Operations

3.0

The following information provides general operating guidelines. Consult your Anadrill representative if local conditions warrant a deviation from standard procedures.
3.1 General specications

Tables 3-1 and 3-2 provide the general performance characteristics of PowerPak motors. These tables are based on the following assumptions: Flow rate The ow-rate columns list the minimum and maximum ow rates through the stator. The overall ow through a PowerPak motor can be increased by tting a nozzle in the rotor and bypassing some of the ow through the center of the motor. When a bypass nozzle is used the total ow rate must not exceed the limit in the bypass column. Rotating speed The listed minimum and maximum rotation speeds are for an unloaded motor (i.e., free-running rotary speeds for the power section over its ow-rate range). Hole diameter These standard minimum and maximum bit/hole sizes for the motors are the most commonly used. Other size bits may be used. Tool weight The listed weights are estimated values for assembled tools. Tool weight increases with the longer length XP power sections. Tool length The length of a PowerPak motor also varies with the power section. These tool lengths for assembled motors include the top sub/dump valve.

39

3.1

Operations

Maximum WOB The maximum weight on bit for a PowerPak motor is determined by its bearing section and is independent of the selected power section. These values are the maximum loads that can be placed on a bit during motor operation. Working overpull The working overpull is the maximum load that can be placed on a stuck motor (pushing or pulling) without crushing the axial bearing parts. The load must be kept less than this amount to allow rerunning the motor after it is unstuck. Absolute overpull Absolute overpull is the maximum load that can be placed on a stuck motor (pushing or pulling) before doing major damage to the motor and possibly leaving a sh in the hole. Bit pressure To maintain a ow of cooling/lubricating uid through the bearing section, the bit used with a motor must have a minimum amount of pressure drop. The bit nozzle must be selected on the basis of bit hydraulics calculations to provide the minimum pressure drop to the bit. The maximum bit pressure drop should not be exceeded for a relatively long time because the axial and radial bearings of the motor could be washed out.

40

Table 3-1. PowerPak motor specications (U.S. units)

Motor Lobes Stages Flow Rate (gpm) Min A213 XP A238 M XP A287 M XP M AD A350 M M A375 XF XC A475 M M XP M XP AD XF XC 5:6 5:6 5:6 5:6 5:6 7:8 7:8 4:5 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 7:8 7:8 7:8 6.0 2.5 5.2 3.3 7.0 3.2 2.0 5.0 3.0 2.0 2.0 3.0 3.5 6.0 2.2 3.8 2.0 2.0 2.0 20 20 20 20 20 30 175 30 30 130 130 Max 50 50 50 80 80 90 525 110 110 190 190 130 130 130 160 160 350 350 350 350 Flow Rate Rotating with Bypass Speed (gpm) (rpm) Min 180 160 160 120 115 75 130 98 48 340 340 225 105 105 56 56 100 105 105 Max 640 400 400 480 460 300 390 360 176 350 350 450 262 262 140 140 230 262 262 Hole Diameter (in.) Min 2.38 2.88 Max 2.88 3.50 80 80 120 140 195 140 165 300 310 225 225 630 620 920 640 900 800 670 670 10.5 8.45 12.52 10.02 14.62 10.02 8.34 15.12 15.12 10.14 10.50 18.87 16.62 22.54 16.62 22.54 20.12 12.66 13.32 3,200 5,000 15,000 22,000 19,000 28,000 Tool Weight (lbm) Tool Length (ft) Max Working WOB Overpull (lbf) (lbf) Absolute Overpull (lbf) Bit Pressure (psi) Min Max 250 1500 250 1500

3.38

4.75

6,500

24,000

39,500

250 1500

4.50

6.00

8,000

30,000

69,500

250 1500

4.50 4.50

4.75 4.75

22,000 22,000

45,000 45,000

80,000 80,000

250 1500 250 1500

Operations

100 200 100 250 100 250 100 250 100 250 875 2041 100 250 100 250

5.88

7.00

25,000

50,000

137,000

250 1500

5.88 5.88

6.13 6.13

25,000 25,000

50,000 50,000

137,000 137,000

250 1500 250 1500

41

3.1

3.1

42
Motor Lobes Stages Flow Rate (gpm) A675 M M XP M XP AD A800 M M XP M XP A962 M M XP M XP A1125 M

Table 3-1. PowerPak motor specications (U.S. units)

Flow Rate Rotating with Bypass Speed (gpm) (rpm) Min 700 700 700 700 1100 1100 1100 1100 1500 1500 1500 1500 1700 180 150 150 86 86 60 210 75 75 48 48 190 133 133 67 67 115 Max 465 300 300 165 165 118 420 225 225 145 145 380 266 266 12.25 26.00 134 134 170 17.50 26.00 9.88 14.75 8.38 9.88 Hole Diameter (in.) Min Max 1780 1750 2170 1750 2260 1930 3655 3650 4700 3500 4020 5180 5100 5750 5400 6130 6400 23.60 21.39 26.51 19.44 25.19 21.85 25.85 23.60 29.27 23.60 27.60 29.21 26.29 30.48 26.29 30.48 29.02 75,000 225,000 650,000 250 1500 75,000 225,000 650,000 250 1500 65,000 125,000 375,000 250 1500 50,000 75,000 255,000 250 1500 Tool Tool Weight Length (lbm) (ft) Max WOB (lbf) Working Overpull (lbf) Absolute Overpull (lbf) Bit Pressure (psi) Min Max

Operations

Min Max 1:2 4:5 4:5 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 1:2 3:4 3:4 5:6 5:6 3:4 4.0 4.8 7.0 3.0 5.0 2.0 4.0 3.6 5.3 3.0 4.0 5.0 4.5 6.0 3.0 4.0 3.6 200 300 300 300 300 500 600 600 600 600

1166 2333 300 300 300 300 300 400 600 900 900 900 900 800

600 1200 600 1200 600 1200 600 1200 1000 1500

ft min

Table 3-2. PowerPak motor specications (metric units)

Motor Lobes Stages Flow Rate (liter/min) Min A213 XP A238 M XP A287 M XP M AD A350 M M A375 XF XC A475 M M XP M XP AD A475 XF XC 5:6 5:6 5:6 5:6 5:6 7:8 7:8 4:5 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 7:8 7:8 7:8 6.0 2.5 5.2 3.3 7.0 3.2 2.0 5.0 3.0 2.0 2.0 3.0 3.5 6.0 2.2 3.8 2.0 2.0 2.0 76 76 76 76 76 114 5 114 114 493 493 379 379 379 379 379 25 379 379 Flow Rate with Bypass Rotating Speed (rpm) Max 640 400 400 480 460 300 395 360 176 350 350 450 262 262 140 140 230 262 262 Hole Diameter (mm) Min 60.5 73.2 Max 73.2 88.9 36.3 36.3 54.4 63.5 88.5 63.5 74.8 136.1 140.6 102 102 285.8 281.2 417.3 290.3 408.2 362.9 304 304 3.20 2.58 3.82 3.05 4.46 3.05 2.54 4.61 4.61 3.1 3.2 5.75 5.07 6.87 5.07 6.87 6.13 3.86 4.05 14,200 22,200 66,700 97,900 84,500 124,600 Tool Tool Weight Length (kg) (m) Max WOB (N) Working Overpull (N) Absolute Overpull (N) Bit Pressure (bar) Min Max

Max (liter/min) Min 189 189 189 303 303 341 15 416 416 719 719 757 946 946 946 946 58 946 946 492 492 492 606 606 1325 1325 1325 1325 180 160 160 120 115 75 130 98 48 340 340 225 105 105 56 56 100 105 105

17.2 103.4 17.2 103.4

85.9 120.7

28,900 106,800

175,700

17.2 103.4

114.3 152.4

35,600 133,400

309,200

17.2 103.4

114.3 120.7 114.3 120.7

98,000 200,000 98,000 200,000

356,000 356,000

17.2 103.4 17.2 103.4

Operations

149.4 177.8

111,200 222,400

609,400

17.2 103.4

149.4 155.8 149.4 155.8

111,200 222,400 111,200 222,400

609,400 609,400

17.2 103.4 17.2 103.4

43

3.1

1.0 3.1

44
Motor Lobes Stages Min A675 M M XP M XP AD A800 M M XP M XP A962 M M XP M XP A1125 M

Table 3-2. PowerPak motor specications (metric units)

Flow Flow Rate Rate with (liter/min) Bypass Max (liter/min) 1893 2271 2271 2271 2271 66 2271 3407 3407 3407 3407 3028 4542 4542 4542 4542 2650 2650 2650 2650 4164 4164 4164 4164 5678 5678 5678 5678 6435 Rotating Speed (rpm) Min 180 150 150 86 86 60 210 75 75 48 48 190 133 133 67 67 115 Max Hole Diameter (mm) Min Max 807.4 793.8 984.3 793.8 1025.1 875.4 1657.9 1655.6 2131.9 1587.6 1823.4 2349.6 2313.3 2608.2 2449.4 2780.5 2903.0 7.19 6.52 8.08 5.93 7.68 6.66 7.88 7.19 8.92 7.19 8.41 8.90 8.01 9.29 8.01 9.29 8.85 Tool Weight (kg) Tool Length (m) Max WOB (N) Working Overpull (N) Absolute Overpull (N) Bit Pressure (bar) Min Max

Introduction Operations

1:2 4:5 4:5 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 1:2 3:4 3:4 5:6 5:6 3:4

4.0 4.8 7.0 3.0 5.0 2.0 4.0 3.6 5.3 3.0 4.0 5.0 4.5 6.0 3.0 4.0 3.6

757 1136 1136 1136 1136 33 1136 1136 1136 1136 1136 1514 2271 2271 2271 2271

465 300 300 212.9 251.0 165 165 118 420 225 225 251.0 374.7 145 145 380 266 266 311.2 660.4 134 134 170 444.5 660.4

222,400

333,600 1,134,300 17.2 103.4

289,100

556,000 1,668,100 17.2 103.4

333,600 1,000,800 2,891,300 17.2 103.4

3785 5678

333,600 1,000,800 2,891,300 17.2 103.4

m3/min

Introduction Operations

1.0 3.2

3.2 Dogleg severity limitation

Dogleg severity (DLS) is a measurement of the curvature of the wellbore. Table 3-3 summarizes the maximum DLS in which PowerPak motors (excluding shortradius motors) can be safely run in the sliding mode and the maximum bend angle above which the motors cannot be rotated, except for orientation purposes.
Table 3-3. Dogleg severity limitations
Motor Max DLS with 3 Bend (/100 ft) 50 62 51 36 20 19 17 15 13 Max Max Bit Bit Offset with Offset with 1.5 Bend 3 Bend (in.) (in.) 0.76 0.97 1.02 1.15 1.52 2.21 2.53 2.92 3.08 1.51 1.93 2.03 2.30 3.03 4.42 5.07 5.83 6.15 Max Bend for Rotation () 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 Absolute Max Bend for XP Power Sections 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83 1.83

A213XP A238M A287M A350M A475M A675M A800M A962M A1125M

45

1.0 3.2

Operations

Table 3-4, which summarizes model results for two typical BHA congurations, serves as a eld guide only: BHA stabilized conguration predictions are calculated for a PowerPak motor with a single surfaceadjustable bent housing. The bearing housing is stabilized with a stabilizer on top of the motor. Both stabilizers have the same gauge: 18-in. undergauge for hole sizes up to 1214 in. and 14-in. undergauge for 1712-in. holes. The stabilizer can be 18- or 14-in. undergauge for holes larger than 1214 in. BHA slick conguration predictions are calculated for an unstabilized PowerPak motor with a single surfaceadjustable bent housing. A slick assembly is above the motor; there is no stabilizer. The behavior of a BHA is highly dependent on local conditions, particularly hole enlargement and formation hardness. It is important to note that the predictions are for equilibrium rates, which require some drilled distance to establish. The predicted values are for 100% sliding with gravity tool face at zero (no turn). Depending on the type of BHA, DLS may be greatly affected by the tool face position. The directional behavior of the BHA in rotary mode often depends on the position and gauge of the second stabilizer. Consult your Anadrill representative for DLS predictions adapted to your drilling conditions and program.

46

Table 3-4. Buildup rate predictions

Motor Hole Size (in.) 278 312 338 334 414 434 6 634 812 978 1058 1058 1214 1214 15 1712 15 1712 Fully Stabilized Bend Setting 0.78 NA NA NA NA NA NA 5.84 5.63 4.43 4.43 4.43 3.91 3.91 3.64 3.11 3.11 2.85 2.98 1.15 NA NA NA NA NA NA 1.5 NA NA NA NA NA NA 2.12 NA NA NA NA NA NA 18.29 18.08 13.58 13.57 13.57 12.01 12.01 10.86 10.86 10.33 9.93 9.44 3.0 NA NA NA NA NA NA 26.42 26.20 20.46 19.55 19.54 17.30 17.30 15.58 15.57 15.04 14.23 13.75 Bearing-Housing Stabilizer Only 0.78 NA NA NA NA NA NA 1.15 NA NA NA NA NA NA 1.5 NA NA NA NA NA NA 14.23 15.50 10.95 12.30 13.03 10.30 11.62 9.13 10.29 11.89 8.23 9.53 2.12 NA NA NA NA NA NA 19.98 21.25 15.17 16.52 17.26 14.04 15.36 12.47 13.62 15.22 11.27 12.58 3.0 NA NA NA NA NA NA 28.11 29.37 22.45 22.49 23.22 19.71 20.64 17.18 18.33 19.93 15.58 16.88 No Bearing-Housing Stabilizer (Slick) 0.78 2.64 0 7.79 2.01 0.39 0 NA NA NA NA NA NA NA NA NA NA NA NA 1.15 19.91 8.85 23.61 17.83 6.46 6.68 NA NA NA NA NA NA NA NA NA NA NA NA 1.5 27.94 16.88 30.97 25.19 11.11 11.47 NA NA NA NA NA NA NA NA NA NA NA NA 2.12 42.12 31.06 43.95 38.17 24.34 19.91 NA NA NA NA NA NA NA NA NA NA NA NA 3.0 62.15 51.09 62.30 56.52 36.28 31.85 NA NA NA NA NA NA NA

A238M A238M A287M A287M A350M A350M A475M A475M A675M A675M A675M A800M A800M A962M A962M A962M A1125M A1125M

9.28 12.54 9.07 12.33 6.96 6.96 6.69 6.15 6.15 5.64 5.64 5.11 5.15 4.67 9.35 9.35 9.35 8.27 8.27 7.53 7.53 7.00 6.88 6.40

7.54 10.98 8.80 12.24 6.02 8.55 7.38 9.90 8.11 10.64 5.94 7.26 8.18 9.50

Operations

5.25 7.24 6.40 8.40 8.01 10.00 4.68 5.99 6.50 7.81

NA NA NA NA NA

NA = not applicable Typical eld values are 25%40% less than these predicted optimum values. A fully stabilized motor has a 18-in. undergauge bearing-housing stabilizer and a 18-in. undergauge string stabilizer above the motor. For hole sizes 1712 in. and larger, the stabilizers are 14-in. undergauge.

47

1.0 3.2

1.0 3.3

Operations

3.3 Job preparation Motor selection

Hole diameter and ow rate usually dictate the tool diameter. After the diameter has been chosen, the other specications can be selected.
Dump valve

The probability of plugging the dump valve can be reduced by running a oat valve above the motor. If a oat valve is run and plugging is still a potential problem, a crossover sub can be run instead of a dump valve.
Rotor/stator conguration

The rotor/stator conguration affects the bit speed (rpm) at a given ow rate. The default standard is 4:5 (or 5:6 for PowerPak model A962M). Other congurations are also available. When OBM is used, the 4:5 ratio is preferred to 7:8 to minimize possible elastomer damage.
Rotor nozzle

A rotor nozzle should be specied if high ow rates are anticipated.

Bent housing setting

The degree of bend depends on the anticipated maximum DLS in the hole section to be drilled. In determining this setting, use Table 3-4 with caution because the calculations are based on idealized hole conditions for a limited number of BHA congurations. Local experience should be taken into consideration, even if it has been obtained using different steerable motors, because those actual gures provide a guideline for the predictions obtained from the planning software. The bend selection also depends on the diameter of any stabilizers. The bend should be set at a reasonable minimum to decrease possible stabilizer hanging. Rotating the string to hold angle rather than continuing
48

Operations

1.0 3.3

to build angle or to ease WOB transfer may lead to premature failure of the motor bearing or housing. It is good practice to anticipate lower buildup rates at low inclination or in soft sections where enlargement occurs.
Stabilizer gauge

If a slick assembly is run, the sleeve threaded-type bearing housing must be used with the protector made up. When stabilization is used, 18- or 14-in. undergauge size is recommended. The buildup rate is controlled by the position and gauge of the second stabilizer.
Connection

The top connection must be checked for compatibility with the BHA.
Bit selection

When selecting the bit to run with a PowerPak motor, the following factors should be taken into account: directional control expected run duration drilling program type of cutting structure required uid passage design expected rate of penetration estimated rotating time. A widely accepted guideline for directional applications is to select a bit that has a tooth structure at least one grade harder than what would be selected for rotary drilling in the same formation. It is advisable to specify gauge protection for the bit because directional drilling subjects the gauge row of teeth to lateral as well as axial loads. Fluid ow passages must have a total ow area that will not cause excessive backpressure to the PowerPak ow restrictor bearings.

49

1.0 3.3

Operations

Hydraulics calculations

Every PowerPak motor is designed to perform efficiently within a range of uid ow rates. The ow ranges are listed in the general specications on Tables 3-1 and 3-2 and the individual motor tables in Chapter 5, Performance Data. Variation above or below recommended volumes and the related pressure drop across the bit may lead to decreased motor efficiency and life. Anadrill uses a specialized hydraulics program to verify that the pressure drop at the bit remains within the specied range. The 250-psi minimum limit ensures proper cooling of the bearing section. The 1500-psi maximum limit prevents excessive erosion. Drilling system pressure drop should be calculated considering the stalling pressure of the motor (i.e., approximately 1.75 times the operating pressure). MWD pressure drop should be accounted for in the calculation. The total pressure drop should be compared with the rig capacity, using the motor stalling pressure and the highest mud weight planned for the run. Mud weight and plastic viscosity affect the total system pressure requirements. If the pressure required to deliver the recommended volume of uid to the PowerPak motor is greater than what the pumps can deliver, it may be necessary to reduce either the volume or pressure drop through both the tool and the bit. Pressure drop can be reduced by decreasing the number of drill collars and/or other elements that affect WOB, as well as by changing bit nozzle size or drilling uid characteristics. Anadrill offers software programs for computing the optimum hydraulics for a specic situation.
Surveying considerations

Anadrill uses a standard model to calculate the length of nonmagnetic material required above the motor.

50

Operations

1.0 3.4

3.4 Running PowerPak motors Lifting and makeup procedure

A lifting sub should always be used for lifting the tool into position for makeup, both on and off the rig oor. A directional driller must be present anytime a PowerPak motor is lifted. For applications calling for rig oorreplaceable, sleeve-type stabilizers, the stabilizer sleeve can be screwed onto the motor body while the motor is hanging in the elevators. After installation, the sleeve should be made up to the torque shown in Table 3-5 according to the outer diameter (OD) of the motor. If no stabilizer is run, a thread protection sleeve should be installed.
Table 3-5. Stabilizer sleeve makeup torque
Motor A475 A675 A800 A962 A1125 Torque 4,000 ft-lbf [5,400 Nm] 10,000 ft-lbf [13,600 Nm] 23,000 ft-lbf [31,200 Nm] 37,000 ft-lbf [50,200 Nm] 37,000 ft-lbf [50,200 Nm]

Note: Increase torque values by 25% if a thread-locking compound is used.

51

1.0 3.4

Operations

Surface check prior to running

All PowerPak motors should be systematically surfacechecked prior to running in the hole. The surface check consists of visual checks, a surface functional test and bent housing adjustment. The procedures are as follows.
Visual checks

1. Check the PowerPak motor for any transportation damage. Record the motors serial number. 2. Perform a surface functional test before anything is added to the tool. A dog collar safety clamp should be placed just below the top sub. If the surface functional test includes an MWD system and the motor has mud-lubricated bearings, install an Anadrill substitute bit on the bottom of the motor to provide the bit pressure drop required to prevent the bearings from running dry. 3. Before the bit is installed, check the bearing clearance or axial play of the motor by measuring the distance between the lower part of the bearing section and the top of the bit sub. Measure the distance twice, rst with the motor hanging free in the elevators, then repeated with the full weight of the motor sitting on the rotary table (Fig. 3-1). The difference between the two distances is the amount of axial bearing clearance. Record the two measurements and compare them with the gures shown in the documentation supplied with the motor. Repeat this check after the motor has been run to determine the amount of bearing wear that occurred during the run. The maximum allowable clearance for both the preinstallation check and after running is shown in Table 3-6.

52

Operations

1.0 3.4

Figure 3-1. Determining axial bearing clearance.

0 A 0 B

Clearance = A B

Table 3-6. Maximum allowable axial bearing clearance

Motor A213 A238 A287 A350 A475 A675 A800 A962 A1125 Clearance 0.12 in. [3 mm] 0.12 in. [3 mm] 0.16 in. [4 mm] 0.16 in. [4 mm] 0.20 in. [5 mm] 0.24 in. [6 mm] 0.24 in. [6 mm] 0.32 in. [8 mm] 0.32 in. [8 mm]

53

1.0 3.4

Operations

Functional test

1. Lift the PowerPak motor with the appropriate lifting sub, set it in the rotary slips, and secure it by placing a dog collar safety clamp just below the top sub. 2. Install a crossover sub, if necessary, between the PowerPak motor and the kelly/topdrive. Next, make up the kelly to the PowerPak motor, remove the safety clamp, and lift the motor from the slips. 3. Open the blowout preventer (BOP) rams, and lower the PowerPak motor below the rotary table. If a dump valve is used, ensure that the valve ports are below the bell nipple, yet still visible. Use the rig tongs to secure the motor and the kelly. 4. The pumps can now be turned on and the stroke speed slowly increased. If mud is used, it should squirt out of the ports on the dump valve until the volume is sufficient to force the piston down and close off the ports. When the ports close, pull up the motor with the pumps on until the drive shaft is visible. Record the ow rate when the dump valve closes if a bit is in place. 5. Check the area at the bottom of the bearing housing and the drive shaft to conrm mud ow from the radial bearing. This discharge is designed to lubricate and cool the bearing pack, and it should be about 4% to 10% of the total mud ow rate. Depending on the mud properties and whether the test is performed before making up the bit to the motor, mud ow may be insignicant or nonexistent as a result of insufficient backpressure across the motor. In this case, the duration of the test should be as short as possible to avoid damaging the bearing. If no bit or a dummy bit is used to provide bit pressure drop, the test should not exceed 1 min in duration. 6. Lower the motor back through the rotary table with the pumps still running. (If the pumps are turned off while the motor is above the table, the dump valve can open and squirt mud on the rig oor.)
54

Operations

1.0 3.4

7. With the dump valve below the rotary table, turn the pumps off. If the valve does not open, bleed off the mud from the standpipe. 8. If the functional test is performed before installing the stabilizer sleeve or drill bit, these should now be made up at the correct torque, according to Table 3-5. The bit can be screwed onto the drive shaft bit box and torqued to specications with a rig makeup tong.
Bent housing adjustment

Anadrill recommends hanging the motor in the elevator to make an adjustment in the bend. If slips are used, they are set on the offset housing, and the driller should slack off until the adjusting ring turns easily. Observe the following procedure for adjusting the bent housing angle (Fig. 3-2). 1. Place a breakout tong on the stator adapter and a makeup tong on the offset housing and break the connection. 2. Unscrew the connection with two full turns. The gap that appears above the adjusting ring allows lifting up the sleeve and turning it to the required setting. 3. Lift up the adjustment ring to disengage the alignment teeth. 4. Place a backup tong on the offset housing. While holding the adjusting ring in the upper position, turn it until just before the upper and lower machine slots are aligned (i.e., the required degree marks are opposite one another). Then, lower the adjusting ring so it gently rests on the top of the alignment teeth, and slowly resume turning until the adjusting ring falls in the required position. The adjusting ring should normally be rotated with chain tongs, although rig tongs may be necessary for large-diameter motors. Properly aligning the setting marks achieves the required bend. The tool face or scribe line for alignment with MWD equipment is through the middle of the two slots that have just been aligned.
55

1.0 3.4

Introduction Operations

5. The tongs can now be reversed and the joint tightened to the correct torque. Once the joint is torqued, according to Table 3-7, check the setting to make sure it did not jump a slot while being tightened.
Figure 3-2. Adjusting the bent housing angle.

Stator adaptor Adjustment ring

0 3 3 0 0 3

Offset housing

3 0

0 3

3 0

Alignment teeth

3
3 3 0 0 3 3 0

56

Operations

1.0 3.4

Table 3-7. Bent housing adjustment makeup torque

Motor A213 A238 A287 A350 A475 A675 A800 A962 A1125 Makeup Torque 650 ft-lbf [875 Nm] 890 ft-lbf [1,200 Nm] 1,650 ft-lbf [2,250 Nm] 3,500 ft-lbf [4,750 Nm] 10,000 ft-lbf [13,600 Nm] 25,000 ft-lbf [33,900 Nm] 35,000 ft-lbf [47,500 Nm] 60,000 ft-lbf [81,300 Nm] 85,000 ft-lbf [115,000 Nm]

Running in hole

Caution is urged when tripping assemblies with large bent housing angles. Special care should be exercised when running through the BOP and wellhead equipment, marine risers, stage cementing collars, casing packers, liner hangers, etc. When running a PowerPak motor in a deep or hightemperature well or in mud systems that may be contaminated with cement or steel cuttings (i.e., after milling a casing window), the trip should include stops to ll the drillpipe and circulate for a few minutes.
Drilling

When bottom is reached, the motor should be held a few feet off-bottom to circulate briey until the planned ow rate is reached. Motor speeds and circulation rates above or below the specied general ranges in Tables 3-1 and 3-2 should be avoided, as they may result in increased wear on motor components. The off-bottom standpipe pressure and pump strokes should be recorded. While lowering the assembly, drilling is indicated by an increase in standpipe

57

1.0 3.4

Operations

pressure corresponding directly to the differential pressure created across the rotor/stator as bit torque increases. Weight must be applied slowly at rst, with any pump pressure changes noted. The driller should proceed carefully while acquiring a feel for the formation and gently break in the bit until a pattern has been cut. Drilling with the PowerPak motor is controlled by the amount of WOB required and the differential pressure (i.e., the difference between drilling and off-bottom circulating pressure) developed by the motor section. The value of this differential pressure is a direct indication of bit torque. It increases as WOB is added and decreases as drill-off occurs. When the optimum drilling rate is reached, constant standpipe pressure should be maintained to give steady torque at the bit. Many drillers make small incremental adjustments to WOB to optimize the rate of penetration. However, the application of WOB must be carefully controlled so that the differential pressure does not exceed the recommended operating values or motor stalling may occur. When motor stalling occurs, the driller must immediately cut back or shut off the pumps to avoid damaging the stator and other tool components. The torque trapped in the drillstring must then be released slowly by using the rotary table brake or clutch to allow the kelly/rotary to turn to the left. Releasing the trapped torque slowly reduces the risk of downhole backoff. Drilling can then be resumed as described above. If a motor stalls frequently under normal drilling conditions, its operating pressure may have to be modied.

58

Operations

1.0 3.4

Paying careful attention to mud pressure variations provides early warning of many common downhole problems. See Table 3-8 in Troubleshooting for information to help identify and correct problems before they lead to costly trips. The rugged design of PowerPak motors makes it possible to exert high overpull in the event of a stuck bit.
Pulling out of hole and surface check after drilling

There are no special procedures required when pulling out of hole (POOH). If the rig is equipped with a top-drive system, the driller will probably backream out of any tight spots while carefully maintaining circulation and avoiding sidetracking if the drillstring is rerun through the backreamed section. PowerPak transmission rotational free play can be checked at the surface by holding the bit and checking the free play between the drive shaft and rotor. The axial bearing clearance should be measured and checked against the last measurement to determine bearing wear. Before the PowerPak motor is laid down, it should be ushed with water. When a hose is used, the body is held with a breakout tong, and the bit is rotated in the bit breaker. When clean water drips out of the lower radial bearing, the bit can be broken off. If the SAB housing was set to a high angle, the housing joint should be broken.

59

1.0 3.4

Introduction Operations

Environmental constraints

There is no Material Safety Data Sheet (MSDS) risk for the PowerPak system; no specic environmental protection procedures need be applied when operating the motors. However, any mud remaining in motors returning from jobs must be safely collected for later recycling or disposal. Anadrill bases are equipped with zero-discharge systems to handle the disposal of all drilling uids.
Troubleshooting

By paying careful attention to variations in mud-ow pressure, it is possible to detect many common downhole problems that may occur while drilling and take corrective action before a costly trip becomes necessary. Information to identify and correct problems is listed in Table 3-8.

60

Table 3-8. Troubleshooting

Observation ROP drops Pressure surges Secondary Observation Unchanged ow rate Torque increases Possible Explanation Motor stalling Remedial Action Stop rotation immediately Pull off-bottom; shut down pumps if pressure drop is not observed Resume drilling carefully Apply WOB gradually Same as above; pump stroke forced down by motor stalling Pull off-bottom; reciprocate string; eventually increase ow rate Proceed with care When stabilizer hanging occurs while sliding, drill a few feet in rotation Eventually POOH to reduce bend in SAB housing Proceed carefully to wash junk away and/or POOH Pull off-bottom Look for trends on charts; POOH Adapt parameters Recycle pumps with various ow rates; reciprocate string Look for trends on charts; POOH

ROP drops Constant pressure ROP decreases Pressure increases

Flow rate drops Normal WOB Torque decreases Normal WOB Torque increases

Motor stalling Bit balling Stabilizers hanging or reaming

ROP decreases Irregular pressure ROP decreases Pressure decreases

Normal WOB Irregular rotary torque Normal WOB Normal torque Normal WOB

Junk in hole Cone locking Washout or dump valve failure Formation change String ID obstructed Possible packoff in annulus Washout Mud losses Formation change

Introduction Operations

ROP normal Pressure surges ROP normal Pressure decreases

Normal WOB, torque Flow rate unchanged Normal WOB, torque Flow rate unchanged Abnormal mud return and pit levels

61
ROP increases

1.0 3.4

Follow lost circulation procedure Adapt parameters

3.5

Operations

3.5 Air drilling

PowerPak motors can be run on air or foam. Special long-stage power sections are available for these applications. However, the standard multilobe PowerPak motor has proved highly reliable when air or foam is used as the circulating medium. The design of long-stage power sections provides two key features when using air. Because the long stage length produces higher torque than the standard power section for the same pressure and volume of air pumped at surface, less surface pressure is required. The longstage power section also produces a bigger cavity between the rotor and stator, which reduces the motors speed and helps prevent runaway when pulling off bottom. Both the standard and long-stage power sections require adding some form of lubricant to the dry air. A minimum of 2% surfactant (soap) in the air stream is recommended. Increasing this amount enhances motor performance. The air volume requirements for a PowerPak motor vary depending on system pressure. In general, the maximum allowable volume of surface air (ft3/min) is equal to maximum flow rate standpipe pressure , 110 (3-1)

where the ow rate is in gpm and the standpipe pressure is in psi. As the surface pressure decreases, so does the maximum volume of air. Motor stalls when air is used do not produce the sudden increase in standpipe pressure that occurs with water- or oil-base mud. The compressibility of air and the volume of the drillpipe result in a gradual increase in air pressure when the motor stalls. This effect increases with measured depth and drillpipe size. The sudden

62

Operations

3.5

decrease in ROP is a better indicator of a stalled motor when drilling with air. A small nozzle should be run in the rotor when using PowerPak motors on air. This helps bleed off air pressure before and during connections, reducing the amount of runaway experienced by the motor.
3.6 Short-radius drilling

Short-radius curves are used in reentry and multilateral drilling where it is desirable to kick off below a problem formation, external casing shoe or internal completion component. A short-radius well requires less total drilling and minimizes the need for an isolation packer or liner by keeping both the curve and the lateral within the desired portion of the reservoir.
PowerPak XF motor

The PowerPak extra ex (XF) motor has articulations above and below a shortened power section and is used for drilling curves down to a 40-ft radius. High build rates are achieved by locating the three points of contact at the bearing section. The build mechanism consists of the bit, rotating stabilizer, bent housing and a pair of shimmable pads that act like an offset eld-adjustable stabilizer. A signicant innovation is the stabilizer geometry located in the bit drive sub (Fig. 3-3). As this second point of contact rotates, it smoothes out steps or ledges created by bit offset and allows easier sliding of the BHA. The stabilizers and pads (Fig. 3-4) are easily congured on the rig oor to achieve build rates as high as 145/100 ft. Above the bearing section, motor exibility is achieved with articulations above and below the power section (Fig. 3-5). These pressure-sealed ball-and-socket mechanisms act much like the universal joints on an automobile drivetrain, transmitting torque yet bending in any plane. This allows the system to rotate while drilling and also negotiate severe doglegs without regard
63

3.6

Operations

Figure 3-3. XF short-radius motor near-bit stabilizer and bit.

Figure 3-4. XF short-radius motor adjustable pads.

64

Operations

3.6

Figure 3-5. Articulation mechanism.

to orientation when tripping in and out of the hole. If greater drilling horsepower is required, the system has the capability to combine a second power section joined by another articulation. Both roller-cone and PDC bits can be used, depending on the formation. It is generally recommended that a roller-cone bit be used for drilling the curve to reduce reactive uctuations in motor torque and improve control of the toolface.
PowerPak XC motor

The PowerPak extra curve (XC) motor is capable of drilling curves down to a 65- to 70-ft radius. The three points of contact for the build are at the bit, the pad at the bend and the top end of the power section. Although the bit offset is much greater than that of the XF motor, the exibility of the components allows the XC motor to bend, compensating for the higher bit offset and allowing a safe trip in and out of the hole. The surfaceadjustable 04 bend mechanism is similar to that of conventional PowerPak motors and is easily congured on the rig oor. The ability to kick off and turn in difficult situations such as soft cement plugs or whipstock faces makes the XC motor popular in the eld.
65

1.0 3.7

Introduction Operations

3.7 Fishing

In the event that it becomes necessary to sh a PowerPak motor, an Anadrill representative should be consulted on the types and sizes of overshot or extension tools that should be used. Fishing for a PowerPak motor does not present any particular problem for a straight pickup job. If circulation is necessary, it is important to remember that reactive torque and vibration tend to unscrew the sh from the overshot. Tables 3-9 through 3-16 summarize the diagrammed shing dimensions for the various PowerPak motors.

66

Table 3-9. Fishing dimensions (U.S. units)

Reference A B C D E F G I J K L M N O P Q R S A B C D E F Description (in.) Dump valve/top sub OD Stator/stator adaptor OD Adjusting ring OD (kick pad) Offset housing OD Stabilizer body maximum OD Bearing housing/nut OD Bit box OD Drive shaft OD Dump valve/top sub length Stator adaptor length Adjusting ring length Offset housing length Bearing housing shing neck Bearing housing bottom neck Drive shaft visible length Bend to bit box length Stabilizer upset length Sleeve length Dump valve/top sub ID Stator/stator adaptor ID Adjusting ring ID Offset housing ID Bearing housing/nut ID Drive shaft ID A213 2.13 2.13 2.25 2.13 NA 2.13 2.25 1.18 4.56 7.44 2.40 11.88 6.84 NA 3.96 24.96 NA NA 0.75 1.50 1.56 1.09 1.33 0.50 A238 2.38 2.38 2.47 2.38 NA 2.38 2.38 1.58 5.91 9.96 2.28 12.60 7.44 NA 3.96 27.48 NA NA 0.75 1.62 1.87 1.31 1.50 0.50 A287 3.06 1.88 2.99 2.90 NA 2.87 3.06 1.88 9.62 14.88 3.00 16.56 9.48 NA 4.92 34.92 NA NA 1.38 1.93 2.20 1.88 1.79 0.75 A350 3.75 3.50 3.59 3.50 NA 3.50 3.75 2.28 9.00 12.48 3.72 19.56 10.56 NA 6.00 40.08 NA NA 1.75 2.25 2.70 2.13 2.15 0.82 A475 4.75 4.75 5.03 4.75 5.38 5.38 4.75 3.00 17.50 14.28 5.40 22.08 3.60 11.04 5.64 48.96 0.48 12.00 2.00 3.38 3.70 2.88 3.06 1.13 A675 6.75 6.75 7.00 6.75 7.50 6.75 6.70 4.00 16.00 16.80 6.12 30.48 8.76 11.40 8.28 72.36 1.56 14.00 3.00 5.00 5.14 4.00 4.44 1.50 A800 8.00 8.25 8.38 8.25 9.25 8.25 8.18 5.25 16.50 19.68 6.36 32.6 13.56 11.04 10.08 84.72 2.76 16.00 3.00 5.88 6.18 5.00 5.13 2.00 A962 9.63 9.63 9.82 9.63 11.00 8.25 14.62 6.25 18.50 22.56 6.36 38.40 10.56 14.52 10.44 93.36 3.12 18.00 3.00 7.00 7.31 6.00 6.19 2.38 A1125 11.25 11.25 11.63 11.25 13.38 11.00 9.63 6.25 15.72 27.48 8.52 43.80 14.28 14.52 10.44 99.48 NA 18.00 4.50 8.50 8.53 7.75 6.19 2.38

Operations

67

3.7

NA = not applicable

Table 3-10. Rotor dimensions (U.S. units)

Motor Lobes Stages Reference T Rotor Contour Length (in.) 79.00 47.50 96.40 51.00 106.00 51.00 65.00 107.00 107.00 38.44 129.00 101.00 173.00 101.00 172.00 143.00 47.50 160.38 134.34 195.50 111.34 181.00 140.00 172.50 145.00 213.00 145.07 188.20 194.00 158.60 210.60 158.60 211.00 182.60 Reference H Standard Rotor Major Diameter (in.) 1.236 1.325 1.325 1.658 1.658 1.815 1.805 1.940 1.964 2.505 2.434 2.912 2.912 2.936 2.945 3.024 3.067 3.820 4.220 4.220 4.520 4.520 4.500 4.360 4.940 4.940 5.186 5.186 5.456 5.978 5.978 6.236 6.236 6.968

A213 A238 A287

XP M XP M XP M AD M M XF M M XP M XP AD XF M M XP M XP AD M M XP M XP M M XP M XP

5:6 5:6 5:6 5:6 5:6 7:8 7:8 4:5 7:8 7:8 1:2 4:5 4:5 7:8 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 1:2 3:4 3:4 5:6 5:6 3:4

6.0 2.5 5.2 3.3 7.0 3.2 2.0 5.0 3.0 2.0 3.0 3.5 6.0 2.2 3.8 2.0 2.0 4.0 4.8 7.0 3.0 5.0 2.0 4.0 3.6 5.3 3.0 4.0 5.0 4.5 6.0 3.0 4.0 3.6

A350 A375 A475

A675

A800

A962

A1125 M

Figure 3-6. PowerPak motor shing diagram.

Pipe connections

T H

B C D R

K L M N

E Q S F I G P O

Figure 3-7. PowerPak motor shing diagram.

Pipe connections

T H

B C D R

K L M N

E Q S F I G P O

Table 3-11. Fishing dimensions (metric units)

Reference A B C D E F G I J K L M N O P Q R S A B C D E F Description (cm) Dump valve/top sub OD Stator/stator adaptor OD Adjusting ring OD (kick pad) Offset housing OD Stabilizer body maximum OD Bearing housing/nut OD Bit box OD Drive shaft OD Dump valve/top sub length Stator adaptor length Adjusting ring length Offset housing length Bearing housing shing neck Bearing housing bottom neck Drive shaft visible length Bend to bit box length Stabilizer upset length Sleeve length Dump valve/top sub ID Stator/stator adaptor ID Adjusting ring ID Offset housing ID Bearing housing/nut ID Drive shaft ID A213 5.41 5.41 5.72 5.41 NA 5.41 5.72 3.00 11.58 18.90 6.10 30.18 17.37 NA 10.06 63.40 NA NA 1.91 3.81 3.96 2.77 3.38 1.27 A238 6.05 6.05 6.27 6.05 NA 6.05 6.05 4.01 15.01 25.30 5.79 32.00 18.90 NA 10.06 69.80 NA NA 1.91 4.11 4.75 3.33 3.81 1.27 A287 7.77 4.78 7.59 7.37 NA 7.29 7.77 4.78 24.43 37.80 7.62 42.06 24.08 NA 12.50 88.70 NA NA 3.51 4.90 5.59 4.78 4.55 1.91 A350 9.53 8.89 9.12 8.89 NA 8.89 9.53 5.79 22.86 31.70 9.45 49.68 26.82 NA 15.24 101.80 NA NA 4.45 5.72 6.86 5.41 5.46 2.08 A475 12.07 12..07 12.78 12.07 13.67 13.67 12.07 7.62 44.54 36.27 13.72 56.08 9.14 28.04 14.33 124.36 1.22 30.48 5.08 8.59 9.40 7.32 7.77 2.87 A675 17.15 17.15 17.78 17.15 19.07 17.15 17.02 10.16 40.64 42.67 15.54 77.42 22.25 28.96 21.03 183.79 3.96 35.56 7.62 12.70 13.06 10.16 11.28 3.81 A800 20.32 20.96 21.29 20.96 23.50 20.96 20.78 13.34 41.91 49.99 16.15 82.91 34.44 28.96 25.60 215.19 7.01 40.64 7.62 14.94 15.70 12.70 13.03 5.08 A962 24.46 24.46 24.94 24.46 27.94 20.96 37.13 15.88 47.00 57.30 16.15 97.54 26.82 36.88 26.52 237.13 7.92 45.72 7.62 17.78 18.57 15.24 15.72 6.05 A1125 28.58 28.58 29.54 28.58 33.99 27.94 24.46 15.88 39.93 69.80 21.64 111.25 36.27 36.88 26.52 252.68 NA 45.72 11.43 21.59 21.67 19.69 15.72 6.05

NA = not applicable

3.7

Operations Introduction

Table 3-12. Rotor dimensions (metric units)

Motor Lobes Stages Reference T Reference H Rotor Contour Standard Rotor Length (cm) Major Diameter (cm) 200.66 120.65 244.86 129.54 269.24 129.54 165.10 271.78 271.78 97.64 327.66 256.54 439.42 256.54 436.88 363.22 120.65 407.37 341.22 496.57 282.80 459.74 355.60 438.15 368.30 541.02 368.48 478.03 492.76 402.84 534.92 402.84 535.94 463.80 3.139 3.366 3.366 4.211 4.211 4.610 4.610 4.928 4.989 6.636 6.182 7.396 7.396 7.457 7.480 7.681 7.790 9.703 10.719 10.719 11.481 11.481 11.430 11.074 12.548 12.548 13.172 13.172 13.858 15.184 15.184 15.839 15.839 17.699

A213 A238 A287

XP M XP M XP M AD M M XF M M XP M XP AD XF M M XP M XP AD M M XP M XP M M XP M XP

5:6 5:6 5:6 5:6 5:6 7:8 7:8 4:5 7:8 7:8 1:2 4:5 4:5 7:8 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 7:8 1:2 4:5 4:5 7:8 7:8 1:2 3:4 3:4 5:6 5:6 3:4

6.0 2.5 5.2 3.3 7.0 3.2 2.0 5.0 3.0 2.0 3.0 3.5 6.0 2.2 3.8 2.0 2.0 4.0 4.8 7.0 3.0 5.0 2.0 4.0 3.6 5.3 3.0 4.0 5.0 4.5 6.0 3.0 4.0 3.6

A350 A375 A475

A675

A800

A962

A1125 M

68

Introduction Operations

3.7

Table 3-13. PowerPak XF shing dimensions (U.S. units)

Reference Length A B C D E F G Overall length Orientation sub to stator Orientation sub to articulated housing Orientation sub to oat sub Stator Articulated housing to shoulder Shoulder to near-bit stabilizer OD dimension H I J K L M N O P Orientation sub Wear band Stator at connection Stator at midbody Top pad assembly Offset housing Lower bearing Drive shaft Near-bit stabilizer ID dimension Q R S T

Description (in.)

A375XF

A475XF

121.68 35.40 30.00 17.04 52.68 28.20 5.88

151.20 43.20 34.80 20.40 64.80 28.44 6.00

3.50 3.87 3.75 3.60 3.75 4.06 2.30

5.00 5.25 4.75 4.75 5.38 4.75 3.06

Depends on hole size

Depends on hole size

Orientation sub Pin Float Stator

2.25 2.06 2.44 3.13

2.75 1.91 2.44 3.75

Depends on power section

69

Table 3-14. PowerPak XF shing dimensions (metric units)

Reference Length A B C D E F G Overall length Orientation sub to stator Orientation sub to articulated housing Orientation sub to oat sub Stator Articulated housing to shoulder Shoulder to near-bit stabilizer OD dimension H I J K L M N O P Orientation sub Wear band Stator at connection Stator at midbody Top pad assembly Offset housing Lower bearing Drive shaft Near-bit stabilizer ID dimension Q R S T

Description (cm)

A375XF

A475XF

310.00 90.19 76.00 43.00 133.00 72.00 15.00

380.00 110.00 90.00 50.00 160.00 70.00 17.00

8.90 9.80 9.50 9.10 9.50 10.30 5.80

12.80 13.30 12.10 12.10 13.70 12.10 7.80

Depends on hole size

Depends on hole size

Orientation sub Pin Float Stator

5.70 5.20 6.20 8.00

7.00 4.80 6.20 9.50

Depends on power section

Figure 3-8. PowerPak XF motor shing diagram.

Pipe connections

H D C B Q R S I I J T

E A

J I L M F

N O P

Figure 3-9. PowerPak XC motor shing diagram.

Pipe connections

J D C B W X Y K K L Z

E A

N O F P Q G J R S T U V

Table 3-15. PowerPak XC shing dimensions (U.S. units)

Reference Length A B C D E F G H I Overall length Orientation sub to stator Orientation sub to articulated housing Orientation sub to oat sub Stator Adjusting ring pad Offset housing Bearing housing Drive sub to bearing OD dimension J K L M N O P Q R S T U V Orientation sub Wear band Stator at connection Stator at midbody Stator at connection Stator adaptor Adjusting ring pad Ofset housing connection Offset housing Bearing housing Bearing shoulder Drive shaft Drive sub ID dimension W X Y Z

Description (in.)

A375XC

A475XC

126.00 35.40 30.00 17.04 52.68 3.60 23.28 8.28 6.12

159.12 43.20 34.80 20.40 64.80 6.00 18.00 11.64 6.00

3.50 3.87 3.75 3.60 3.75 3.75 3.75 3.63 3.75 4.06 2.30 4.06

5.00 5.25 4.75 4.75 4.75 4.75 4.75 4.56 4.75 4.75 3.06 4.75

Depends on hole size

Orientation sub Pin Float Stator

2.25 2.06 2.44 3.13

2.75 1.91 2.44 3.75

Depends on power section

3.7

Operations

Table 3-16. PowerPak XC shing dimensions (metric units)

Reference Length A B C D E F G H I Overall length Orientation sub to stator Orientation sub to articulated housing Orientation sub to oat sub Stator Adjusting ring pad Offset housing Bearing housing Drive sub to bearing OD dimension J K L M N O P Q R S T U V Orientation sub Wear band Stator at connection Stator at midbody Stator at connection Stator adaptor Adjusting ring pad Ofset housing connection Offset housing Bearing housing Bearing shoulder Drive shaft Drive sub ID dimension W X Y Z

Description (cm)

A375XC

A475XC

320.00 90.19 76.00 43.00 133.00 9.14 59.00 21.00 16.00

400.00 110.00 90.00 50.00 160.00 15.00 46.00 30.00 15.00

8.90 9.80 9.50 9.10 9.50 9.50 9.50 9.20 9.50 10.30 5.80 10.30

12.80 13.30 12.10 12.10 12.10 12.10 12.10 11.60 12.10 12.10 7.80 12.10

Depends on hole size

Orientation sub Pin Float Stator

5.70 5.20 6.20 8.00

7.00 4.80 6.20 9.50

Depends on power section

70