sperry drill handbook lr

DIRECTIONAL DRILLING

SperryDrill Technical Information Handbook

Third Edition


Third Edition

DIRECTIONAL DRILLING

SPERRYDRILL TECHNICAL INFORMATION HANDBOOKTHIRD EDITION

1993, 1995, 1999, 2009 HalliburtonAll rights reserved.

1st edition 1st printing June, 1993

1st edition 2nd printing June, 1995

2nd edition 1st printing July, 1999

3rd edition 1st printing September, 2009

This work contains the confidential and proprietary information of Sperry Drilling. Neither this document nor any information disclosed herein shall be reproduced in any form, or used, or disclosed to others for any purpose, including manufacturing, without the express written permission of Sperry Drilling.

This handbook is provided for informational and illustration purposes only. Actual field conditions may vary the results of Sperry Drilling and products, and no information, result or statement contained herein shall be construed as any type of representation, warranty or guarantee by Sperry Drilling. The obligations of Sperry Drilling for and with respect to its services and products are entirely subject to independent, written agreements negotiated with individual clients.

Consequently, Sperry Drilling shall have no liability for anything contained herein.

ABI, ACCOLADE, AcoustiCaliper, ADT, AGS, BARASILC, DDS, DrilSaver, ENCORE, FullDrift, GABI, GEM, GeoForce, Geo-Pilot, Geo-Pilot GXT,

Geo-Span, INNOVERT, InSite, INTEGRADE, Max3Di, MaxBHA, MGT, RMRS, SlickBore, SperryDrill, SperryFlex, SperryMet, V-Pilot, WHIRL, and XP-07 are

trademarks of Halliburton.

2009 Halliburton. All rights reserved. Sales of Halliburton products and services will be in accord solely with the terms and conditions contained in the contract between Halliburton and the

customer that is applicable to the sale.

H06793 9/09

Preface

This handbook is a guide to the successful operation of SperryDrill and GeoForce downhole drilling motors. It contains information that is necessary for understanding the operating characteristics and application of the motors.

The handbook consists of the following:

Section One Essential DataEssential motor configuration and operating data, motor specifications, performance graphs and graph usage information.

Section Two Essential InformationImportant motor applications planning, motor operations and optimization information.

Section Three AppendicesGeneral motor product line information; applications types, motor functioning information, support systems, engineering formulae, conversions and technical data.

Additional SperryDrill and GeoForce drilling motor data, motor specifications, performance graphs and software modules are available via the SperryDrill Technical Information Handbook Web site.

General Sperry Drilling information is available from www.halliburton.com .

Select Products and Services, then Sperry Drilling.


iii

Contents

Section One Essential Data1.1 Motor Type Overview, Configuration Data Tables

and Procedures

1.1.1 Motor Choice and Configuration ................................................11.1.2 Motor Input/Output Characteristics (Imperial) ...........................41.1.3 Motor Input/Output Characteristics (Metric) .............................51.1.4 Motor Connection Torque Data ..................................................61.1.5 Motor Configuration Inspection ..................................................81.1.6 Motor Adjustable Bent Housing Setting Procedure and

Connection Torque Data ........................................................91.1.7 Motor Sleeve Stabilizers ..........................................................271.1.8 Rotor Jet Nozzling ....................................................................291.1.9 Drill Bits ....................................................................................321.1.10 Pre-Run Motor Surface Tests ...................................................331.1.11 Thrust Bearings .........................................................................371.1.12 Float Valves ...............................................................................391.1.13 Drillpipe Filters .........................................................................391.1.14 Circulating Subs ........................................................................391.1.15 Running In Hole ........................................................................391.1.16 Initial Motor Operations ...........................................................431.1.17 Weight On Bit ...........................................................................571.1.18 Rotation of Drillstring/Motor ....................................................571.1.19 Dogleg Prediction and Drillstring Rotation Rate vs.

Bent Housing Angle ............................................................621.1.20 Vibration and Shock Loading ....................................................811.1.21 Flow Rates and Drilling Fluids ..................................................861.1.22 Operating Specifications For Downhole Temperatures

(inc. HPHT Applications)......................................................871.1.23 Overpulling and Jarring ............................................................941.1.24 Hole Cleaning and Tripping Out of the Hole ...........................961.1.25 Post-Run Motor Surface Tests/Motor Flushing ........................971.1.26 Operations Data Reporting .....................................................1011.1.27 Motor Operations Problem Diagnosis and Reporting ............1011.1.28 Fishing Diagrams ....................................................................102

1.2 Motor Specification Sheets and Performance Graphs

1.2.1 Introduction .............................................................................1031.2.2 Use of Motor Performance Graphs .........................................1041.2.3 Motor Free-Running (No-Load/Off-Bottom) Pressure Losses 1091.2.4 Motor Specification Sheets and Performance Graphs ...........111


iv

Section Two Essential Information2.1 Motor Configuration and Applications Planning

2.1.1 Power Unit Options .................................................................1472.1.2 GeoForce Motors ....................................................................1502.1.3 (1) SlickBore ...............................................................................1552.1.3 (2) SperryFlex .............................................................................1572.1.3 (3) ABI Sensor Equipped ..............................................................1602.1.3 (4) GABI Sensor Equipped ........................................................1622.1.4 Other Motor Internal and External Configuration Options .....1652.1.5 Dump Subs ..............................................................................1652.1.6 Motor Applications Planning and Monitoring ........................1652.1.7 Operations Planning, Data Monitoring and Analysis .............166

2.2 Motor Operations

2.2.1 Motor Operating Differential Pressure and No-Load (Off-bottom/Free Running) Pressure Losses .....................171

2.2.2 Motor Stall ..............................................................................1762.2.3 Motor Reactive Torque and Stick-Slip ....................................1802.2.4 Weight On Bit .........................................................................1822.2.5 Rotation of Drillstring/Motor ..................................................1842.2.6 Hydraulics ...............................................................................1952.2.7 Motor Elastomers and Coatings .............................................1982.2.8 Circulating Fluids ....................................................................2102.2.9 Drill Bits ..................................................................................2262.2.10 Motor Operations Problem Diagnosis and Reporting ............240

Section Three Supporting InformationAppendix A Motor Applications Types

A.1 Conventional Directional Drilling ...........................................255A.2 Steerable and Horizontal Drilling ...........................................258A.3 Medium and Intermediate Radius Applications .....................262A.4 Short Radius Applications ......................................................265A.5 Performance Drilling ...............................................................269A.6 Geo-Pilot GXT Combined Motor and Rotary Steerable

Drilling System ..................................................................271A.7 Horizontal Drilling ...................................................................272A.8 Hole Opening ..........................................................................273A.9 Hole Spudding ........................................................................273A.10 Conductor Pipe Drill Down .....................................................274A.11 Underreaming and Casing Cutting .........................................274A.12 Milling Applications ...............................................................275A.13 Slimhole Motor Applications ..................................................275A.14 Coring Applications ................................................................276


v

A.15 Air, Gas and Foam Drilling ......................................................276A.16 Underbalanced Drilling ...........................................................277A.17 High Pressure High Temperature (HPHT) Applications ..........278A.18 Vertical Drilling .......................................................................279A.19 Casing while Drilling (CwD) and Directional Drilling while

Casing (DCwD) ..................................................................282A.20 Coil Tubing/TTRD (Through Tubing Rotary Drilling) ................283A.21 Magnetic Ranging Drilling Systems .......................................285

Appendix B Motor Functioning and Support Systems

B.1 General Motor Operating Principles .......................................287B.2 Motor Power Unit (Rotor/Stator) ............................................288B.3 Motor Transmission Unit ........................................................292B.4 Motor Bearing Section Assembly ...........................................294B.5 Tubular Housings and Stabilizers ...........................................297B.6 Motor Quality, Reliability and Support Systems ....................306

Appendix C Engineering Formulae, Conversions and Data

C.1 Hydraulics and Associated Formulae .....................................309C.2 TFA of Jet Nozzles ..................................................................319C.3 Fluid Densities and Pressure Gradients .................................320C.4 Bouyancy Factors ....................................................................321C.5 Drill Collar Linear Weight .......................................................322C.6 Drillpipe and Connection Data ...............................................323C.7 Rotary Shouldered Connection Interchange Data ..................333C.8.1 IADC Dull Bit Grading System ................................................334C.8.2 API Bit Tolerances ...................................................................336C.9 Common Conversion Factors ..................................................337C.10 Millimetre and Decimal Equivalents ......................................343C.11 Millimetre Equivalents of Common Inch Measurements .......344C.12 Chemical Element Symbols ....................................................346C.13 SI Prefixes ...............................................................................346

Subject Index ................................................................................347


vi

Subject Index

A ABI (At-Bit Inclination), 160ACFM, 303Adjustable HousingProcedures/Settings, 9Adjustable HousingRPM/Increment Limits, 62Air, Gas and Foam Drilling, 276Aniline Point, 205Applications Planning, 147Articulated Motor, 267

B Back Reaming, 58, 61, 65, 187Bearing Section, 294Bent Housing, 256BHA Modeling (MaxBHA), 167Bi-Center Bit, 161, 239Bit Bounce, 82Bit Design, 226Bit Displacement/Interference, 317Bit Grading, 334Build-Up Rate, 68

C Carbide, 208Carbon Dioxide (CO2), 223224Casing While Drilling (CWD), 282Cement/Float Equipment, 46Chloride Content, 222, 207Circulating (off-bottom), 188Circulating Fluids/Muds, 203, 210Circulating Sub, 39Coatings, 206Coil Tubing Drilling, 283Compatibility (Testing), 204, 206Conductor Pipe Drill Down, 274Configuration/Options, 147ConnectionsGeneral, 298ConnectionsGeoForce, 155ConnectionsInterchange, 333ConnectionsTorque Data, 6Conversion Factors, 337Coring Applications, 276Corrosion, 222Cumulative Effects, viii, 57, 63, 198, 290CV Assembly (Transmission Unit), 292Cyclic Loading, 67, 185, 189, 223

D Data Tables, 319Differential Pressure, 171Digital Directional Drilling Inteface (Max 3Di), 169Dogleg Severity/Prediction, 62Downthrust, 183, 292Drain/Leakage, 34, 97, 224Drill Bits, 32, 226Drilling Applications, 2, 255Drilling Muds, 86, 203, 210Drill-Off Test, 49Drillpipe Filters, 39Drillstring Dynamics Sensor (DDS), 60


SUBJECT INDEX

Drillstring Rotation, 57, 96, 184, 192Drillstring RPM Limit, 5770Drive Shaft, 297Dull Bit Grading, 334Dump Sub, 165

E ElastomerRubber, 198Equal Rubber Thickness, 148, 150Erosion, 176

F Fatigue, 58, 67, 184195Fishing Data, 102Fit (mating rotor and stator), 35, 87, 98, 291Flex Housings (Stator), 69, 157Float Valves, 39Flow Rates, 86Flow Restrictor, 196, 296Fluctuations, 218Fluid Drain/Leakage, 34, 100Fluids, 203, 210Flush, 100Formulae, Conversion Factors and Data Tables, 309Free Running (off-bottom, no load), 109, 173FullDrift Bit, 155, 230Functioning, 179, 287

G GABI (Gamma-At-Bit Inclination), 162GeoForce Motors, 148, 150GXT (Motor + Geo-Pilot) Applications, 271

H High Speed Motors, 149High Temperature / High Pressure Drilling, 87, 278Hole Condition, 189Hole Opening, 273Horizontal Drilling, 258, 272HousingsTubulars (Connections), 297HPHT, 87, 94HSI, 197Hydraulics, 167, 195Hydrogen Sulphide (H2S), 223225Hydrostatic Pressure, 199

I Initial Operations, 43Input/Output Specifications, 4Insite, 166Inspection, 306Intermediate and Short Radius Applications, 158, 262

J Jarring, 94Jet Nozzling of Rotors, 29, 315

L Lateral Motor, 266Lateral Shocks, 84LCM, 221Leakage/Drain, 34, 97, 224Low Speed Motors, 148

M Magnetic Ranging Applications (MGT, RMRS), 285Make-Up Torque, 6, 324Mating Fit, 35, 88, 98, 291Max3Di (Digital Directional Drilling Interface), 169MaxBHA (BHA modeling), 167Mechanical Loading, 58, 182, 184195, 294


SUBJECT INDEX

Medium Radius Applications, 262Medium Speed Motors, 149Metrology (SperryMet for Power Units), 88, 291Micro-stalling, 177Milling Applications, 275Modal Coupling, 86Modeling BHAs (MaxBHA), 167Monitoring, 166, 169Motor Models, 3, 112Motor Rotation, 57, 184, 192Mud Weight, 174, 203Muds/Circulating Fluids, 203206, 210

N Nitrogen (N), 277No Load (free running, off-bottom), 109, 173Nominal Operating Zone, 105Nozzling of Rotors, 29, 315

O Off-bottom (no load, free running), 109, 173Operating Hours, 307Operating Pressure, 171Operating Principles, 287Optimization, 51, 105, 169, 172Output Specifications, 4Overgauge Hole, 189Overpull and Jarring, 94Oversize/Undersize, 291

P Performance Drilling, 269Performance GraphsGraphs and How To Use, 103Performance Power Units, 148Performance-Plus Power Units, 148pH Level, 220224Planning, ix, 165Post-RunTest/Flushing, 97Power Unit/Production, 288Pre-RunInspection/Test, 8, 33PressureDifferential, 171PressurePer Stage, 291Problem Reporting, Diagnosis & Analysis, 101, 240Product Support System, 306Pulling Out Of Hole, 96

Q Quality Assurance, ix, 302, 306R Radial Bearings, 35, 99, 294

Radius Of Curvature (ROC), 318Reactive Torque, 180, 193Real-Time Directional Drilling Operations, 169Reaming, 40Reliability (Reliability Factor), ix, 51, 306Repair and Maintenance System, 306Re-running, 203Rotary Steerable Motor Drilling GXT), 271Rotation Drillstring/Motors, 57, 184, 192Rotation Limit, 5770Rotor Catcher, 292Rotor Jet Nozzling, 29, 315Rotor/Stator, 288RPM Limit, 5770


SUBJECT INDEX

RubberElastomer, 198Running In Hole, 39, 88

S Sand Content, 210, 218SDCalcs (Drilling Engineering Software), 309Short Radius Applications, 265Sleeve StabilizerAdjustment/Torque, 27Slickbore, 155Slimhole Motor Applications, 275Software Systems, 166170Special Service, 89Specification Listings, 4, 112SperryFlex System, 69, 157SperryMet Metrology System (power units), 88, 291Spudding, 273Stabilizers, 303Stall, 31, 107, 176, 194Stall Torque, 107, 176Stall Zone, 107Stall-Micro, 177Stall-Soft, 31, 178Standard Power Units, 148Stator/Rotor, 288Steerable and Horizontal Drilling, 258Stick-slip, 81, 180, 193String Rotation, 57, 96, 184, 192String RPM Limit, 5770Stringers, 50Support Systems, 306Surface Tests (pre/post), 33, 97

T Tagging Bottom, 42TemperatureCompensated, 90TemperatureConversions, 314TemperatureSpecifications, 87TemperatureStatic/Dynamic, 88Thrust Bearings, 37, 38, 99, 294Torque DataConnections, 6Torque Testing, 57Torsional Resonance, 84Transition Zone, 106Transmission Unit, 292Tripping In Hole, 39, 88Tripping Out of Hole, 96TTRD (Through Tubing Re-entry Drilling), 283Tubular HousingsConnections, 297

U Underbalanced Drilling, 277Underreaming, 274Uniform Rubber Thickness, 148, 150

V Vertical Drilling (V-Pilot), 279Vibration, 81Viscosity, 210, 277

W Wear (Abrasion), 288,Weight On Bit, 57, 182Whipstock, 52Whirl, 82


SUBJECT INDEX

HAL30673

Power Unit (Rotor and Stator)

Transmission Unit

Bearing Section Assembly

Sleeve Stabilizer

1:2 2:3 3:4 4:5 5:6

6:7 7:8 8:9 9:10

2:3 GF 3:4 GF 4:5 GF 5:6 GF 6:7 GF 7:8 GF

Figure 0.1 (2)

SperryDrill Motor Product

Since the 1980s Sperry Drilling has applied its experience gained as a market leader in drilling services to the development of SperryDrill and GeoForce downhole drilling motors.

The SperryDrill and GeoForce motors are designed to operate reliably under a wide range of downhole conditions. The continued involvement by field operations personnel in the development of the motors has resulted in constant improvement and refinement of motor designs to fit specific applications.

Many variable downhole operating environment parameters are coincident upon downhole drilling motors during their operation. SperryDrill and GeoForce motor designs account for the cumulative effects of these downhole parameters: abrasion, corrosion, erosion, dynamic mechanical loadings, vibration and shock loadings and geothermal effects.

The motor designs, materials and manufacturing methods provide fit-for-purpose quality drilling motors. Various power unit configuration options are available which are tailored to specific application types such as performance, high temperature, underbalanced and air drilling. SperryDrill and GeoForce motors are also utilized with rotary steerable and vertical drilling systems.

HA

L306

74


viii

The motor transmissions, driveshaft assemblies, radial and thrust bearings are designed to provide optimum performance in all drilling application types. The tubular motor housing connections employed in SperryDrill and GeoForce motors are of an advanced design and the connections are high make-up torque, high radial strength types.

An in-house advanced dynamometer test facility in Alberta ensures that motors and components are dynamically tested and characterized under appropriate mechanical and hydraulic loading conditions, circulating fluid temperature being elevated if required.

The thoroughly trained and competent directional drilling teams who operate the SperryDrill and GeoForce motors are backed by an extensive network of motor service centers which employ advanced power unit metrology software systems. Testing facilities, run history databases and QA/QC systems further support the SperryDrill and GeoForce drilling motors.

Motor applications planning ensures optimum motor performance, reliability and longevity through the use of advanced software systems, empirical downhole motor applications knowledge and in-depth understanding of motor functioning/directional drilling engineering. SperryDrill and GeoForce motor applications can be further enhanced and optimized through the use of real-time remote operations software systems. The result is reliable and predictable drilling motor performance.

The SperryDrill and GeoForce drilling motors are a natural complement to the innovative MWD/LWD tool systems, highly accurate surveying systems, dependable surface logging systems, advanced drilling software systems, formation look-ahead systems and drilling engineering support offered by Sperry Drilling.


ix

HA

L306

75

1.1 Motor Type Overview, Configuration Data Tables and Procedures

1.1.1 Motor Choice and Configuration

Motor Dimensions

Power Unit Type

Motor Housing Options

Diameter 1-3/4 in. to 11-1/4 in.(45 mm to 286 mm)

Low Speed

Medium Speed

High Speed

Dump Sub Fitted Y/N ?

Optional SleeveStabilizer or Kick Pad?

(various sizes)

Standard

Performance

Specialty

Adjustable Bent Housing(0 3, 4 on some models)

Fixed Bent Housing(0 3, 4 on some models)

Stator/Elastomer Type(relative to downhole

operating temperatureand drilling fluid)

Inlet and BitConnection Type

(various)

Jet Nozzled Rotor?(various sizes)

Advanced Rotor Coating?

SperryDrill Motor

Configuration

Figure 1.1.1 (1)


1SECTION ONE ESSENTIAL DATA

The diversity of possible configurations permits the utilization of SperryDrill and GeoForce motors in a wide variety of drilling applications:

Conventional Directional Drilling

Steerable and Horizontal Drilling

Performance Drilling

Conductor Pipe Drill Down

Underreaming and Casing Cutting

Coiled Tubing Drilling

Short/Intermediate Radius Drilling

Air/Foam and Underbalanced Drilling

Coring

Slimhole Drilling

Hole Opening

Hole Spudding

Milling

Casing Drilling

Medium Radius Drilling

Motor + Rotary Steerable Drilling

Vertical Drilling

For any size of SperryDrill or GeoForce motor there are a number of power unit configuration options available:

Standard

Performance

Performance Plus (extended length)

Uniform Rubber Thickness (GeoForce)

Power unit options for air/foam/ underbalanced drilling

2


SECTION ONE ESSENTIAL DATA

SperryDrill Motor ModelsFor the latest model updates and releases, see the Motor Handbook Web site.

Motor ModelsMotor Size

(in.)Lobe

Config. StagesPower Unit

Type SpeedSee Web

site4-3/4 2:3 8.0 P High4-3/4 4:5 6.3 P Medium4-3/4 5:6 8.3 PP Medium4-3/4 7:8 2.0 Air Low4-3/4 7:8 2.2 Std Low4-3/4 7:8 2.9 PP Low4-3/4 7:8 3.8 P Low

5 4:5 5.4 GF Medium 5 6:7 2.5 GF Low5 6:7 4.5 GF Low5 6:7 6.0 P Low5 6:7 8.0 PP Low

6-1/4 7:8 2.9 PP Low6-1/4 7:8 4.8 P Low6-1/2 7:8 2.0 Air Low6-1/2 8:9 3.0 Std Low6-3/4 2:3 7.0 P High6-3/4 4:5 7.0 P Medium6-3/4 6:7 5.0 P Low6-3/4 7:8 2.0 Air Low6-3/4 7:8 2.9 PP Low6-3/4 7:8 3.0 Std Low

7 6:7 2.9 GF Low7 6:7 4.5 GF Low7 7:8 7.5 PP Low8 4:5 5.3 P Medium8 5:6 5.2 GF Medium8 6:7 4.0 P Low8 7:8 2.0 Air Low8 7:8 3.0 Std Low

9-5/8 2:3 7.5 P High9-5/8 3:4 6.0 P Medium9-5/8 6:7 3.0 GF Low9-5/8 6:7 3.5 GF Low9-5/8 6:7 5.0 P Low9-5/8 6:7 6.0 PP Low

11-1/4 3:4 3.6 Std Medium11-1/4 6:7 5.5 PP Low

P: Performance; PP: Performance Plus; GF: GeoForce; Std.: Standard. 1-3/4, 2-3/8, 2-7/8, 3-1/8, 3-3/8 and 3-5/8-in. diameter motors are available; see the Motor Handbook Web site or contact Sperry Drilling for more information. For medium, intermediate and short radius motor information see A.3.

Figure 1.1.2 (1)

3



1.1.2 Motor Input/Output Characteristics (Imperial)

Motor Size

Lobe Config Stages

Flow (gpm)

Bit Speed (RPM)

MaxTorque (ft. lb)

Rev/ Gal

Power Unit Type Speed

4.75 2:3 8.0 100265 200550 1365 2.08 P High4.75 4:5 6.3 100250 105262 2146 1.05 P Med4.75 5:6 8.3 150300 150300 3050 1.00 PP Med4.75 7:8 2.2 100250 56140 1445 0.56 Std. Low4.75 7:8 2.9 150250 3075 3900 0.30 PP Low4.75 7:8 3.8 150250 84140 2350 0.56 P Low

5 6:7 2.5 100325 55145 5700 0.45 GF Low5 6:7 4.5 100315 80252 4515 0.80 GF Low5 6:7 6.0 150350 115280 2780 0.80 P Low

6.25 7:8 2.9 200600 34102 6900 0.17 PP Low6.25 7:8 4.8 150400 51136 5700 0.34 P Low6.5 7:8 2.0 300600 4284 4500 0.14 Air Low6.5 8:9 3.0 200500 58145 3740 0.29 Std. Low

6.75 2:3 7.0 300600 250500 2700 0.83 P High6.75 4:5 7.0 300600 150300 5174 0.50 P Med6.75 6:7 5.0 300600 87174 5956 0.29 P Low6.75 7:8 2.9 200600 33100 7375 0.17 PP Low6.75 7:8 3.0 300600 86172 3380 0.29 Std. Low

7 6:7 2.9 300650 65140 11950 0.21 GF Low7 6:7 4.5 300675 80246 8750 0.36 GF Low7 7:8 7.5 300600 92185 9550 0.31 PP Low8 4:5 5.3 300900 75230 7500 0.26 P Med8 5:6 5.2 300900 71215 17120 0.24 GF Med8 6:7 4.0 300900 51153 8500 0.17 P Low8 7:8 2.0 300900 3090 7000 0.10 Air Low8 7:8 3.0 300900 48144 6894 0.16 Std. Low

9.63 2:3 7.5 6001200 285569 4508 0.47 P High9.63 3:4 6.0 6001200 130265 9500 0.22 P Med9.63 6:7 3.0 6001200 75148 16500 0.12 GF Low9.63 6:7 3.5 6001200 65125 32275 0.11 GF Low9.63 6:7 5.0 6001200 76153 13315 0.13 P Low11.25 3:4 3.6 10001500 120180 10200 0.12 Std. Med11.25 6:7 5.5 9001800 80158 22000 0.09 PP Low

P: Performance; PP: Performance Plus; GF: GeoForce; Std.: Standard. For additional new and specialist models see the Motor Handbook Web site.

Figure 1.1.2 (2)

4



1.1.3 Motor Input/Output Characteristics (Metric)

Motor Size

Lobe Config Stages

Flow (lpm)

Bit Speed (RPM)

MaxTorque (Nm)

Rev/ Litre

Power Unit Type Speed

4.75 2:3 8.0 379-1004 200550 1851 0.55 P High4.75 4:5 6.3 379-947 105262 2910 0.28 P Med4.75 5:6 8.3 568-1136 150300 4135 0.26 PP Med4.75 7:8 2.2 379-947 56140 1960 0.15 Std. Low4.75 7:8 2.9 568-947 3075 5288 0.08 PP Low4.75 7:8 3.8 568-947 84140 3187 0.15 P Low

5 6:7 2.5 379-1230 55145 7728 0.12 GF Low5 6:7 4.5 379-1200 80252 6124 0.21 GF Low5 6:7 6.0 586-1325 115280 3769 0.21 P Low

6.25 7:8 2.9 757-2271 34102 9999 0.04 PP Low6.25 7:8 4.8 568-1514 51136 7728 0.08 P Low6.5 7:8 2.0 1136-2271 4284 6101 0.04 Air Low6.5 8:9 3.0 758-1893 58145 5071 0.08 Std. Low6.75 2:3 7.0 1136-2272 250500 3661 0.22 P High6.75 4:5 7.0 1136-2272 150300 7015 0.13 P Med6.75 6:7 5.0 1136-2272 87174 8075 0.08 P Low6.75 7:8 2.9 757-2272 33100 9999 0.04 PP Low6.75 7:8 3.0 1136-2272 86172 5193 0.08 Std. Low

7 6:7 2.9 1136-2459 65140 16252 0.05 GF Low7 6:7 4.5 1136-2556 80246 11865 0.09 GF Low7 7:8 7.5 1136-2272 92185 7048 0.08 PP Low8 4:5 5.3 1136-3407 75230 10169 0.07 P Med8 5:6 5.2 1136-3407 71215 23212 0.06 GF Med8 6:7 4.0 1136-3407 51153 11524 0.04 P Low8 7:8 2.0 1136-3407 3090 9485 0.03 Air Low8 7:8 3.0 1136-3407 48144 9347 0.04 Std. Low

9.63 2:3 7.5 2272-4452 285569 6112 0.13 P High9.63 3:4 6.0 2272-4452 130265 12880 0.06 P Med9.63 6:7 3.0 2272-4452 75148 22371 0.03 GF Low9.63 6:7 3.5 2272-4452 65125 43733 0.03 GF Low9.63 6:7 5.0 2272-4452 76153 18053 0.03 P Low11.25 3:4 3.6 3785-5678 120180 13829 0.03 Std. Med11.25 6:7 5.5 3411-6810 80158 29831 0.02 PP Low

P: Performance; PP: Performance Plus; GF: GeoForce; Std.: Standard. For additional new and specialist models see the Motor Handbook Web site.

Figure 1.1.3 (1)

5



Note: Specific maximum torque values apply to motor top and motor bit connections. For general drillpipe and collar connection torque data see C.6.

Motor O.D.

inches (mm)

Lifting Sub ft. lb (Nm)

1

Top Connection

(to BHA) ft. lb (Nm)

2

Alternative Top

Connection ft. lb (Nm)

3

Adjustable Housing


4

Sleeve Stabilizer


5

4.75(121.0)

4,000(5,423)

3-1/2 in. REG8,000

(10,846)

NC 38 (3-1/2 in. IF)

9,900 (13,442)

10,000(13,560)

7,000(9,500)

5(127.0)

5,000(6,779)

3-1/2 in. REG10,900 (14,778)

NC 38 (3-1/2 in. IF)

13,800 (18,710)

12,000(16,270)

7,000(9,500)

6.25(159.0)

10,000(13,550)

4-1/2 in. REG22,000 (29,825)

NC 50 (4-1/2 in. IF)

29,500 (40,000)

20,000(27,115)

10,000(13,560)

6.5(165.0)

10,000(13,550)

4-1/2 in. REG22,000 (29,825)

NC 50 (4-1/2 in. IF)

29,500 (40,000)

20,000(27,115)

10,000(13,560)

6.75(171.5)

10,000(13,550)

4-1/2 in. REG22,000 (29,825)

NC 50 (4-1/2 in. IF)

29,500 (40,000)

25,000(33,895)

12,000(16,270)

7(178.0)

12,000(16,270)

4-1/2 in. REG25,000 (33,900)

NC 50 (4-1/2 in. IF)

30,000 (40,675)

28,000(37,960)

12,000(16,270)

8(203.5)

20,000(27,100

6-5/8 in. REG45,000 (61,000)

6-5/8 in. H9049,000 (66,435)

35,000(47,450)

26,000(35,250)

9.63(244.5)

30,000(40,650)

7-5/8 in. REG74,000

(100,300)

6-5/8 in. REG47,000 (63,720)

60,000(81,350)

45,000(61,000)

11.25(268.5)

40,000(54,232)

7-5/8 in. REG74,000

(100,300)

6-5/8 in. REG60,000 (81,350)

80,000(108,465)

60,000(81,350)

1 2

3

45

HAL30761

1.1.4 Motor Connection Torque Data

6



Sleeve Stab Connection

Thread Protector ft. lb (Nm)

6

Bit Box Connection ft. lb (Nm)

7

Alternative Bit Box


8

Bit Pin Connection ft. lb (Nm)

9

Alternative Bit Pin


10

3,600(4,480)

3-1/2 in. REG7,000 (9,491)

N/AN/A

N/AN/A

N/AN/A

3,600(4,480)

3-1/2 in. REG8,000 (10,850)

N/AN/A

3-1/2 in. IF10,000 (13,560)

N/AN/A

6,000(8,135)

4-1/2 in. REG12,000 (16,270)

N/AN/A

N/AN/A

N/AN/A

6,000(8,135)

4-1/2 in. REG12,000 (16,270)

6-5/8 in. REG28,000

(37,950)

N/AN/A

N/AN/A

7,000(9,500)

4-1/2 in. REG12,000 (16,270)

6-5/8 in. REG28,000

(37,950)

N/AN/A

N/AN/A

7,000(9,500)

4-1/2 in. REG14,000 (18,980)

6-5/8 in. REG28,000

(37,950)

4-1/2 in. Reg14,000 (18,980)

N/AN/A

15,000(20,335)

6-5/8 in. REG28,000 (37,950)

N/AN/A

6-5/8 in. Reg28,000 (37,950)

N/AN/A

25,000(33,895)

6-5/8 in. REG28,000 (37,950)

7-5/8 in. REG34,000

(46,100)

6-5/8 in. Reg28,000 (37,950)

7 5/8 in. Reg34,000 (46,100)

45,000(61,000)

7-5/8 in. REG34,000 (46,100)

N/AN/A

N/AN/A

N/AN/A

68

7

910

HAL30761

7



1.1.5 Motor Configuration Inspection

The following information should be recorded prior to motor operations:

Motor type/size (check against shipping documents)

Motor serial number (located on stator housing)

Dump sub fitted?

Stabilizer type/size (including blade information)

Adjustable housing angle

Fixed bent housing angle

Rotor jet nozzle size (if any)

Visually check general condition of motor housings, top and bit connections (including seal faces), bent housing/adjustable housing and stabilizer or protector sleeve

Lengths between bit box to stabilizer, stabilizer to bent housing/adjustable housing, bent housing/adjustable housing to connection at bottom of dump sub, connection at bottom of dump sub to top of motor

8



1.1.6 Motor Adjustable Bent Housing Setting Procedure and Connection Torque Data

HA

L306

77

3-5/8 to 11-1/4 in. (not 5 in. or 7 in.) 5 in. and 7 in.

Figure 1.1.6 (1)

Adjusting Ring

Lower Sub

Upper Sub

Stator

SummaryThe rig floor adjustable integral bent housings can be set from the straight position to the desired angular offset required to achieve required doglegs. A housing offset which allows for slightly higher than planned doglegs may be used as a contingency; however, higher angular offsets tend to increase hole gauge and can increase the mechanical loading on the motor. Modeling should be undertaken in order that the correct angular offset is selected (See 1.1.19). Note that adjustable housing setting increments are not uniform and differ between some motor sizes.

Adjustable Housing Bend Increments (in degrees)

Up to 9-5/8 in. Motor(not 5 in. and 7 in.)

0.39 0.78 1.15 1.50 1.83 2.122.38 2.60 2.77 2.89 2.97 3.00

5 in. and 7 in. Motors0 0.31 0.62 0.93 1.22 1.50 1.76 2.00

2.23 2.43 2.60 2.74 2.85 2.93 2.98 3.00

11-1/4 in. Motor0.26 0.52 0.77 1.00 1.22 1.411.59 1.73 1.85 1.93 1.98 2.00

Figure 1.1.6 (2)

Note: Housing settings are not equally incremented.

Optional adjustable bent housings are available for some motors with bend settings of up to 4 degrees offset. Optional adjustable bent housings are available for some motors with smaller bend increments up to 2 degrees offset.

NoteOn motor sizes other than the 5 in. and 7 in. O.D. the internal v-teeth used to lock in the desired Adjustable Bent Housing bend setting are on the lower edge (downhole end) of the Adjusting Ring, and the upper edge (up-hole end) of the lower sub. (The v-teeth on the Adjusting Ring are internal at the lower edge of the ring).

10



The Adjustable Bent Housings on the 5 in. and 7 in. motors are of a different design than that of the other motor sizes. The principal design difference is that the internal v-teeth used to lock in the desired Adjustable Bent Housing bend setting are on the upper edge (up-hole end) of the Adjusting Ring and the lower edge (downhole end) of the upper sub. (The v-teeth on the Adjusting ring protrude above the upper edge of the ring).

4-3/4 11-1/4 in. (not 5 in. or 7 in.) Adjusting Ring

5 in. and 7 in. Adjusting Ring

Figure 1.1.6 (3)

11



HA

L306

78H

AL3

0676

Figure 1.1.6 (4)

HA

L307

32

Make-up

Break-out

Procedure For Setting Motor Adjustable Bent Housings (Other than 5 in. and 7 in. Motors)This procedure applies to 4 in. though 11 in. motors except for the 5 in. and 7 in. motors. (For 5 in. and 7 in. motor adjustable housing setting, see the next procedure).

Close attention must be given to power tong placement to ensure that the correct connection is broken and finally re-torqued. Should the wrong connection be broken, refer to the nearest Motor Facility for the correct re-torque value. (The make-up torque for connections other than the Adjustable Bent Housing itself may be different to that specified in this handbook for the Adjustable Bent Housing).

Note: All threads are right hand.

Bent housing adjustment is most easily made 1. without BHA components made-up above the motor. Set the motor in the slips for stability.

Clearly mark the two corresponding bend angle 2. number slots which relate to the desired bend setting prior to tong operations.

Place the power tongs where indicated in 3. Fig. 1.1.6 (4) The tongs should be placed at least 6 in. (150 mm) back from connection shoulders and number slots. Break the upper sub connection. Do not back out the connection. Replace the upper power tong on the upper sub with a chain tong. Remove the lower power tong.

13



Figure 1.1.6 (5)

A

B

HA

L307

34

Keep the Adjusting Ring engaged to the Lower 4. Sub by holding the ring down with a small chain tong. (The Adjusting Ring must remain connected to the Lower Sub when the Upper Sub is being backed-off to avoid internal v-tooth damage).

Back-off the Upper Sub (5. Adjustment A Fig. 1.1.6 (5) rotate it counterclockwise when looking downhole) until there is enough space for the Adjusting Ring to be raised to disengage the internal v-teeth (Adjustment B Fig. 1.1.6 (5)). This can be accomplished with approximately three rotations of the Upper Sub.

Note: Ensure that the connection shoulders of the Upper Sub, Adjusting Ring and Lower Sub are thoroughly cleaned and then doped with copper-based grease as these faces provide structural and sealing integrity. Raise the adjusting ring with a small chain tong in order to clean/lubricate the ring lower shoulder face.

15



CFigure 1.1.6 (6)

D

HA

L307

39

Using a small chain tong, disengage the v-teeth 6. by raising the Adjusting Ring and with the ring raised, rotate the Adjusting Ring clockwise (when looking downhole Adjustment C Fig. 1.1.6 (6)) until the Adjusting Ring will no longer rotate. (At this point the mating v-teeth begin to touch; do not apply high torque/heavy load to the ring).

Using a small chain tong, rotate the Adjusting 7. Ring counterclockwise (when looking downhole Adjustment D Fig. 1.1.6 (6)) until the desired bend angle number slots first align, then engage the v-teeth. (Do not rotate the bend angle number slots on the Adjusting Ring beyond the range of bend angle number slots on the Lower Sub).

Hold the Adjustment Ring down, maintaining 8. the number slot alignment and v-teeth engagement, and turn the Upper Sub clockwise (looking downhole) with the chain tong until hand tight.

Note: After making up the Upper Sub with a chain tong there should be no gap between either the Upper Sub and the Adjusting Ring or the Adjusting Ring and the Lower Sub (check with a feeler gauge).

If there is a gap, this is because the Upper Sub has been backed off too much at step 5. Do not make-up the connections further using the power tongs.

Corrective Action: Repeat steps 4 through 8 using chain tongs. If there is still a gap, repeat these steps.

Remove both chain tongs. Torque up the Upper 9. Sub to the Lower Sub using the power tongs.

Re-torque to the value listed below:

17



Adjustable Housing Torque ValuesMotor O.D. Torque Motor O.D. Torque

in. ft. lb Nm in. ft. lb Nm3-1/8 3,500 4,745 6-1/2 20,000 27,1153-3/8 3,500 4,745 6-3/4 25,000 33,8953-5/8 3,500 4,745 8 35,000 47,4504-3/4 10,000 13,560 9-5/8 60,000* 81,350*6-1/4 20,000 27,115 11-1/4 80,000* 108,465*

Figure 1.1.6 (7)

* The quoted torque values are maximum values which can be applied. Applied torque is dependent upon rig equipment capacity, rig floor safety and empirical knowledge of the specific application; in applications where drilling is not considered to be demanding and vibration is considered to be low, lower torque values can be applied. The applied torque should not be reduced beyond 20% of that quoted above (advice should first be obtained from local directional drilling support personnel).

Procedure For Setting 5 in. and 7 in. Motor Adjustable HousingsNote that this procedure does not apply to early design 7 in. adjustable housings which are now used only in specific locations. For adjustment of early design 7 in. adjustable housings see the previous procedure.

Close attention must be given to power tong placement to ensure that the correct connection is broken and finally re-torqued. Should the wrong connection be broken, refer to the nearest Motor Facility for the correct re-torque value. (The make-up torque for connections other than the Adjustable Bent Housing itself may be different to that specified in this handbook for the Adjustable Bent Housing).

Note: All threads are right hand.

Bent housing adjustment is most easily made 1. without BHA components made-up above the motor. Set the motor in the slips for stability.

Clearly mark the two corresponding bend angle 2. number slots prior to tong operations.

Place the power tongs where indicated in 3. Fig. 1.1.6 (8). The tongs should be placed at least 6 in. (150 mm) back from connection

18



Figure 1.1.6 (8)

Make-up

Break-out

HA

L307

36

shoulders and number slots. Break the Upper Sub connection. Do not back out the connection. Replace the upper power tong on the Upper Sub with a chain tong. Remove the lower power tong.

Keep the Adjusting Ring engaged to the 4. Upper Sub by holding the ring up with a small chain tong. (The Adjusting Ring must remain connected to the Upper Sub when the Upper Sub is being backed-off to avoid internal v-tooth damage).

Back-off the Upper Sub (5. Adjustment A Fig. 1.1.6 (9) by rotating it counterclockwise when looking downhole) until there is enough space for the Adjusting Ring to be lowered to disengage the internal v-teeth (Adjustment B Fig. 1.1.6 (9)). This can be accomplished with approximately three rotations of the Upper Sub.

Note: Ensure that the connection shoulders of the Upper Sub, Adjusting Ring and Lower Sub are thoroughly cleaned and then doped with copper-based grease as these faces provide structural and sealing integrity. If it is not already sitting down against the Lower Sub, lower the Adjusting Ring with a small chain tong in order to clean/lubricate the ring upper shoulder face.

20



Figure 1.1.6 (9)

A

B

HA

L307

40

With the v-teeth disengaged, rotate the 6. Adjusting Ring counterclockwise (when looking downhole Adjustment C Fig. 1.1.6 (10)) until the Adjusting Ring will no longer rotate (At this point the mating v-teeth begin to touch; do not apply high torque/heavy load to the ring).

Using a small chain tong, rotate the 7. Adjusting Ring clockwise (when looking downhole Adjustment D Fig. 1.1.6 (10)) until the desired bend angle number slots first align. (Do not rotate the bend angle number slots on the Adjusting Ring beyond the range of bend angle number slots on the Lower Sub).

22



Figure 1.1.6 (10)

D

CH

AL3

0737

Remove the upper chain tong. Remove the 8. slips. Place a chain tong on the Lower Sub. Raise and hold up the Adjustment Ring, maintaining the number slot alignment and v-teeth engagement (Adjustment E Fig.1.1.6 (12)) and turn the Lower Sub counterclockwise (looking downhole (Adjustment F Fig.1.1.6 (12)) with the chain tong until hand tight.

Note: After making up the Lower Sub with a chain tong there should be no gap between either the Lower Sub and the Adjusting Ring or the Adjusting Ring and the Upper Sub (check with a feeler gauge).

If there is a gap, this is because the Upper Sub has been backed off too much at step 5. Do not make-up the connections further using the power tongs.

Corrective Action: Repeat steps 4 through 8 using chain tongs. If there is still a gap, repeat these steps.

Remove both chain tongs. Reposition the slips. 9. Torque up the Upper Sub to the Lower Sub using the power tongs.

Re-Torque to the value listed below:10.

Adjustable Housing Torque Values

Motor O.D. Torquein. ft. lb Nm5 12,000 16,2707 25,000 33,895

Figure 1.1.6 (11)

Prior to laying down a motor for return from the rig site, set the adjustable housing to zero degrees to reduce the potential for damage when in storage/transit.

24



EF

Figure 1.1.6 (12)

HA

L307

38

Figure 1.1.7 (1)

HA

L306

80

Do Not Tong

Tong

Tong

Do Not Tong

1.1.7 Motor Sleeve StabilizersTorque Values

Stabilizer Protector SleeveMotor O.D. Torque

Motor O.D. Torque

in. ft. lb Nm in. ft. lb Nm3-1/8 1,800 2,440 3-1/8 1,000 1,3553-3/8 3,500 4,745 3-3/8 1,000 1,3553-5/8 3,500 4,745 3-5/8 1,000 1,3554-3/4 7,000 9,500 4-3/4 3,600 4,8805 7,000 9,500 5 3,600 4,880

6-1/4 10,000 13,560 6-1/4 6,000 8,1356-1/2 10,000 13,560 6-1/2 6,000 8,1356-3/4 12,000 16,270 6-3/4 7,000 9,5007 12,000 16,270 7 7,000 9,5008 26,000 35,250 8 15,000 20,335

9-5/8 45,000 61,000 9-5/8 25,000 33,89511-1/4 60,000 81,350 11-1/4 45,000 61,000

Figure 1.1.7 (2)

Close attention must be given to tong placement to ensure that the correct connection is un-torqued and re-torqued. Should the wrong connection be un-torqued, refer to the nearest Motor Facility.

Extreme caution and good rig practice should always be exercised when handling large diameter stabilizers, especially when threading onto and off of the motor bearing housing.

SperryDrill and GeoForce motors are equipped with externally threaded bearing housings to allow for rig site changing of stabilizers and offset pads. To install a pad or stabilizer, complete the following steps:

Raise the motor by the lifting sub and hang the 1. bit box in the rotary table to steady.Clean the exterior of the motor to remove all 2. debris near the stabilizer thread area.Position the make-up tong on the thread 3. protector, and break-out tong on the bearing housing immediately above the stabilizer upset.Break the thread protector loose from the 4. bearing housing.Remove the tongs.5.

27



Unthread the protector by hand or with a chain 6. tong if necessary.Remove the protector by raising the motor and 7. sliding it down over the bit box.Thoroughly clean the bearing housing upset 8. threads and the stabilizer internal threads.Apply appropriate thread dope to both threads.9. For small diameter tools, slide the stabilizer 10. over the bit box and thread onto the motor by hand. For larger diameter motors, position the stabilizer over the rotary table or mouse hole and gently lower the motor onto the stabilizer. Using a chain tong, turn the motor into the stabilizer until the threads start. Ensure the that the lifting sub does not unscrew. After threads start, lift the motor slightly and continue to thread the stabilizer onto the motor.Position the motor with the bit box back in the 11. rotary table.Place the make-up tong on the bearing housing 12. above the stabilizer thread upset. Do not tong below the stabilizer as this is a left hand threaded component (Fig. 1.1.7 (1)).Position the back-up tong on the stabilizer 13. body or tong neck if so equipped.Torque the stabilizer to values in 14. Fig. 1.1.7 (1).If pad alignment is required, shims may be 15. installed as required between the pad sleeve and bearing housing. It is important to note that these shims must be oriented so as to complement the angle on the sleeve and bearing housing upset shoulders, if applicable.After drilling operations are completed, 16. the stabilizer connection should be broken, stabilizer removed, and protector replaced in a fashion similar to the steps outlined above.

If a pad or stabilizer is to be aligned to an 17. adjustable bent housing, the adjustable bend should be set first.

28



1.1.8 Rotor Jet Nozzling

GeneralRotor jet nozzling may be used to provide for motor operating flow rates which are greater than the standard maximum flow rate specified for a specific motor type. Excessive operating flow rates reduce rotor/stator efficiency and promote accelerated rotor and stator wear.

Only a limited amount of excess flow can be accommodated by using rotor jet nozzles.

Rotor jet nozzling is also used where there are concerns regarding demanding drilling conditions causing motor stalling, which can lead to stator elastomer damage. (Motors of 3 in. diameter and larger can be configured with rotor jet nozzles).

Figure 1.1.8 (1)

The jet nozzle is positioned at the top of the rotor. The nozzle size is carefully selected for specific applications. The jet nozzle is sized to permit a specific amount of fluid to pass through it at a specific operating differential pressure across the rotor and stator; this is based on the required bit torque and rotation speed.

HA

L306

82

29



When the drilling mud enters the top of a jetted motor it can either pass between the rotor and stator developing power, or it can simply bypass the stator through the bore of the rotor.

The pressure drop across the rotor and stator and the pressure drop across the rotor jet nozzle are the same. This pressure drop is equal to the pressure required to start the motor and maintain output power at a specific level.

Since the pressure drops across both paths are always equal, if the pressure drop across the rotor and stator is high, then the flow rate through the jet nozzle is high. If the pressure drop across the rotor and stator is low then the flow rate through the jet nozzle is low.

Operations With Jet Nozzled RotorsTotal flow rate through a jet nozzled rotor should be no more than 10% above the maximum standard flow rate. When using a jet nozzled rotor, the flow rate maintained between the rotor and stator should not be less than 70% of the maximum standard flow rate.

Motors with jet nozzled rotors require more stringent operational control when difficult drilling conditions arise. Under typical operating conditions the characteristics of the motor are not significantly affected by jet nozzling the rotor. The operating differential pressure-to-output torque relationship is not affected by jet nozzling. Slightly more WOB may be required to achieve the same differential pressure as with a non-jetted rotor.

Since the motor operating differential pressure is proportional to the torque output, and since the drop in loaded motor RPM with a jet nozzled rotor is not significant (for typical operating differentials), then for a given operating differential pressure with a jet nozzled rotor, the mechanical loading of the bit is similar to that of a non-jet nozzled (blank) rotor at similar differential pressure.

30



When using a jet nozzled rotor with a flow rate higher than the standard (non-jetted) maximum recommended flow rate, off-bottom circulating at full-flow rate will result in excessively high flow rates between the rotor and stator (overpumping) which causes premature wear and can cause elastomer damage. Drilling with very low operating differential pressures also can result in excessively high flow rates between the rotor and stator which results in premature wear.

When using a jet nozzled rotor and drilling with higher than the standard (non-jetted) maximum recommended flow rate, the circulation rate should be reduced below the standard (non-jetted) maximum recommended flow rate prior to lifting up off-bottom.

Motor Stall With Jet Nozzled RotorsThe stalling of a motor with a jet nozzled rotor is not as apparent on the standpipe pressure gauge since the jet nozzle permits the passage of fluid through the rotor bore; this is referred to as a soft stall.

Motor stall with a jet nozzled rotor is characterized by an increase in differential pressure and no ROP, the differential pressure increase being less than that observed with a full stall of a motor with a non-jetted rotor in the same application.

Note that, although during soft stall mode less fluid passes between the rotor and the stator, the soft stall mode is still potentially damaging to a motor. As soon as a stall is detected, /prior to lifting up off-bottom, circulation should be stopped immediately.

For additional rotor jetting information and calculation methods see the Motor Handbook web site.

See 2.2.2 for motor stall information.

31



1.1.9 Drill Bits

Bit Make-UpInspect the bit for any damage caused during shipping and ensure there is no debris inside the bit or in the nozzle courses.

Double check the nozzles for tightness and make sure the TFA corresponds with that required to meet the hydraulic objectives of the interval to be drilled.

Use the correct serviceable breaker for the bit being made up. Bit specification sheets list the breaker plate required.

Never place the bit cutting structure down on the rig floor. Always protect the cutting structure from damage by laying down a piece of wood or rubber to place the bit on.

Place the bit breaker on the bit and lower the bit and breaker onto the Kelly bushing or breaker holder.

Apply the correct thread compound to the API connection and snug up the connection. If a bent motor or sub is being made up, care should be taken to avoid cross-threading.

Before applying the full make-up torque to the connection, ensure that when torque is applied, the bit is being pulled into and not out of the breaker plate. This can be done by positioning the breaker with the opening towards the V-door, skate, or away from the draw works. On larger bits utilizing pinned breakers, ensure the floor bushing is not excessively worn; and in the case of split bushings, place the breaker into the bushing so that the opening is not straddling the split.

For additional data relating to bit operations see 1.1.16. For bit design information see 2.2.9.

32



1.1.10 Pre-Run Motor Surface Tests

Also reference 1.1.25.

Pick-Up / Lifting SubsPick-up subs are designed for a specific purpose. Those supplied with SperryDrill and GeoForce motors are for picking up these motors only. Motor pick-up subs are not rated or certified to lift other equipment or pull stands of drillpipe, collars, BHA tools or combinations of all three. SperryDrill and GeoForce motor pick-up subs should not be used with crossovers.

SperryDrill and GeoForce motors can be picked up using subs of appropriate geometry which did not originate with the motors if the subs are rated appropriately and correctly certified.

As well as considering the pick-up sub thread in terms of geometry and material properties in relation to the tensile load applied to it from the equipment being lifted or pulled, consideration must also be given to the material properties and geometry at the neck and top upset of the pick-up sub.

A correctly rated and certified pick-up sub should be used for lifting and pulling stands of drillpipe, collars and BHA tools. (Note that some non-SperryDrill and GeoForce pick-up subs may be of welded construction).

Surface TestsTo assist in the assessment of motor performance, condition and problem diagnosis, a number of basic motor tests should be performed before and after operation downhole (also see 1.1.25).

Note: For correct motor operation the standpipe pressure, WOB, flow rate and drillstring RPM, rig floor gauging and indicators must be accurate. Pulsation dampeners must be in good working order.

33



If a significant period of time has passed since a used motor was last tested after a previous run, and the motor was not flushed with water/appropriate oil, it should be re-tested prior to use.

If fitted, check the operation of the dump sub 1. by moving the sliding piston with the aid of a wooden drift. (Do not use a metallic drift).

Pick up the SperryDrill or GeoForce motor 2. using a lifting sub, and if a dump sub is fitted, lower it until the dump sub is below the rotary table. Make the motor up using the kelly or rig top drive, then lift the motor free of the slips. Note: Avoid possible bit damage by testing the motor without the bit attached. A thread protector should be placed in the bit box (on the bit pin) during lifting operations, and removed prior to flow testing. Prolonged running with no bit, or at very low flow rates should be avoided to minimize bearing assembly heating.

Gradually raise the flow rate to the minimum 3. specified rate for the particular SperryDrill or GeoForce motor and record flow rate and corresponding pressure. (If possible, record the flow rate and corresponding pressure at which the dump sub closes if fitted).

If possible, further raise the pump flow rate 4. and record the flow rate and corresponding pressure. A relatively high level of vibration and noise can occur during testing due to lack of overall constraint/stabilization.

Note: When considered on their own, motor free running (no load) pressure values, the draining of drilling fluid from the bit/driveshaft, and the amount of resistance to the manual rotation of motor drive shafts, are not reliable guides to motor condition and performance downhole (see 2.2.1).

34



Motors are designed to operate downhole at higher temperatures than at surface. Motors are configured with mating part fits which provide allowance for thermal expansion of components such as the elastomer (rubber) stator. At surface temperature, a motors fluid sealing capacity is less than when the motor is at downhole temperature. Motors are heated externally by the formation and internally by the action of the rotor running in the stator.

With the pumps still running, raise the dump 5. sub (if fitted) above the rotary table and inspect the fluid ports for leakage. (Clean the housing/ports for ease of observation).

For mud-lubricated bearing assemblies, 6. further raise the motor to observe the bearing assembly fluid leakage over the rotating drive shaft (58% of total flow rate is acceptable). Observe drive shaft rotation, which should not be erratic.

If fitted, lower the dump sub below the rotary 7. table, stop the pumps and allow the dump sub to open (which may require opening of surface equipment bleed valve due to pressure lock).

Raise the motor above the rotary table and 8. perform the thrust bearing gap (play) check. The play in the thrust bearing assembly should be checked on both new and used motors. A number of bearing assembly options are available for SperryDrill and GeoForce motors. For bearing checking procedures and bearing play data see 1.1.11.

Radial bearing play can be checked by placing 9. a chain tong on the bit box and applying side loading to the drive shaft. On a new motor, radial bearing play should be negligible. On a used motor, the amount of wear should be assessed in terms of prior personal training, prior experience, and with respect to planned

35



operations. A specific value of radial play at a specific reference point is not applied to individual motors. The bearing assemblies are designed to allow continued use with a relatively large amount of radial play; however a large amount of radial play can affect directional tendencies. As a general rule, radial play in excess of in. (3.2 mm) between the driveshaft and bearing housing bore (at the lower face of the bearing housing) requires that the motor be replaced.

The bit is made up by positioning the make-10. up tong at the motor bit box/pin (rotating component) and the bit breaker on the bit (see 1.1.9).

36



1.1.11 Thrust Bearings

SperryDrill and GeoForce motors use double-acting thrust bearings, both mud-lubricated and sealed oil-lubricated types.

The thrust bearings are designed and configured taking into consideration hydraulic downthrust, bit/formation interaction characteristics, any equipment being run below the motors (e.g. Geo-Pilot rotary steerable tool) and circulating fluid characteristics. The standard thrust bearing configuration accommodates conditions found in the vast majority of drilling applications for a specific motor size. Rig site balancing of hydraulic downthrust and WOB is not required.

L1

L2

Figure 1.11 (1)

HA

L307

25

37



Thrust Bearing PlayDouble Acting Bearings * Cartridge Bearings **

Maximum Bearing Gap Play L1 L2 Motor O.D. New Motor

Previously Run Motor New Motor

Previously Run Motor

in. in. mm in. mm in. mm in. mm4-3/4 0.063 1.6 0.125 3.2 0.080 2.0 0.160 4.1

5 0.063 1.6 0.125 3.2 N/A N/A N/A N/A6-1/4 0.081 2.1 0.162 4.2 0.065 1.7 0.236 6.06-1/2 0.088 2.2 0.175 4.4 0.065 1.7 0.236 6.06-3/4 0.088 2.2 0.175 4.4 0.065 1.7 0.236 6.0

7 0.088 2.2 0.175 4.4 N/A N/A N/A N/A8 0.113 2.9 0.230 5.8 0.040 1.0 0.275 7.0

9-5/8 0.125 3.2 0.250 6.4 0.025 0.6 0.314 8.011-1/4 0.140 3.6 0.310 7.9 N/A N/A N/A N/A

* Current in the majority of motors.** Original cartridge/canned type specific applications only.

Figure 1.11 (2)

It is recommended that only the weight of the motor is used during the measurement of value L2. To permit relative bearing wear assessment, ensure that the load applied to measure value L2 is the same before and after the motor run.

If BHA components and/or the kelly are made-up to the motor, only the weight of the motor should be slacked-off on the drive shaft and bearings.

It is recommended that thrust bearing gap measurement operations be undertaken after the motor has been flow tested, permitting the maximum L1 value to be measured.

Also see B.4.

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1.1.12 Float Valves

A float valve may be run above the motor to avoid potential fouling of the motor and bit with solids. Use of a float valve is recommended when drilling unconsolidated formations, drilling underbalanced or milling steel. Should a float valve not be available, fluid should be displaced regularly while tripping in hole.

1.1.13 Drillpipe Filters

To minimize the potential for damage to motor components from solids and foreign objects in the circulating fluid, it is recommended that surface drillpipe filters be utilized during all motor operations. (This includes tripping in hole operations). Any appreciable solids/foreign objects should be observed and noted and the necessary corrective action taken.

Note: Attention should be given to the observation of solids/foreign objects at the shakers.

1.1.14 Circulating Subs

A circulating sub can be run above SperryDrill and GeoForce motors to allow the displacement of LCM or permit high flow rate circulation. A float valve should be run below the circulating sub.

1.1.15 Running In Hole

When running in hole, the traveling speed of the drillstring should be controlled to avoid contact with BOPs, wellheads, casing shoes, completion equipment, bridges etc.

In open hole, care should be taken at suspected or known tight spots, ledges, excessive doglegs or key seats.

Should tight spots be encountered, the motor can be run at minimum specified flow rate with minimum

39



drillstring rotation. Tight spots can cause high contact forces on the periphery of the bit, requiring significant torque output levels from the motor, which may be new and yet to be run in.

Note: At tight spots and restrictions, a rollercone bit has more give than a fixed cutter bit does.

Reciprocate the string if required, stopping at differing depths to avoid creating ledges. When rotating the drillstring, caution must be shown with respect to bent subs, bent housings, motor stabilizers and housing configurations since excessive drillstring rotation and the effects of hole constraints can cause high-level cyclic loading of motor housings and connections (see 1.1.18 and 2.2.5).

ReamingStandard PDC bits are not designed for reaming. If it is expected that extensive reaming will be necessary, do not run a PDC bit; excessive reaming will destroy the gauge.

Reaming may be required with steerable and bent sub assemblies due to doglegs and hole gauge changes. In order to avoid sidetracking tendency at obstructions, an attempt should first be made to pass the obstruction without pumping.

1. The drillstring should be worked up and down while rotating through 90 degree (1/4 turn) increments. This will vary how the bit/BHA (bend) is oriented towards and interacts with the restriction. Upward and downward movement of the string will ensure that the 90 degree (1/4 turn) increments applied at surface are worked down to the restriction location. Repeat this a number of times in a controlled manner with light WOB.

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Note: Weight should not be applied to the restriction when only drillstring rotation is applied, i.e., with no flow rate. This can cause the stator to rotate over the rotor, tending to cause stator damage. See 1.1.18.

2. If the restriction cannot be passed, low flow rate and rotary speed should be used. The flow rate should be approximately 30% below the minimum specified operating flow rate for the motor model. Note that at this low flow rate the motor will be relatively underpowered, may be difficult to control, and can still stall. Operations at less than minimum specified flow rate should be undertaken only for a very short period of time to move through a restriction.

Apply low drillstring rotation (up to 50 RPM max in 10 RPM increments) with no more than 5,000 lbs WOB.

Note: When pumping, there is a tendency to sidetrack. Continuous upward and downward movement of the string will produce varying bit/BHA/restriction interactions and will avoid a ledge being cut or sidetracking being initiated.

Very close attention must be paid to the applied flow and WOB parameters and the resulting ROP. If the original hole is being followed then the relatively low flow, drillstring RPM and WOB should produce low motor operating differential and higher ROP than when first drilling at that location (assuming similar motor and bit type).

3. If the restriction cannot be passed, use the minimum specified operating flow rate for the motor model and repeat procedure step 2.

4. If the restriction cannot be passed, 30% less than the planned drilling flow rate should be applied without drillstring rotation. Orient the

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toolface to the highside and apply WOB slowly, maintaining only low WOB.

Very close attention must be paid to the resulting ROP. If the original hole is being followed then the applied parameters should produce low motor operating differential pressure and higher ROP than when first drilling at that location (assuming similar motor and bit type).

Should the operating parameters and ROP indicate that sidetracking has been initiated/drilling-ahead has commenced, stop immediately. Advise the customers representative and seek immediate assistance from appropriate DD operations management/survey management/the real-time operations centre.

Also see 1.1.18.

Tagging BottomAvoid running the bit into any settled solids, cement or the hole bottom. Settled solids at the hole bottom are common and can cause unexpected WOB, bit side loading and motor loading/differential pressure spikes. Reduce the rate of running in hole as hole bottom is approached. At a short distance above hole bottom or above any settled solids, slowly raise the flow rate to the planned motor operating rate and establish circulation (reciprocate the string if necessary) to remove settled solids.

For information relating to running a motor into elevated temperature wells see 1.1.22.

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1.1.16 Initial Motor Operations

Individual Motor Specification and Performance Data see 1.2.Motor Operating Differential Pressure and Stall information see 2.2.1 and 2.2.2.Motor Reactive Torque and Stick-Slip Data see 1.1.20 and 2.2.3.

Weight On Bit Data see 1.1.17 and 2.2.4.

Drillstring Rotation Data see 1.1.18 and 2.2.5.

Dogleg Prediction Data see 1.1.19.

Vibration and Shock Loading Data see 1.1.20.

Flow Rates and Drilling Fluids Data see 1.1.21 and 2.2.8.

Downhole Temperature Data see 1.1.22.

Note: A new motor should be run-in for 1015 minutes at reduced operating parameters.

During this initial period, ROP may be slow and erratic. The string should be periodically lifted off bottom to ensure cuttings cleaning. When first going on-bottom, particularly with a new motor, and/or at high temperature, ensure that any automatic or semi-automatic drilling equipment is not capable of heavily loading the motor. Drillstring rotation should be maintained at a minimal rate during the run-in period.

1.1.16 (1) Initial Motor FunctioningHaving carefully tagged hole bottom, pick up off bottom and record pick-up/slack-off weights and rotary torque values. Gradually increase flow rate to the minimum planned operating flow rate and record the off-bottom, free-running or no-load pressure. This pressure is used as a reference from which motor operating differential pressure, and therefore torque, can be calculated. Motor torque and bit rotation speed

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can be readily approximated using the performance graph for a particular motor.

The essence of drilling with a downhole motor is to apply surface parameters which maintain consistent rotary and torsional loading at the bit, ensuring optimum loading and formation cutting action at the bit, and optimal loading of the motor and associated BHA tooling. Consistently applied rotary and torsional loading also provides benefits in ROP and hole quality, while fluctuating rotary and torsional loading promotes drilling tool component wear, reduces ROP and negatively affects hole quality.

Maximum Operating PressureStall Pressure

Off-Bottom; Motor No Load Pressure (Reference Pressure)

Optimum Motor Operating Pressure Range for Particular Conditions

High Motor Operating Pressure (Wear/Stall Tendency) *

Sudden Rise to Stall

* The High Motor Operating Pressure Zone shown occurs at high loadings where drilling conditions are less than optimum. Within this zone, wear rate and stall tendency is increased (See 2.2.1 and 2.2.2).

Figure 1.1.16 (1)

HA

L307

26

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Note: Always start the pumps before drillstring rotation; start the pumps then rotate the string before going on hole bottom. Do not adjust string rotation speed while the motor is operating on bottom. Reduce standpipe pressure differential prior to lifting a motor off-bottom (whether lifting off-bottom to make a connection, to adjust or re-establish drilling parameters, or to ream or correct a motor stall).

Lifting a motor off-bottom with standpipe pressure differential applied (particularly after a motor stall has occurred) and the bit face loading reducing to zero, can result in abrupt irregular loading and motion of both the motor and bit.

With the motor off the hole bottom, start the pumps and gradually raise the flow rate to the planned operating value, then slowly lower the drillstring and apply 2,000 to 5,000 WOB. As the bit contacts the formation, torque is required to maintain rotation and penetrate the formation; this increases the pump pressure. Increasing WOB increases the pump pressure and decreasing WOB reduces it.

PDC and diamond bits initially should be run at the lowest bit weights possible, increasing weight as the job progresses until the optimum weight is achieved. Tri-cone bits typically have less frictional drag losses than PDC or diamond bits. Therefore, operating differential pressures are less given similar formation and operating parameters.

Allow the motor and bit to run-in for 1015 minutes at reduced operating parameters, then slowly raise the WOB in small increments until the planned operating WOB is achieved.

It is essential that motors in elevated temperature applications are initially run with caution, and always run with operating differential pressure reduced to recommended levels (see 1.1.22).

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During drilling operations, the off-bottom reference pressure should be checked periodically to allow for circulating fluid rheology changes, increased hole depth or any changes in flow rate.

It should be noted that in any application there are specific combinations of motor output torque and RPM for the particular drill bit and formation interaction characteristics which produce optimum ROP and motor reliability. For a given application there is a level of torque and RPM beyond which operations are less than optimum.

If a motor stall occurs, any drillstring rotation should immediately be stopped. Flow should be stopped and standpipe differential pressure reduced prior to lifting the motor off-bottom. See 2.2.2.

1.1.16 (2) Drilling Cement Float Equipment/Casing Shoe/Rathole

Great care should be taken when drilling cement and float equipment, particularly when a motor/bit is new, or if the bit is considered to be aggressive.

Drillable plugs consist of rubber with a wood, plastic, or aluminum core. It is essential that the drilling of the rubber is initiated and completed in a balanced and controlled manner to avoid potential damage to the motor, bit or casing.

Wash down the last 30 60 feet to the bottom of the cased hole and tag the cement gently.

High drillstring rotation rate is not necessary; 20 to 40 RPM is usually sufficient to ensure good drilling and adequate cleaning. Damage to the bit and/or casing can result from excessive rotation of a bent motor inside cased hole.

Mark the kelly (or drill pipe at the kelly bushing) and pick up until all of the weight is on the hook, mark the kelly again, then pick up approximately one foot.

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Flow should be established and maintained such that adequate hydraulic horsepower is delivered to the motor to initiate and complete the drilling of the rubber float equipment while minimizing erratic motor loading and associated motor differential pressure fluctuations, micro-stalls or full stalls.

In addition to possibly damaging the motor, excessive erratic loading and movement could cause bit cutter or even casing damage. High flow through the motor can rotate the bit too fast and can damage the bit and/or casing.

The bit should be placed on the rubber gently, and weight applied to a previously agreed upon moderate amount. Cement equipment manufacturers provide guidelines for float equipment drilling. Excessive weight should not be applied. Weight should be applied in a controlled manner.

The motor should take load, and the motor operating differential pressure (standpipe pressure) should rise, as the bit bites into the rubber. This step may be repeated with increasing amounts of WOB if the bit does not bite initially. Be patient, it may take some time to initiate drilling of the rubber.

The motor loading/operating differential pressure increase may be erratic. No motor load/standpipe pressure rise/fluctuations indicates that the bit is not drilling through the rubber.

When rubber drilling is established, the rubber gets ripped and torn-up and loose pieces get wedged and trapped around the bit as they try to pass between the bit and the casing. This adds to the erratic bit/motor loading caused by the irregular bit/rubber interaction and results in standpipe pressure fluctuations.

Note: Surface screens should be monitored during float equipment drill-out. Recovered float rubber should not be mistaken for motor stator elastomer.

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Allow WOB to drill off before applying more, as the sudden addition of WOB may spin the rubber and/or induce stick-slip. Once progress is being made, flow can be increased to optimize debris removal.

Reciprocate the bit only if penetration stops and while maintaining flow to continue removing debris from junk slots.

If there are problems establishing the drilling of the rubber it may be necessary to force the bit cutting structure into the rubber, pinching the rubber between the bit and cement and/or internal components of the float or shoe. This should be done with no flow applied. Significant WOB must not be applied and the bit should be sat down on the rubber, NOT run into the rubber.

Pick up off bottom and return to drilling.

If the plug appears to be spinning, reduce flow rate, pick up off bottom, shut off the pumps, and sit the bit down gently on the plug until it begins to take weight (see above). Pick up off bottom, re-establish parameters and return to drilling.

Note: In most instances, the clearance between casing I.D. and bit O.D. is small. Therefore, the chances of cocking the bit and damaging the bit cutters is minimal. The possibility of cocking the bit is further reduced by the bit gauge pad contact area.

Always check the casing I.D. before doing this. If there is more than 0.25 in. clearance on diameter, be very cautious regarding how rough the drill-out process becomes. More than 0.25 in. clearance on diameter may permit the bit to move enough to cause impact damage to the gauge cutters.

If a reamer shoe has been used apply caution when drilling, similar to that detailed above.

Once the shoe track is considered to be clean, low string rpm must be applied (typically less than 60

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RPM) in the rathole and consideration should be given to pulling the BHA back into the casing at short intervals below the shoe.

The rathole is relatively large diameter where cuttings or cement debris can accumulate, there can be the risk of pack-off issues and irregular BHA stabilization, care should be taken whenever sitting in or passing through the rathole and at the rathole to new gauge hole transition. Monitor BHA dynamic loading data if available.

Pump flow rate should not be increased quickly while in the rathole to avoid disturbing cuttings which may pack-off between the BHA and casing bore or settle on the low side of the hole, monitor the equivalent circulating density (ECD) and be aware that motor operating differential pressure can fluctuate due to the effect of any hole cleaning pills being pumped.

1.1.16 (3) Drill-Off TestOnce formation drilling has commenced and the bottomhole pattern has been established, a drilling test can be conducted to determine the optimum bit energy levels to achieve optimum performance.

Consider the desired bit speed (based on past history with this BHA type and/or speed analysis) in terms of the cumulative drillstring speed plus the loaded motor operating speed (motor output speed for specific flow rate and operating differential pressure due to applied WOB).

Apply the planned flow rate and drillstring rotation.

Select a bit weight (at the low end of the planned/expected WOB range), apply this and hold constant. Mark five feet on the kelly and record the amount of time necessary to drill that distance.

After the five foot interval has been drilled, increase the bit weight by 5,000 to 10,000 lbs. Mark the kelly and

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record the amount of time to drill this distance. Repeat this procedure until an increase in bit weight does not produce a significant increase in penetration rate.

Plot the data on a graph (weight vs. penetration rate).

Repeat the above procedure adjusting the rotary speed.

The optimum bit energy level will be the lowest WOB and drillstring + motor output RPM combination which will achieve the highest penetration rate for the given flow rate.

Alternatively a specified time period can be selected, approximately 10 to 30 minutes, during which the operating parameters are held constant, bit weight being at the low end of the planned/expected WOB range, and the footage drilled during the time period is related to the footage drilled during similar time periods where increased WOB has been applied and maintained (similar flow and drillstring rotation rates being maintained during test time periods).

Note: Bearing in mind the importance of motor reliability and longevity, it is prudent to reduce the ROP in order to maximize reliability and longevity.

1.1.16 (4) Hard StringersAs soon as hard stringers are encountered, reduce drillstring rotation rate and maintain WOB.

Increase WOB, not drillstring rotation, to achieve acceptable ROP.

If motor stall occurs when the stringer is encountered, immediately stop the pumps and pull the bit off bottom. Vary parameters and return to bottom slowly. If stalling still occurs, repeat lifting off bottom and parameter variance.

Maintaining the rotation of a motor with a bent housing is significant in maintaining bit stability when transitioning into a harder formation. Keeping the bit

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engaged in the formation and efficiently shearing the formation is the key to good performance through interbedded stringers.

Continue drilling under these parameters through the entire stringer. Once through the stringer, return to the previously applied WOB first, then increase drillstring rotation rate.

Note: Adequate flow rate is required to provide necessary hydraulic horsepower to the motor and to ensure the bit cutters are receiving as much cooling as possible.

1.1.16 (5) Motor Functioning with Respect to Balancing ROP and Reliability

Individual motor performance graphs are contained in section 1.2. The data contained in SperryDrill and GeoForce motor performance graphs is a representation of the input and output characteristics of the various motor models, as achieved through repeated dynamometer testing.

The motor dynamometer tests are undertaken at ambient surface temperature with water. Actual downhole dynamic loadings are different and cannot be easily reproduced at surface, hence the maximum operating differential pressure achievable in some downhole applications can be less than that achievable on a dynamometer. The loading demands at the bit may suddenly increase for short time durations; these load fluctuations may not be evident at surface.

In all applications (typical, demanding, HPHT and air drilling), maintaining a balance of reasonable ROP at reasonable motor operating differential pressures produces reliability benefits, which is in contrast to running at maximum achievable ROP, which produces high loadings at the bit that are transferred via the motor driveshaft to the transmission components, the rotor and stator, and the housing connections.

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Continuous, reliable motor operation at the stated Maximum Operating Load values is possible only given optimum drilling conditions. These Maximum Operating Load values should not be confused with higher Stall Torque values where no rotation of the drill bit, and therefore no drilling, occurs.

1.1.16 (6) Drilling Off WhipstocksThere are two specific application types which need to be considered when drilling off a whipstock, hence it is important that the objectives for the casing exit and required sidetrack are clearly understood by all involved prior to operations start-up.

The majority of whipstocks are used in conventional re-entry sidetrack applications where an existing well is being abandoned, with the intention being to mill a window in the original casing such that a new reservoir section can then be drilled and completed to access additional or unswept reserves. In the majority of conventional whipstock sidetracks, the whipstock is permanently installed in the well.

Whipstocks are also used in multilateral applications in both new and existing wells. Typically in a multilateral application, greater consideration regarding the casing exit and the immediate well profile in the new hole section is required for several reasons:

In a multilateral application, the whipstock will be retrieved from the well at some point to re-establish communication with the main wellbore, hence mitigating steps are required to prevent unnecessary whipstock damage which could potentially compromise whipstock retrieval.

Secondly the completion requirements / potential through-completion intervention requirements, dictate that the wellbore profile in the immediate junction area is planned and subsequently drilled to ensure these completion objectives are not compromised.

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In general terms the guidelines outlined below need to be considered when drilling off a whipstock with a steerable BHA:

Ensure that the drilling assembly is compatible with the whipstock in terms of the expected and modelled dogleg capability, e.g. 3D rotary steerable-based systems and typical LWD tool string configurations require a dogleg severity of less than 10 deg/100 ft across the window.

Discuss rat hole requirements with involved personnel prior to commencing operations. In horizontal applications, with high side milled exits, minimize the amount of formation rat hole milled with the milling BHA.

Ensure debris management and well clean-up measures are in place, and required equipment, e.g. ditch magnet

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