displacement motors - sigma quadrant · robello samuel dmitry f. baldenko fedor d. baldenko...
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Robello Samuel Dmitry F. Baldenko Fedor D. Baldenko
POSITIVE DISPLACEMENT MOTORSTheory and Applications
A SigmaQuadrant Engineering Publication
PositiveDisplacement MotorsTheory and Applications
Robello Samuel Dmitry F. Baldenko
Fedor D. Baldenko
A Sigmaquadrant Engineering PublicationHouston/Beijing/Chennai/Moscow
σ
iv
DISCLAIMERWhile the authors and the publisher have used their best efforts in preparing and producing the book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by marketing or sales representatives or in print or online sales and marketing materials. The advice and strategies contained herein are the opinions of the authors and may not be suitable for your situation. You should consult with the proper professional where appropriate. Neither the publisher nor the authors shall be held liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or any other damage.
This publication or any part thereof may not be copied, reproduced, stored in a physical or electronic retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, scanning, recording, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either: (1) the prior written permission of the publisher, or (2) authorization through payment of the appro-priate per-copy fee to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, Massachusetts, 01923, (978) 750-8400, fax (978) 646-8600, or at www.copyright.com.
Positive Displacement Motors – Theory and Applications
Copyright © 2015 by Sigmaquadrant LLC, Houston, Texas. All rights reserved. No part of his publication may be reproduced or transmitted in any form without the prior written permission of the publisher.HOUSTON, TX:Sigmaquadrant.com11306 Dawnheath drCypress, TX 77433
Director: Dorothy SamuelManaging Editor: Dorothy SamuelProduction Editor: Hubert DanielSenior Design Editor: Kryon Publishing Services (P) Ltd.
Library of Congress Cataloging-in-Publication DataSamuel, Robello.Positive Displacement Motors – Theory and Applications / Robello Samuel.p. cm.Ies bibliographical references and index.ISBN: 978-0-9906836-0-510 9 8 7 6 5 4 3 2 1
1. Positive Displacement Motors—Equipment and supplies. 2. Oil well drilling—Equipment and supplies. 3. Oil well drilling. 4. Gas well drilling. I. Title.Printed in the United States of AmericaPrinted on acid-free paper.
Text design and composition by: Kryon Publishing Services (P) Ltd., Chennai, India. www.kryonpublishing.com
“Great engineering minds march off the maps, Mediocre engineering minds stay within the boundary,
Small engineering minds never draw the line”
— Ollebor Leumas
Contents
viii Preface
ix Acknowledgments
x About the Authors
chapter 1 1 General Introduction
chapter 2 39 Downhole Drilling Motors
chapter 3 55 Motor Components
chapter 4 71 Geometrical Description
chapter 5 117 Kinematical Description and Operation
chapter 6 165 Design and Motor Operation
chapter 7 207 Contact Line, Wear, Leakage, and Losses
chapter 8 259 Motor Bottomhole Assembly
chapter 9 293 Motor Operating Parameters
chapter 10 347 Pneumatic Motor
chapter 11 393 Advances
409 Bibliography
421 Index
Preface
This book provides detailed theory and working princi-ples of positive displacement motors based on Moineau principle. Our aims are to (1) emphasize the basic prin-ciple involved in the operation; (2) instill theory in the operation of the motor; (3) explain the application with reference to drilling framework; and (4) provide the advancement in this area in the recent years. The text is intended for designers, practical field personals, and drilling engineers. It can also be used as a supple-ment book for downhole drilling tools study and other advanced drilling courses. The mathematics, science, and engineering presented provides in depth under-standing of this simple machine but complex intricate geometry. Undoubtedly, analytical and geometrical treatment provided gives a systematic approach for the use under downhole conditions. More advanced treatment with mathematical rigor is also interspersed throughout the book wherever needed and justified. Numerous problems and supplementary problems are given at the end of each chapter so as to give more understanding of the theory presented.
Painstaking efforts have been taken to present usable material; however, errors are sometimes inevitable. We encourage readers to send their suggestions and comments toward the improvement of this book. They can download the errata sheets from the site sigmaquadrant.com.
Authors
Acknowledgments
We thank Kryon Publishing Services (P) Ltd. who helped us with the copyediting and proofreading of this book. We thank Saravanan Boopathy who devel-oped to put together the cover image for this book. We would also like to thank Dr. Hubert (Kannan) Daniel of John Hopkins University and Balaji Srinivasan of Kryon Publishing Services, Chennai for helping us at various stages of the book. Every possible effort has been taken to acknowledge and give appropriate credits in using the copyrighted materials. Should there be any omis-sion, we sincerely apologize for the mistake and suitable corrections will be made at the first possible update.
We would like to dedicate this piece of work to our fellow drilling engineers, technicians, field hands, designers, and manufacturers who have worked on this amazing piece of tool.
About the Authors
Dr. Robello Samuel is a Chief Technical Advisor and Halliburton Technology Fellow with Halliburton since 1998. He helps to lead well engineering applications and is responsible for research in new drilling tech-nologies. He makes decisions and recom-mendations that are authoritative and have far- reaching impact on research and scien-tific activities of the company and he serves
as a corporate resource, providing technical direction and advice to management in long-range planning for new or projected areas of drilling. He has more than 30 years of multi-disciplinary experi-ence in oil and gas operations, management, consulting, software development, and teaching. His special areas of oilfield expertise include onshore and offshore well engineering, cost estimating, and drilling supervision.
Dr. Samuel has written or coauthored more than 150 journal articles, conference papers, and technical articles and is regarded as one of the world’s most influential contributors to advancement of research and practice in drilling engineering. He has given sev-eral graduate seminars at various universities and keynote speeches at forums and conferences. Dr. Samuel has been the recipient of numerous awards including the SPE Regional Drilling Engineering Award and the “CEO for A Day (Halliburton)” award. He presently serves as a review chairman on several journals and professional committees. He has been on the faculty of various universities and holds an adjunct professor appointment (concurrently) for the past 12 years, at the University of Houston and Texas Tech University in Lubbock.
xiAbout the Authors
Dr. Samuel, a Society of Petroleum Engineer Distinguished Lec-turer, holds B.S. and M.S. degrees in mechanical engineering from the University of Madurai and College of Engineering, Guindy. He also holds M.S. and Ph.D. degrees in Petroleum Engineering from Tulsa University.
Dr. Samuel’s unique blend of skills as a field engineer, researcher, and instructor has helped him author 10 drilling books and a forth-coming book “Drilling Engineering Optimization.” He can be reached via e-mail at [email protected] or phone at (832) 275-8810.
Dr. Dmitry F. Baldenko, doctor of technical sciences, is an active member of the Russian Academy of Natural Sciences. He graduated from Moscow Oil Institute named after Gubkin (now Russian State University of Oil and Gas) with specialty in “Machinery and Equipment of Oil and Gas Fields.”
From 1957 to 1969, D. Baldenko was a lead designer for production of rodless pumps
and participated in the creation of single-screw submersible pumps for oil production and water lifting and other oilfield machineries. Since 1969, D. Baldenko has been working for the Russian Scien-tific Research Institute of Drilling Techniques (VNIIBT). As a chief designer of screw-type hydraulic machinery, he was directly involved in design, testing, and implementation of multi-stage positive dis-placement motors (PDMs). As one of the inventors of Russian PDM, D. Baldenko established initial contacts between Russian and western companies to promote this technology in the western markets.
He was the first to propose and demonstrate the advantages of multi-lobe progressive cavity pumps, as well as a scheme of sub-mersible hydraulic drive screw pumping unit for oil production.
Dr. Dmitry Baldenko authored 200 scientific publications, including 12 books and reviews in the area of drilling and oilfield technology and is the owner of more than 250 Russian and foreign patents for invention.
About the Authors
Dr. Fedor D. Baldenko, in 1980, graduated from the Moscow Institute of Petrochemical and Gas Industry named after Gubkin with spe-cialty “Machinery and Equipment of Oil and Gas Fields” and is constantly working in this institution (now Russian State University of Oil and Gas).
As an associate professor of the oil and gas industry machinery and equipment depart-
ment, F. Baldenko gives courses on “Machinery and equipment for drilling oil and gas wells”, “Installation and operation of drilling and oilfield equipment” and “Hydraulic machines and compres-sors.” He conducts research in the field of operation of single-screw hydraulic machines, theory cycloidal gearing, geometry optimi-zation of screw working bodies, modeling of dynamic systems of drilling, and oilfield machinery.
F. Baldenko has authored 120 scientific publications, including 8 monographs and reviews in the area of drilling and oilfield equip-ment. He is also the author of more than 50 patents for invention.
xii
General IntroductionSelection of proper downhole motor is important in designing the bottomhole assembly (BHA) with mud motors. Improper designs may lead to costly problems such as wellbore crookedness, improper build rate, and string failures. One of the components in the BHA is a downhole motor. Before going through in detail about the working principle, position of the motor in the BHA, and operating param-eters few basic terms need to be understood. This chapter outlines the basic terms involved in the wellpath and motor design.
PUMPS AND MOTORS
A hydraulic pump converts mechanical power into hydraulic power. The input of mechanical power into the pump is the product of the angular velocity of the pump and torque, whereas the output hydraulic power is equal to the volumetric flowrate and the pres-sure drop across the pump as shown in Fig. 1.1.
Hydraulic motors can be broadly classified as shown in the chart (Fig. 1.2).
Hydraulic motors are used to turn hydraulic power into rotary motion and they can be classified as
• Gear motors• Vane motors• Gerotor motors
1C H A P T E R
Motor Components 65
Figure 3.8 Rotor cross-section.
As the number of lobes increase the speed decreases and torque increases.
Universal Joint
Eccentric rotation of the rotor is converted to concentric rotation by the use of a universal joint or a flexible joint, and an adjustable universal drive shaft is shown in Fig. 3.9.
Adjustable Bent Housing
It is an option to provide wide range of build rates with the motor. Different manufacturers provide different adjustment settings.
Bearing Assembly and Drive Shaft
The axial load is transmitted to the bit through the thrust bearing assembly. The drive shaft rotation is made smooth by radial bearings.
Positive Displacement Motors98
5 Stationary Circle
(n + 1)r
6 Rolling Circle
4 Power Section Axisy
x
1 2 3 7
e
r
∆x1
ru
2πr
δ2
Figure 4.20 Formation of the conjugate profile with interference.The chart description is as follows: 1 – shortened cycloid, 2 – offset cycloid, 3 – equidistant,
4 – motor axis, 5 – stationary circle, 6 – rolling circle, 7 – resulting position rack.
a 2
h
12
a 1
D 1
hh*
* D 2*
D2D
1
Figure 4.21 Shrinkage profile of stator.1 - the nominal profile, 2 - the actual profile.
Positive Displacement Motors166
III. Calculation of axial forces IV. Calculation of rotor and the motor output rotor V. Calculation of rotor section VI. General design of components VII. Calculation of deflection layout
The details of the design in the respective categories are explained in detail.
I. Calculation of the geometric parameters of the power section (rotor and stator)
1. Outer diameter of the motor stator D (Fig. 6.1) To provide the necessary clearance (gap between the borehole
wall and the motor stator) that can be calculated using the simple equation: D = (0.8 -> 0.9) Dh (6.1)
2. Pitch circle diameter of the stator
Dc = D – 2(εM + εp) (6.2)
Figure 6.1 Outer diameter of the motor stator.
Dc εp εM
p o
D
e
p s
Positive Displacement Motors336
0
200
400
600
800
1000
1200
1400
1600
Flow Rate (gpm)
Impa
ct F
orce
(lbf
)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
TFA
(in2 )WOB 30 kips
WOB 50 kips
WOB 70 kips
No Motor
No Motor
WOB 30 kips
WOB 70 kips
WOB 50 kips
Motor Config:0.5
0 100 200 300 400 500 600 700 800
Figure 9.20 Impact force vs flow rate.
0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,0000
10
20
30
40
50
60
WOB (lbf)
RO
P (
ft/h
r)
1/2
2/3
3/44/5
5/66/7
7/8
Figure 9.21 ROP vs WOB.
Positive Displacement Motors398
The resultant force acting at the contact point is given by
Fn = π ρL S d pd
eNss
s( ) i ∆ 22
2 22
2+
(11.4)
where i = winding or configuration ratio
i = nn + 1
n = number of rotor lobes of the motor (winding number)
Because of the contact forces, the piezoelectric material under-goes strain as shown in Fig. 11.5 for a 3:2 lobe motor. The number of piezoelectric material embedded in the motor will also be a function of the number of lobes in the power section of the motor.
*
**
**
*
PiezoelectricMaterial
Figure 11.5 Piezoelectric material placements for 3:2 lobe motor.
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A comprehensive and valuable book
written by a team of outstanding
experts in this tool and published
through SigmaQuadrant publishing.
The Positive Displacement Motors
covers the full spectrum of topics in
terms of analysis and design of the
downhole mud motor that serves
the workhorse of the downhole drill-
ing system for several decades. This
book presents functional, operational
and technical aspects of positive
displacement motor. It provides a
platform ideal to seasoned engi-
neer, experienced researcher and
other professionals involved in the
drilling operations as it offers real
insight into this simple but complex
machine. It highlights the background
and development of this tool
• Provides details of the design
• Offers operational guidelines of
this tool
• Emphasizes technology selection
and innovation in the offing
• Incorporates practical operating
envelop
Dr. Robello Samuel has been a Chief
Technical Advisor and Technology
Fellow (Drilling Engineering) working
with Halliburton since 1998 in Houston.
He is currently a research and engi-
neering lead for well engineering applications and
responsible for research and scientific activities
for new drilling technologies. In his present role
he also conceives and develops creative/inno-
vative technology and drilling solutions critical
to the company’s success. He has more than 30
years of multi-disciplinary experience in domestic
and international oil/gas drilling operations. He
has been an adjunct Professor at the University
of Houston for the past 12 years teaching. He has
published more than 150 technical papers, reports
and 10 books. He started his career working on
rigs as a drilling engineer. He holds BS and MS
degrees in mechanical engineering, as well as MS
and PhD degrees in petroleum engineering.
Dr. Dmitry F. Baldenko, graduated from
Moscow Oil Institute (now Russian State
University of Oil and Gas) with specialty
in “Machinery and Equipment of Oil and
Gas Fields.” From 1957 to 1969, he was
a lead designer for production of rodless pumps
and involved in the development of single-screw
submersible pumps. Since 1969, he has been work-
ing for the Russian Scientific Research Institute of
Drilling Techniques (VNIIBT). As a chief designer
he was directly involved in design, testing and
implementation of multi-stage positive displace-
ment downhole motors (PDM). He authored 200
scientific publications, including 12 books and
holds more than 250 Russian and foreign patents.
Dr. Fedor D. Baldenko, graduated from
the Moscow Institute of Petrochemical
and Gas Industry with specialty
“Machinery and equipment of oil and
gas fields” and is currently working in
this institution (now Russian State University of Oil
and Gas). As an Associate Professor at the O&G
machinery and equipment department he teaches
several course and conducts research in the field
of hydraulic machines, theory cycloidal gearing,
optimization of screw working bodies, modeling
of dynamic systems of drilling and oilfield machin-
ery. He has 120 scientific publications, including
8 monographs and holds more than 50 patents for
invention.
Robello Samuel
Dmitry F. Baldenko
Fedor D. Baldenko
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ISBN 978-0-9906836-2-9
ISBN: 978-0-9906836-2-9
POSITIVE DISPLACEMENT MOTORS - Theory and Applications
DR
ILLING
EN
GIN
EE
RIN
G O
PTIM
IZATIO
N
sigmaquadrant.comuadrant
501 SOLVED
PROBLEM
S AND
CALCULATION
S FOR D
RILLING
OPERATIO
NS
501Solved Problems
and CALCULATIONS for
DRILLING OPERATIONS
ROBELLO SAMUEL
A SigmaQuadrant Engineering Publication
uadrant
Dr. Robello Samuel is a Chief Technical Advisor and Technology
Fellow with Halliburton. He is currently a research and engineering
lead for well engineering applications and responsible for research
and scienti� c activities for new drilling technologies. He has
more than 30 years of multi-disciplinary experience in domestic
and international oil/gas drilling and completion operations,
management, consulting, software development and teaching.
He is also an adjunct Professor at the University of Houston and
Texas Tech University, Lubbock for the past 10 years. Dr. Samuel,
a SPE Distinguished Lecturer, holds B.S. and M.S. (mechanical
engineering) degrees from University of Madurai and College of
Engineering, Guindy, Anna University (Chennai), M.S. and Ph.D.
(petroleum engineering) degrees from Tulsa University. He is also
the author of nine bestselling drilling engineering books.
This book is an expanded and corrected version of the author’s
“Formulas and Calculation for Drilling Operations – Edition 1”
book. It is the most comprehensive practical handbook with
calculations and solved problems for drilling operations. The
central premise of this book is easy to use step-by-step calculations
which can be used by students, lecturers, drilling engineers,
consultants, software programmers, operational managers, and
researchers. Apart from a basic introductory chapter giving a brief
treatment of calculations on rig math, this book consists entirely of
problems and solutions on focused topics encountered in drilling
operations. 501 solved Problems and calculations will help you
to connect relevant engineering theories associated with drilling
operations and quickly identify the parameters in� uencing the
operations.
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A comprehensive and valuable book written by a team of outstanding experts in this tool and published through SigmaQuadrant publishing. The Positive Displacement Motors covers the full spectrum of topics in terms of analysis and design of the downhole mud motor that serves the workhorse of the downhole drill-ing system for several decades. This book presents functional, operational and technical aspects of positive displacement motor. It provides a platform ideal to seasoned engi-neer, experienced researcher and other professionals involved in the drilling operations as it offers real insight into this simple but complex machine. It highlights the background and development of this tool
• Provides details of the design
• Offers operational guidelines of this tool
• Emphasizes technology selection and innovation in the offing
• Incorporates practical operating envelop
Dr. Robello Samuel has been a Chief Technical Advisor and Technology Fellow (Drilling Engineering) working with Halliburton since 1998 in Houston. He is currently a research and engi-
neering lead for well engineering applications and responsible for research and scientific activities for new drilling technologies. In his present role he also conceives and develops creative/inno-vative technology and drilling solutions critical to the company’s success. He has more than 30 years of multi-disciplinary experience in domestic and international oil/gas drilling operations. He has been an adjunct Professor at the University of Houston for the past 12 years teaching. He has published more than 150 technical papers, reports and 10 books. He started his career working on rigs as a drilling engineer. He holds BS and MS degrees in mechanical engineering, as well as MS and PhD degrees in petroleum engineering.
Dr. Dmitry F. Baldenko, graduated from Moscow Oil Institute (now Russian State University of Oil and Gas) with specialty in “Machinery and Equipment of Oil and Gas Fields.” From 1957 to 1969, he was
a lead designer for production of rodless pumps and involved in the development of single-screw submersible pumps. Since 1969, he has been work-ing for the Russian Scientific Research Institute of Drilling Techniques (VNIIBT). As a chief designer he was directly involved in design, testing and implementation of multi-stage positive displace-ment downhole motors (PDM). He authored 200 scientific publications, including 12 books and holds more than 250 Russian and foreign patents.
Dr. Fedor D. Baldenko, graduated from the Moscow Institute of Petrochemical and Gas Industry with specialty “Machinery and equipment of oil and gas fields” and is currently working in
this institution (now Russian State University of Oil and Gas). As an Associate Professor at the O&G machinery and equipment department he teaches several course and conducts research in the field of hydraulic machines, theory cycloidal gearing, optimization of screw working bodies, modeling of dynamic systems of drilling and oilfield machin-ery. He has 120 scientific publications, including 8 monographs and holds more than 50 patents for invention.
About the Authors
POSITIVE D
ISPLACEM
ENT M
OTO
RS