
350 7000
Torque
300 6000
250 5000
Speed (rpm)
Torque (ft/lbf)
200
900 gal/min
150
Power (hp)
600 gal/min
100
50
Recommended max 300 gal/min
operating pressure
0
0 100 200 300 400 500 600 700
On-bottom pressure off-bottom pressure (psi)
99
PPK5 (whole) 12/6/96 9:00 AM Page 100
Performance
250 1000
rpm at 900 gal/min
Torque
200 8000 Torque (ft/lbf)
Speed (rpm)
100 4000
rpm at 300 gal/min
0 0
0 100 200 300 400 500 600 700 800 900 1000
Off-bottom pressure drop
87 psi at 300 gal/min
120 psi at 600 gal/min
175 psi at 900 gal/min
800
300
250 900 gal/min
200
Power (hp)
600 gal/min
150
100
300 gal/min
50 Recommended max
operating pressure
0
0 100 200 300 400 500 600 700 800 900 1000
On-bottom pressure off-bottom pressure (psi)
100
PPK5 (whole) 12/6/96 9:00 AM Page 101
Performance
250 10000
225 9000
Torque
200 8000
175 7000
Torque (ft/lbf)
Speed (rpm)
140
900 gal/min
120
100
Power (hp)
600 gal/min
80
60
40
Recommended max 300 gal/min
20 operating pressure
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
101
PPK5 (whole) 12/6/96 9:00 AM Page 102
Performance
175 14000
150 rpm at 900 gal/min 12000
Torque
125 10000
Torque (ft/lbf)
Speed (rpm)
200
900 gal/min
150
Power (hp)
600 gal/min
100
50 300 gal/min
Recommended max
operating pressure
0
0 100 200 300 400 500 600 700 800
On-bottom pressure off-bottom pressure (psi)
102
PPK5 (whole) 12/6/96 9:00 AM Page 103
PowerPak A962
958-in. OD
Ultimate WOB/overpull
C
(motor damage will occur) 650,000 lbf [2890 kN]
962
103
PPK5 (whole) 12/6/96 9:00 AM Page 104
Performance
500 5000
450 4500
Torque
400 rpm at 800 gal/min 4000
350 3500
Torque (ft/lbf)
Speed (rpm)
250
800 gal/min
200
600 gal/min
Power (hp)
150
962
0
0 100 200 300 400 500 600 700 800
On-bottom pressure off-bottom pressure (psi)
104
PPK5 (whole) 12/6/96 9:00 AM Page 105
Performance
500 10000
Torque
450 9000
400 8000
350 7000
Torque (ft/lbf)
Speed (rpm)
300 6000
rpm at 1200 gal/min
250 5000
rpm at 900 gal/min
200 4000
150 rpm at 600 gal/min 3000
100 2000
Recommended max
50 operating pressure 1000
0 0
0 100 200 300 400 500 600 700 800
Off-bottom pressure drop
80 psi at 600 gal/min
98 psi at 900 gal/min
124 psi at 1200 gal/min
350
300 1200 gal/min
250
Power (hp)
200
962
900 gal/min
150
100 Recommended max
operating pressure 600 gal/min
50
0
0 100 200 300 400 500 600 700 800
On-bottom pressure off-bottom pressure (psi)
105
PPK5 (whole) 12/6/96 9:00 AM Page 106
Performance
350 14000
300 12000
rpm at 1200 gal/min Torque
250 10000
Torque (ft/lbf)
Speed (rpm)
500
1200 gal/min
400
Power (hp)
900 gal/min
300
962
0
0 100 200 300 400 500 600 700 800 900 1000
On-bottom pressure off-bottom pressure (psi)
106
PPK5 (whole) 12/6/96 9:00 AM Page 107
Performance
175 14000
Torque
150 12000
rpm at 1200 gal/min
125 10000
Torque (ft/lbf)
Speed (rpm)
200
1200 gal/min
150
Power (hp)
900 gal/min
962
100
600 gal/min
50 Recommended max
operating pressure
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
107
PPK5 (whole) 12/6/96 9:00 AM Page 108
Performance
225 18000
200 16000
Torque
175 14000 Torque (ft/lbf)
Speed (rpm)
150 12000
rpm at 1200 gal/min
125 10000
100 rpm at 900 gal/min 8000
70 rpm at 600 gal/min 6000
50 4000
Recommended max
25 operating pressure 2000
0 0
0 100 200 300 400 500 600 700
Off-bottom pressure drop
80 psi at 600 gal/min
109 psi at 900 gal/min
149 psi at 1200 gal/min
300
1200 gal/min
250
200
Power (hp)
962
600 gal/min
150
100
Recommended max
900 gal/min
operating pressure
50
0
0 100 200 300 400 500 600 700
On-bottom pressure off-bottom pressure (psi)
108
PPK5 (whole) 12/6/96 9:00 AM Page 109
PowerPak A1125M
1114-in. OD
Ultimate WOB/overpull
C
(motor damage will occur) 650,000 lbf [2890 kN]
109
PPK5 (whole) 12/6/96 9:00 AM Page 110
Performance
200 16000
Torque
175 rpm at 1500 gal/min 14000
150 rpm at 1250 gal/min 12000
Torque (ft/lbf)
Speed (rpm)
350
1500 gal/min
300
1250 gal/min
250
Power (hp)
0
0 100 200 300 400 500 600
On-bottom pressure off-bottom pressure (psi)
110
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111
PPKBO110.QXP (DRILLER'S TAB) 12/6/96 9:11 AM Page 112
8.5 0.871
9.0 0.863
9.5 0.855
10.0 0.847
10.5 0.840
11.0 0.832
11.5 0.825
12.0 0.817
12.5 0.810
13.0 0.802
13.5 0.794
14.0 0.786
14.5 0.779
15.0 0.771
15.5 0.764
16.0 0.756
16.5 0.749
17.0 0.741
17.5 0.733
18.0 0.725
112
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2 8
7
19 18 16
3 21 20 18
318 22 22 20
314 26 24 22
312 30 29 27
334 35 33 32
4 40 39 37 35 32 29
418 43 41 39 37 35 32
414 46 44 42 40 38 35
412 51 50 48 46 43 41
434 54 52 50 47 44
5 61 59 56 53 50
514 68 65 63 60 57
512 75 73 70 67 64 60
534 82 80 78 75 72 67 64 60
6 90 88 85 83 79 75 72 68
614 98 96 94 91 88 83 80 76 72
612 107 105 102 99 96 91 89 85 80
634 116 114 111 108 105 100 98 93 89
7 120 117 114 110 107 103 98 93 84
714 130 127 124 119 116 112 108 103 93
712 139 137 133 129 126 122 117 113 102
734 150 147 144 139 136 132 128 123 112
8 160 157 154 150 147 143 138 133 122
814 171 168 165 160 158 154 149 144 133
812 182 179 176 172 169 165 160 155 150
9 203 200 195 192 188 184 179 174
912 227 224 220 216 212 209 206 198
934 240 237 232 229 225 221 216 211
10 254 251 246 243 239 235 230 225
11 310 307 302 299 295 291 286 281
12 371 368 364 361 357 352 347 342
Source: API RP76
114
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115
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2 8
3
4.85
4.43 0.190 1.995 1.3042
6.65 6.26 0.280 1.815 1.8429
116
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Table 6-7. Recommended minimum makeup torque (ft-lbf)
Bore of Drill Collar (in.)
Size and Type of Connection OD (in.) 1 114 112 134 2 214 212 21316 3 314 312 334
API NC 23 3 2,500
2,500
2,500
Drillers Data
278-in. API IF, 378 4,600 4,600 4,600 4,600
API NC 31 or 418 7,300 7,300 7,300 6,800
312-in. slimhole 414 8,800 8,800 8,100 6,800
412 10,000 9,300 8,100 6,800
6.0
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118
6.0
Table 6-7. Recommended minimum makeup torque (ft-lbf)
Drillers Data
Bore of Drill Collar (in.)
Size and Type of Connection OD (in.) 1 114 112 134 2 214 212 21316 3 314 312 334
Size and Type of Connection OD (in.) 1 114 112 134 2 214 212 21316 3 314 312 334
4-in. H-90
5 4
1
12,500
12,500
12,500
12,500
Drillers Data
612 25,000 23,300 21,200 18,000
412-in. API full hole 512 12,900 12,900 12,900 12,900 12,900
534 17,900 17,900 17,900 17,900 17,700
6 23,300 23,300 22,800 19,800 17,700
614 27,000 25,000 22,800 19,800 17,700
612 27,000 25,000 22,800 19,800 17,700
119
6.0
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120
6.0
Table 6-7. Recommended minimum makeup torque (ft-lbf)
Drillers Data
Bore of Drill Collar (in.)
Size and Type of Connection OD (in.) 1 114 112 134 2 214 212 21316 3 314 312 334
Drillers Data
734 51,000 47,000 45,000 41,500
6.0
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122
6.0
Table 6-7. Recommended minimum makeup torque (ft-lbf)
Drillers Data
Bore of Drill Collar (in.)
Size and Type of Connection OD (in.) 1 114 112 134 2 214 212 21316 3 314 312 334
658-in. API full hole 812 67,000 67,000 67,000 67,000 66,500
834 78,000 78,000 76,000 72,000 66,500
PPKBO110.QXP (DRILLER'S TAB) 12/6/96 9:11 AM Page 123
Table 6-7. Recommended minimum makeup torque (ft-lbf)
Bore of Drill Collar (in.)
658-in. API full hole (cont.) 9 83,000 80,000 76,000 72,000 66,500
914 83,000 80,000 76,000 72,000 66,500
912 83,000 80,000 76,000 72,000 66,500
Drillers Data
1034 143,000 138,000 133,000 128,000
11 143,000 138,000 133,000 128,000
Connections with Full Face
7-in. H-90
8 53,000 53,000 53,000 53,000
814 63,000 63,000 63,000 60,500
812 71,500 68,500 65,000 60,500
6.0
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124
6.0
Table 6-7. Recommended minimum makeup torque (ft-lbf)
Drillers Data
Bore of Drill Collar (in.)
Size and Type of Connection OD (in.) 1 114 112 134 2 214 212 21316 3 314 312 334
7-in. H-90
8 4
3
67,500 67,500 66,500 62,000
9 74,000 71,000 66,500 62,000
Size and Type of Connection OD (in.) 1 114 112 134 2 214 212 21316 3 314 312 334
Drillers Data
1114 128,000 128,000 128,000 128,000
Notes: (a) Basis of calculations for recommended makeup torque assumed the use of a thread compound containing 40% to 60% by weight of finely powdered metallic zinc or 60% by weight of finely pow-
dered metallic lead, applied thoroughly to all threads and shoulders. (b) The modified screw jack formula was used as shown in the IADC Tool Pushers Manual and API Spec. RP7G (seventh edition, April
1976) and for a unit stress of 62,500 psi in the box or pin, whichever is weaker. (c) Normal torque range is the tabulated minimum value to 10% greater. Largest diameter shown for each connection is the maxi-
mum recommended for that connection. If the connections are used on drill collars larger than the maximum shown, increase the torque values shown by 10% for a minimum value. In addition to the increased
minimum torque value, it is also recommended that a fishing neck be machined to the maximum diameter shown. (d) Largest diameter shown is the maximum recommended for those full-face connections. If
larger diameters are used, machine connections with low-torque faces and use the torque values shown under low-torque face tables. If low-torque faces are not used, see (c) for increased torque values.
The weaker member for the corresponding outside diameter and bore is the box. For all other torque values the weaker member is the pin.
278-in. P.A.C. makeup torque based on 87,500-psi stress and other factors as stated.
H-90 connection makeup torque based on 56,250-psi stress and other factors as stated.
125
6.0
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127
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128
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129
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130
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131
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5 1214 5.10
978 2.96
834 2.10
812 1.93
133
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134
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Table 6-15. Length
Multiply
Nautical
to Obtain by Centimeters Feet Inches Kilometers Miles Meters Mils Miles Millimeters Yards
Feet 3.281 10 2
1 8.333 10 2
3281 6080.27 3.281 8.333 10 5
5280 3.281 10 3
3
Inches 0.3937 12 1 3.937 104 7.296 104 39.37 0.001 6.336 104 3.937 102 36
Kilometers 105 3.048 104 2.540 105 1 1.853 0.001 2.540 108 1.609 106 9.144 104
Nautical
Miles 1.645 104 0.5396 1 5.396 104 0.8684 4.934 104
Meters 0.01 0.3048 2.540 102 1000 1853 1 1609 0.001 0.9144
Miles 6.214 10 6
1.894 10 4
1.578 10 5
0.6214 1.1516 6.214 10 4
1 6.214 107 5.682 104
Drillers Data
Millimeters 10 304.8 25.40 105 1000 2.540 102 1 914.4
Yards 1.094 10 2
0.3333 2.778 10 2
1094 2027 1.094 2.778 10 5
1760 1.094 10 3
1
135
6.0
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136
6.0
Table 6-16. Area
Multiply
Circular Square Square Square Square Square Square Square Square
to Obtain by Acres Mils Centimeters Feet Inches Kilometers Meters Miles Millimeters Yards
Drillers Data
Acres 1 2.296 105 247.1 2.471 104 640 2.066 104
Circular
Mils 1 1.973 105 1.833 108 1.273 106 1.973 109 1973
Square
Centimeters 5.067 106 1 929.0 6.452 1010 104 2.590 1010 0.01 8361
Square
Feet 4.356 104 1.076 103 1 6.944 103 1.076 107 10.76 2.788 107 1.076 105 9
Square
Inches 6,272,640 7.854 107 0.1550 144 1 1.550 109 1550 4.015 109 1.550 103 1296
Square
Kilometers 4.047 103 1010 9.290 108 6.452 1010 1 106 2.590 1012 8.361 107
Square
Meters 4047 0.0001 9.290 102 6.452 104 106 1 2.590 106 106 0.8361
Square
Miles 1.562 103 3.861 1011 3.587 108 0.3861 3.861 107 1 3.861 1013 3.228 107
Square
Millimeters 5.067 104 100 9.290 104 645.2 1012 106 1 8.361 105
Square
Yards 4840 1.196 104 0.1111 7.716 104 1.196 106 1.196 3.098 106 1.196 106 1
PPKBO110.QXP (DRILLER'S TAB) 12/6/96 9:11 AM Page 137
Table 6-17. Volume
Multiply
Barrels Cubic Cubic Cubic Cubic Cubic Gallons Pints Quarts
to Obtain by (US) Centimeters Feet Inches Meters Yards (Liquid) Liters (Liquid) (Liquid)
Barrels (US) 1 6.289 106 0.1781 1.0316 104 6.289 4.808 2.381 102 6.289 103 2.976 103 5.952 103
Cubic
Centimeters 158,984 1 2.832 104 16.39 106 7.646 105 3785 1000 473.2 946.4
Cubic Feet 5.614 3.531 105 1 5.787 104 35.31 27 0.1337 3.531 102 1.671 102 3.342 102
Cubic
Inches 9701 6.102 102 1728 1 6.102 104 46,656 231 61.02 28.87 57.75
Cubic
Meters 0.1589 106 2.832 102 1.639 105 1 0.7646 3.785 103 0.001 4.732 104 9.464 104
Cubic
Yards 0.208 1.308 106 3.704 102 2.143 105 1.308 1 4.951 103 1.308 103 6.189 104 1.238 103
Drillers Data
Gallons
(Liquid) 42 2.642 104 7.481 4.329 103 264.2 202.0 1 0.2642 0.125 0.25
Liters 1.58.984 0.001 28.32 1.639 102 1000 764.6 3.785 1 0.4732 0.9464
Pints
(Liquid) 336 2.113 103 59.84 3.463 102 2113 1616 8 2.113 1 2
Quarts
(Liquid) 168 1.057 103 29.92 1.732 102 1057 807.9 4 1.057 0.5 1
137
6.0
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138
6.0
Table 6-18. Mass and weight
Drillers Data
Multiply
Tons Tons Tons
to Obtain by Grains Grams Kilograms Milligrams Ounces Pounds (Long) (Metric) (Short)
Grams 6.481 10 2
1 1000 0.001 28.35 453.6 1.016 106 106 9.072 105
Kilograms 6.481 105 0.001 1 106 2.835 102 0.4536 1016 1000 907.2
Ounces 2.286 103 3.527 102 35.27 3.527 105 1 16 3.584 104 3.527 104 3.2 104
Pounds 1.429 104 2.205 103 2.205 2.205 106 6.250 102 1 2240 2205 2000
Tons (Metric) 106 0.001 109 2.835 105 4.536 104 1.016 1 0.9072
Tons (Short) 1.102 106 1.102 103 1.102 109 3.125 105 0.0005 1.120 1.102 1
Engineering Formulas
Mechanical horsepower
Hydraulic horsepower
gpm psi
hp(US ) =
1714
Motor efficiency
139
PPKBO110.QXP (DRILLER'S TAB) 12/6/96 9:11 AM Page 140
Fluid velocity
0.3208 gpm
v [ft/sec] =
flow area
bar =
(mud flow)2 [liter/min] mud weight [ kg/liter]
3.6 (total flow area) [mm]
2
140
Return to Master Index
Table of Contents
9 Troubleshooting Page
9.1 GENERAL...............................................................................................................9-1
Table of Contents
Troubleshooting
9 Troubleshooting
9.1 General
Table 9-1 Troubleshooting PowerPak Motor Operations
Observation Secondary Possible Remedial Action
observation explanation
ROP drops Unchanged flow rate Motor stalling Stop rotation immediately.
Pressure surges Torque increases Shut down pumps and pull
off bottom.
Release torque from string
and re-establish circulation.
Resume drilling carefully.
Apply WOB gradually.
ROP drops Flow rate drops Motor stalling Same as above.
Constant SPM forced down by motor
pressure stalling.
ROP decreases Normal WOB. Bit balling Pull off-bottom, reciprocate
Pressure Torque decreases. string, eventually increase
fluctuates flow rate
Normal WOB. Stabilizer hanging Proceed with care.
Torque increases. or reaming. When stabilizer hanging
occurs while sliding, drill a
few feet in rotation.
Eventually POH to reduce
bend setting.
ROP decreases Normal WOB Junk in hole Proceed carefully to wash
Irregular pressure Irregular rotary Cone locking junk away and/or POOH.
torque
ROP decreases Normal WOB Washout or dump Pull off-bottom
Pressure Normal Torque valve failure Look for trends on charts
decreases POOH
Normal WOB Formation change Adapt parameters
ROP normal Normal WOB, torque String ID obstructed Re-cycle pumps with various
Pressure surges Flow rate unchanged flow rates.
Reciprocate string.
ROP normal Normal WOB, torque Washout Look for trends on charts
Pressure Flow rate unchanged POOH
decreases
Abnormal mud Mud losses Follow lost circulation
return and pit levels procedure
ROP increases Formation change Adapt parameters