SPE

Society of PetroIeun Engineers of AIME

SPE 11842

The Application of Mud Motors for Surface Hole Drilling

by Gary Foret and Jim Kerr, Dyna-Drill
Members SPE-AIME

Copyright 1983 Society of Petroleum Engineers

This paper was presented at the Rocky Mountain Regional Meeting held in Salt Lake City, UT, May 23-25,1983. The material is subject to correction by
the author. Permission to copy is restricted to an abstract of not more than 300 words. Write SPE, 6200 North Central Expressway, Drawer 64706, Dallas,
Texas 75206 USA. Telex 730989 SPEDAl.

ABSTRACT:
Mud motor drilling with mill-tooth or insert-
type bits in the surface upper hole can often result
in increased rates of penetration and less hole
deviation -- two factors that can often mean cost
savings to the operator.
Most people associate mud motors with two differen
types of drilling -- controlled directional and long-
interval straight-hole drilling. Using mud motors is
now the norm rather than the exception in drilling a
directional section, and in the last five years, mud
motors, when used with diamond or PCD type bit$, have
gained wide acceptance in many long-interval drilling
applications. The reasons for the increased use of mud
motors in straight-hole drilling are higher rates of
penetration (ROP) than traditional methods, less hole
deviation, and much improved tool performance, result-
ing in savings for the operator.
Recent case histories in the Rocky Mountain Region
show that these same reasons apply to a section of the
hole not often associated with mud motors, but never-
theless where mud motors are now providing a viable
alternative to rotary drilling -- the surface or upper
hole. Drilling a large (12~", l7J;;" , 26") surface hole
with a mud motor and mill-tooth or insert-type bits
can, in many cases, 1) increase ROP, and 2) maintain a
straighter upper hole which helps minimize subsequent
problems as the hole depth increases. In some cases,
rates of penetration have been improved even when
drilling single pass large diameter hole, thus also
eliminating the need for hole opening operations, and
adding to cost savings.
INTRODUCTION
A concept not often considered but rapidly ga1n1ng
attention in the drilling industry is surface hole
drilling with mud motors. With today's cost-conscious
drilling requirements, methods of saving time and money
are being incorporated into existing programs whenever
possible. Surface hole of l2~" to 26" diameter, in
many cases, can require excessive time to complete.
Deviation control, hole opening operations, and in some
cases, fishing operations are commonly encountered.
These are but a few reasons for seeking more cost-
effective methods of drilling surface hole.
277
Drilling with motors can increase the rate of
penetration over rotary methods, maintain a vertical
wellbore, and greatly reduce the risk of drill collar
twist-offs. In some areas, in selected formations, a
mill-tooth or insert-type bit in combination with a
mud motor can eliminate the need for hole opening.
As with any drilling program, drilling with mud
motors requires a well-planned system. The success or
failure of any particular job depends on how well the
system functions. The primary function of straight-
hole drilling with motors is to out perform rotary
drilling, and if the system is properly designed, moto
drilling can be a very cost-effective tool.
PLANNING SURFACE HOLE APPLICATIONS WITH MOTORS
A well-planned motor program consists of system-
planning. Before a job has actually begun, several
factors must be considered in order to achieve success
ful performance; these include:
1) Available Rig Equipment
2) Bit Selection
3) Hydraulic System Analysis
4) Motor/Bit Performance for Given Operating
Parameters
1) RIG EQUIPMENT
When planning ~or a mud motor application, it is
very important to ensure that the rig is capable of
supplying adequate hydraulic energy for optimum motor
performance. Within the hole size range discussed in
this paper, l2~" to 26", fluid volume requirements for
the 9-5/8" tool are 500-800 gpm; fluid volume require-
ments for the 12" tool are 800-1200 gpm (refer to
Tables 1 - 2. During planning, the volumetric and
mechanical efficiency of the pumps must be considered
to ensure that the pumps are actually supplying the
correct recommended volumes.
References and illustrations at end of paper.
2 THE APPLICATION OF MUD MOTORS FOR SURFACE HOLE DRILLING
Accurately calibrated standpipe pressure gauges are
desirable for determining the total system pressure
losses. This is extremely important since accurate
system pressure loss monitoring is essential in measur-
ing optimum motor performance values.
2) BIT SELECTION
Drilling in the Rockies is both demanding and
challenging. In order to obtain the most from any
drilling program, proper bit selection is essential
when planning to drill surface hole with motors. In
many cases, bit selection for motor drilling is not the
same as bit selection for conventional rotary drilling.
There are several factors to be considered.
An analysis of the formations to be drilled must
be conducted to determine the optimum bit for the job.
Bit life is also a factor to consider when planning a
motor run. Depending on fluid volume, bit speeds from
125-188 rpm are obtained with 12" motors, while speeds
of 200-420 rpm are obtained with 9-5/8" motors. (Refer
to Tables 1 - 2). Since higher rates of penetrat·ion
are generally achieved in motor drilling, bit life must
be weighed against possible total footage to determine
possible economic advantages. Proper bit hydraulic
horsepower and adequate fluid volume are also essential
in providing maximum bit performance and cuttings
removal.
3) HYDRAULIC SYSTEM ANALYSIS
A complete hydraulics program must be planned and
designed to assure optimum motor and bit performance.
Most available rig drilling fluid systems are adequate
and require very little, if any, modifications to en-
sure success when drilling with motors. Optimum motor
performance is achieved within a range of fluid volume,
pressure, and weight on bit. Proper hydraulics plan-
ning will ensure that the hydraulic requirements of
the motor/bit combination are kept within the recom-
mended operating parameters. (Refer to Tables 1 - 2).
There are other significant differences when
drilling with mud motors versus conventional rotary
drilling. Bit selection and weight on bit will vary
from conventional rotary drilling methods. Hydraulic
thrust and indicated weight balance parameters are
established. When conditions permit, bit weight and
bearing balance guidelines are utilized to maximize
drilling time with motors. (See Fig. 1).
To use the chart, the pressure differential
across the nozzles of the roller bit must be known.
This bit pressure differential is then matched on the
chart to a diagonal line of the same value. Where the
diagonal line intersects the charts horizontal line
(indicated weight), is the recommended bit weight that
will provide optimum balance between the hydraulic
thrust and weight on bit. At this point, the thrust
bearings in the tool are subject to the least load,
resulting in maximum bearing life.
Proper hydraulics is the fundamental control
parameter of a successful mud motor drilling operation.
Based on rig site operating conditions furnished by the
operator, a hydraulic analysis should be prepared
prior to a motor run to establish the estimated operat-
ing parameters for the motor. Some factors to be
considered are: rig pump capability, surface equipment,
system pressure losses, mud data, and hole-cleaning
needs.
278
SPE 11842
The hydraulic analysis shown in Fig. 2 gives an esti-
mate of the total system pressure losses at 600' or
beginning depth, along with estimated on-bottom and
off-bottom pressures at 850 & 900 gpm. The off-bottom
pressure plus the maximum recommended motor differen-
tial pressures created when the weight is applied to
the bit (motor loaded), equals the total maximum
recommended on-bottom pressure. As the bit is lowered
to bottom and drilling begins, the torque demand on
the motor increases and the pressure differential
across the motor increases proportionally. Depending
on individual hole conditions and resulting torque
demand on the motor, the pressure differential across
the motor may be less than the recommended calculated
values, but should never be allowed to exceed the
maximum.
Fig. 2 also shows the hydraulic analysis for
operation at 2000'. In addition to a computer-
assisted hydraulics program a mud motor drilling pro-
posal is prepared. Well geometry, bottom hole drilling
assembly and operating parameters are all part of a
complete motor drilling proposal.
For a specific project, a cost proposal is pre-
pared to determine economic feasibility. This will
reflect the breakeven rate of penetration required to
be cost-effective. The standard formula used to
determine total cost-per-foot of hole drilled with
rotary methods is:
COST/FOOT FORMULA-ROTARY
(Drilling + Trip) x (Rig + Support Cost) + (Bit Cost)
Footage Drilled
When drilling with motors, additional costs are .in-
curred. The additional motor charges are added to the
rotary cost/foot formula to determine projected cost-
per-foot.
COST/FOOT FORMULA-MOTORS
(Drilling + Trip) x (Rig + Support Cost) + (Bit Cost)
+ (Total Motor Cost)
Footage Drilled
When considering the cost-effectiveness of a project,
a breakeven rate of penetration is calculated to deter
mine the rate of penetration needed to compete with
rotary drilling.
BREAKEVEN FORMULA
(C/F Rotary) x (Ftg. Drld.) - (Bit Cost) - (Rig +
Support Cost) x (Trip + Service Man Charge)
(Rig + Support Cost + Motor Cost)
After completion of the project, actual results can be
used to determine real cost-per-foot. There are
several non-quantifiable advantages of downhole motor
drilling which should be considered. Reduced casing
and drillstring wear and improved deviation control at
desired penetration rates cannot be calculated in
projected cost savings calculations. Nonetheless,
these are important and viable advantages of downhole
motor drilling.
SPE 11842 G. Foret/J. Kerr 3

SURFACE HOLE MOTOR DRILLING II. Location: UINTA COUNTY, WYOMING

Hole Size: l7~"
Drilling surface hole with large motors, in most Motor Size: 12" DELTA 500
cases, will provide improved deviation control and Formation: TERTIARY CONGLOMERATE
frequently increase the rate of penetration two or Mud Wt.: 8.9lbs./gal.
three times over conventional rotary methods. The 12" Depth: 2552' - 3441'
mud motor can operate effectively with practically all Footage: 889'
types of drilling fluids which range from light to Hours Drild: 53.0 hrs.
very heavy drilling muds, including oil-base, salt ROP: l6.8'/hr. (Rotary--ll.3'/hr.)
water, oil emulsion, clay-base, and high viscosity Bit: HTC-X22; Dull bit grade, 4-5-1/4
muds. However, when drilling l7~" to 26" diameter WOB: 28,.000 lbs.
holes, adequate cuttings removal must be considered.
Mud characteristics can be modified to ensure proper The objectbve here was to slowly dEop angle
cuttings removal for faster rates of penetration. In from 2-1/2 to not more than 1-1/2. The rate
most cases, funnel viscosities of 45-70 have shown to of penetration was increased significantly
provide proper cuttings removal. over rotary methods, and hole angle at the end
of the run was 10. In this particular case,
Maintaining a vertical wellbore in surface hole a 90' pendulum hook up was used to accomplish
sets the pattern for minimizing deviation problems in the objective of dropping the hole angle.
deeper sections. Proper stabilization is often a key
factor. In conjunction with 12" and 9-5/8" motors and III. Location: GARFIELD COUNTY, COLORADO
roller bits, a conventional pendulum is suggested with Hole Size: 14-3/4"
the first roller reamer at 60' or 90' from the bit. Motor Size: 905/8" DELTA 500
In the case of drilling surface boulders, a slick Formation: SURFACE/BOULDERS
bottom-hole assembly is recommended. These recommen- Mud Wt.: 8.3 lbs. / gal.
dations will apply in the majority of applications, Depth: 81' - 605'
however, in certain situations other stabilization Footage: 524'
techniques may be required. It is suggested that a Hours Drld: 47 hrs.
downhole motor representative be contacted before ROP: ll.l'/hr. (Rotary-2.0'/hr.)
deciding stabilization. Bit: SEC-M4NJ
WOB: 10,000 - 15,000 lbs.
After all facets of the project have been con-
sidered, it is then the responsiblity of the Field As a result of extremely low ROP
Service Representative to monitor and maintain the when rotary drilling, a 9-5/8"
system parameters to ensure maximum motor and bit life DELTA 500 was used to increase
Included are a few example case histories of properly the rate of penetration and main-
planned and executed mud motor drilling projects. tain aovertical angle of not more
than 1. The results were an
CASE HISTORIES overall rate of penetration of
ll.l'/hr. and final survey at
0
With today's varied and fluctuating rig costs, 605' was 1/4 This section was
economic feasibility must be calculated on a case-by- drilled with two bits. The first
case basis. The following case histories are run was 309' drilled in 31.5 hrs.
representative of surface hole drilling with motors The second run was 215' drilled
in the Rocky Mountain Region during the past two in 15.5 hrs. Dull bit grading
years. was 4-2-1/8 and 2-4-IN respect-
ively. Cost savings to the
I. Location: SUMMIT COUNTY, UTAH operator were $78.92 per foot of
Hole Size: l7~" hole drilled.
Motor Size: 12" DELTA 500
Formation: TERTIARY CONGLOMERATE IV. Location: SUMMIT COUNTY, UTAH
Mud Wt: 8.8 lbs/gal Hole Size: 26"
Depth: 1344' - 2356' Motor Size: 12" DELTA 500
Footage: 1012' Formation: BEAR RIVER, KELVIN
Hrs Drld: 25.5 hrs Mud Wt: 8.6 - 9.1 lbs./gal.
ROP 39.7'/hr (Rotary--17.8'/hr) Depth: 105' - 966'
Bit: HTC-X22; Dull bit grade, 6-5-1 Footage: 861'
WOB: 45,000 lbs Hours Drld: 91.5 hrs.
ROP: 9.4'/hr. (Rotary--2.9'/hr.)
The objective in this project was to increase Bit: STC-DSJ, REED Y-ll-J, HTC-OSCIG
rate of penetration and control deviation. WOB: 20,000 - 30,000
The penetration rate compared to rotary was
more than double on this motor run. Cuttings The objective in this case was tc
removal was a major concern due to the high drill the surface hole with 26"
rate of penetration. With good system hy- bit and eliminate the hole open-
draulics and cuttings removal the job was a ing procedures. This was one
completg success. The final survey at 2356' particular case where the forma-
was 3/4 tion changed almost immediately
from what was expected.

279
 4 THE APPLICATION OF MUD MOTORS FOR SURFACE HOLE DRILLING
It was originally planned that
the Frontier Formation would be
present throughout the entire
section. However, due to an up-
lift in the formation, the entire
section drilled was in the Bear
River and Kelvin Formations.
Overall, the rates of penetration
exceeded rotary drilling. The
interval was drilled with seven
bits; these runs included: 17,
22.5, 17, 13, 9.5, 6, 6.5 hours
with ROPs of 11.4, 12.4, 9.8, 7.0
8.1, 5.2, 3.3 ft./hr. respect-
ively. The objective was
accomplished and hole opening
procedures were not necessary.
V. Location: UINTA COUNTY, WYOMING
Hole Size: 12-1/4"
Motor Size: 9-5/8" DELTA 500
Formation: GANNETT
Mud Wt: 8.7lbs./gal.
Depth: 2953' - 3473'
Footage: 520'
Hours Drld: 48 hrs.
ROP: 10.8'/hr. (Rotary--5.6'/hr.)
Bit: STC-F2
WOB: 18,000 - 25,000 lbs.
Deviation control and increased
rate of penetration was the main
objective in this case. Rotary
drilling had slowed 5.6'/hr o'
and hole angle was at 2-1/4 •
The downhole motor was used to
increase the ROP and drop angle.
The job was successfully com-
pleted, and both objectives were
accomplished. The final survey
showed l~o of angle. The inter-
val was drilled in two runs of
165' and 355' with drilling rates
of 8.6' and l2.2'/hr. respect-
ively.
In the above examples, the non-quantifiable benefits,
such as reduced casing and drillstring wear and im-
SPE 11842
proved deviation control, were significant factors in
considering overall success.
CONCLUSION
Surface hole drilling with motors has become a
viable alternative to rotary drilling. To ensure
continued success, advanced system planning must be
incorporated into drilling programs well in advance to
actual spud dates. Good lines of communication between
the oil companies and motor supplier are essential.
DYNA-DRILL offers qualified and experienced technical
:assistance in planning and executing mud motor drill-
ing programs. Each region has a Field Engineering
Coordinator who is experienced in determining the
proper operating guidelines to provide optimum motor
performance. With a well-planned system and the aid of
computer-assisted hydraulics program, optimum perfor-
mance can be assured. Once the initial drilling pro-
posal is accepted and drilling has begun, it is
extremely important that modifications in drilling
conditions be noted, so proper adjustments can be
incorporated into the system.
The advantages and results of using a downhole motor
in surface drilling can be very impressive, and through
continued development of this drilling technique,
better performance and increased cost savings can be
recognized.
NOMENCLATURE
SE = Surface Equipment
DP = Drill Pipe
DC = Drill Collar
RMR3 = 3pt. Roller Reamer
MTR = Mud Motor
MTR/BRG = Mud Motor Bearings
OH/MTR = Open Hole / Mud Motor
OH/DC = Open Hole / Drill Collar
OH/RMR3 = Open Hole / Roller Reamer
OH/DP = Open Hole / Drill Pipe
CSG/DP = Casing/Drill Pipe
GPM = Gallons per Minute
P-Drop = Pressure Drop
Vel = Velocity
BTM = Bottom
Ann Vel = Annular Velocity

TABLE 1:

TOOL PERFORMANCE VALUES FOR VARIOUS OPERATING RANGES

9-5/8" Standard Tool

Volume Bit Speed Motor Diff. Press. Torque Power

GPM RPM Psi Ft/Lbs HP

500 200 360 1775 67.6

600 275 360 1775 93.0
700 350 360 1775 118.3
800 420 360 1775 142.0

280
 TABLE 2:

TOOL PERFORMANCE VALUES FOR VARIOUS OPERATING RANGES

12" DELTA 500

Volume Bit Speed Motor Diff. Press. Torque Power

GPM RPM Psi Ft/Lbs HP

800 125 360 5666 134.8

900 140 360 5666 151.0
1000 155 360 5666 167.2
1100 173 360 5666 186.6
1200 188 360 5666 202.8

4~--~--~~~~~~--~--~~~~~~--~--~--------M~A-X-IM~U~M~R=EC=O~M~M~EN7.D~E~D~O~F~F~-B~O~T~TO~M~B~EA~R~IN~G~LO~A~D~

200 PSI } RECOMMENDED BIT PRESSURE

3
DIFFERENTIAL: 200-1000 PSI
1000 PSI
2

1500 PSI

6
MAXIMUM RECOMMENDED ON-BOTTOM BEARING LOAD

Fig. 1-Hydraulic thrust and indicated weight balance_

DEPTH: 600 HUD WT: 9.00

FLOW RATE: 850 GPM --------900 GPH ------------

LENGTH BORE BORE VEL P-DROP ACCUM'D BORE VEL P-DROP ACCUM'D
P-DROP P-DROP
SE 73.51 73.51 81. 76 81. 76
279 DP 1139.43 37.45 110.96 1206.45 41. 65 123.41
250 DC 2314.83 187.86 298.82 2451. 00 208.93 332.34
7 RMR3 2314.83 5.26 304.08 2451.00 5.85 338.19
30 DC 2314.83 22.54 326.62 2451.00 25.07 363.26
33 HTR/BRG 99.69 426.31 102.28 465.54
1 BIT 417.58 843.89 468.16 933.69

600
ACCUM'D ACCUM'D
ANNULUS ANN VEL P-DROP P-DROP lI..NN VEL P-DROP P-DROP

OH /HTR 128.47 .13 844.02 136.03 .14 933.83

OH /DC 101.06 .05 844.07 107.01 .06 933.89
OH /RMR3 103.60 .01 844.09 109.70 .01 933.91
OH /DC 101.06 .05 844.14 107.01 .06 933.96
CSG/DC 78.44 .19 844.33 83.06 .21 934.17
CSG/DP 61.17 .09 844.42 64.77 .10 934.28

TOTAL OFF BTl>l @ 850 GPM 844.42 @ 900 GPM 934.28

HOTOR LOADED 360.00 1204.42 360.00 1294.28

TOTAL ON BTH @ 850 GPH 1204.42 @ 900 GPM 1294.28

DEPTH: 2000 MUD WT: 9.00

FLOW RATE: -------- 850 GPM ----------- --------900 GPM ------------

LENGTH BORE BORE VEL P-DROP ACCUM'D BORE VEL P-DROP ACCUM'D
P-DROP P-DROP

SE 73.51 73.51 81. 76 81. 76

1400 DP 1139.43 187.92 261.43 1206.45 209.00 290.76
279 DP 1139.43 37.45 298.88 1206.45 41.65 332.41
250 DC 2314.83 187.86 486.74 2451. 00 208.93 541. 34
7 RMR3 2314.83 5.26 492.00 2451. 00 5.85 547.19
30 DC 2314.83 22.54 514.54 2451. 00 25.07 572.26
33 MRT/BRG 99.69 614.23 102.28 674.54
1 BIT 417.59 1031.82 468.16 1142.70

2000
ACCUM'D ACCUH'D
ANNULUS ANN VEL P-DROP P-DROP Al~N VEL P-DROP P-DROP

OH /MTR 128.47 .13 1031. 94 136.03 .14 1142.84

OH /DC 101. 06 .05 1032.00 107.01 .06 1142.89
OH /RMR3 103.60 .01 1032.01 109.70 .01 1142.91
OH /DC 101. 06 .43 1032.44 107.01 .48 1143.39
OH /DP 74.11 .16 1032.60 78.47 .17 1143.56
OH /DP 74.11 .45 1033.04 78.47 .50 1144.06
OH /DP 74.11 .06 1033.10 78.47 .06 1144.12
CSG/DP 61.17 .17 1033.27 64.77 .19 1144.31

TOTAL OFF BTM @ 850 GPN 1033.27 @ 900 GPM 1144.31

MOTOR LOADED 360.00 1393.27 360.00 1504.31

TOTAL ON BTM @ 850 GPM 1393.27 @ 900 GPM 1504.31

Fig. 2-Hydraulics report.

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