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Downhole Mud Motors

Deflecting a wellbore
Directional Well

There are two major types of downhole motors powered by mud flow;

Downhole Mud Motors

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1) The turbine, which is basically a centrifugal or axial pump and

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2) The positive displacement mud motor (PDM). The principles of operation are shown in
Figure and the design of the tool are totally different.
Turbines were in wide use a number of years ago and are seeing some increased use lately
but the PDM is the main workhorse for directional drilling.

Motor Selection

Four configurations of drilling motors provide the broad range of bit speeds and torque
outputs required satisfying a multitude of drilling applications. These configurations include:
High Speed / Low Torque
Medium Speed / Medium Torque
Low Speed / High Torque
Low Speed / High Torque -Gear Reduced
The high speed drilling motor utilizes a 1:2 lobe power section to produce high speeds and
low torque outputs. They are popular choices when drilling with a diamond bit, tri-cone bit
drilling in soft formations and directional applications where single shot orientations are
being used.
The medium speed drilling motor typically utilizes a 4:5 lobe power section to produce
medium speeds and medium torque outputs. They are commonly used in most conventional
directional and horizontal wells, in diamond bit and coring applications, as well as
sidetracking.
The low speed drilling motor typically utilizes a 7:8 lobe power section to produce low
speeds and high torque outputs. They are used in directional and horizontal wells, medium
to hard formation drilling, and PDC bit drilling applications.
The gear reduced drilling motor combines a patented gear reduction system with a 1:2 lobe
high speed power section. This system reduces the output speed of the 1:2 lobe power
section by a factor of three, and increases the output torque by a factor of three. The result
is a drilling motor with similar performance outputs as a low speed drilling motor, but with
some significant benefits. The 1:2 lobe power section is more efficient at converting
hydraulic power to mechanical power than a multi-lobe power section and also maintains
more consistent bit speed as weight on bit is applied. This motor can be used in directional
and horizontal wells, hard formation drilling, and PDC bit drilling applications.
Some other motor selections are also available including a tandem and modified motor.
These variations are described below.
Tandem Drilling Motor - The drilling motor utilizes two linked power sections for increased
torque capacity.
Modified Drilling Motor - The bearing section of the drilling motor has been modified to
provide different drilling characteristics (ie. change bit to bend distance, etc.).

Components
All drilling motors consist of five major assemblies:

1.
2.
3.
4.
5.

Dump Sub Assembly

Power Section
Drive Assembly
Adjustable Assembly
Sealed or Mud Lubricated Bearing Section.

The gear reduced drilling motor contains an additional section, the gear reducer assembly
located within the sealed bearing section. Some other motor manufacturers have bearing
sections that are lubricated by the drilling fluid.

Dump Sub Assembly

As a result of the power section (described below), the drilling motor will seal off the drill
string ID from the annulus. In order to prevent wet trips and pressure problems, a dump sub
assembly is utilized. The dump sub assembly is a hydraulically actuated valve located at the
top of the drilling motor that allows the drill string to fill when running in hole, and drain when
tripping out of hole. When the pumps are engaged, the valve automatically closes and
directs all drilling fluid flow through the motor.
In the event that the dump sub assembly is not required, such as in underbalanced drilling
using nitrogen gas or air, its effect can be negated by simply replacing the discharge plugs
with blank plugs. This allows the motor to be adjusted as necessary, even in the field. Drilling
motors 95 mm (3 3/4) and smaller require the dump sub assembly to be replaced with a
special blank sub.

Power Section
The drilling motor power section is an adaptation of the Moineau type positive displacement
hydraulic pump in a reversed application. It essentially converts hydraulic power from the
drilling fluid into mechanical power to drive the bit.
The power section is comprised of two components; the stator and the rotor. The stator
consists of a steel tube that contains a bonded elastomer insert with a lobed, helical pattern
bore through the centre. The rotor is a lobed, helical steel rod. When the rotor is installed
into the stator, the combination of the helical shapes and lobes form sealed cavities between
the two components. When drilling fluid is forced through the power section, the pressure
drop across the cavities will cause the rotor to turn inside the stator. This is how the drilling
motor is powered.
It is the pattern of the lobes and the length of the helix that dictate what output
characteristics will be developed by the power section. By the nature of the design, the
stator always has one more lobe than the rotor. The illustrations in Figure show a 1:2 lobe
cross-section, a 4:5 lobe cross-section and a 7:8 lobe cross-section. Generally, as the lobe
ratio is increased, the speed of rotation is decreased.

The second control on power section output characteristics is length. A stage is defined as a
full helical rotation of the lobed stator. Therefore, power sections may be classified in stages.
A four stage power section contains one more full rotation to the stator elastomer, when
compared to a three stage. With more stages, the power section is capable of greater overall
pressure differential, which in turn provides more torque to the rotor.
As mentioned above, these two design characteristics can be used to control the output
characteristics of any size power section. This allows for the modular design of drilling
motors making it possible to simply replace power sections when different output
characteristics are required.
In addition, the variation of dimensions and materials will allow for specialized drilling
conditions. With increased temperatures, or certain drilling fluids, the stator elastomer will
expand and form a tighter seal onto the rotor and create more of an interference fit, which
may result in stator elastomer damage. Special stator materials or interference fit can be
requested for these conditions.

Drive Assembly
Due to the design nature of the power section, there is an eccentric rotation of the rotor
inside of the stator. To compensate for this eccentric motion and convert it to a purely
concentric rotation drilling motors utilize a high strength jointed drive assembly. The drive
assembly consists of a drive shaft with a sealed and lubricated drive joint located at each
end. The drive joints are designed to withstand the high torque values delivered by the
power section while creating minimal stress through the drive assembly components for
extended life and increased reliability. The drive assembly also provides a point in the drive
line that will compensate for the bend in the drilling motor required for directional control.

Adjustable Assembly
Most drilling motors today are supplied with a surface adjustable assembly. The adjustable
assembly can be set from zero to three degrees in varying increments in the field. This
durable design results in wide range of potential build rates used in directional, horizontal
and re-entry wells. Also, to minimize the wear to the adjustable components, wear pads are
normally located directly above and below the adjustable bend.

Sealed or Mud Lubricated Bearing Section

The bearing section contains the radial and thrust bearings and bushings. They transmit the
axial and radial loads from the bit to the drill string while providing a drive line that allows the
power section to rotate the bit. The bearing section may utilize sealed, oil filled, and pressure
compensated or mud lubricated assemblies. With a sealed assembly the bearings are not
subjected to drilling fluid and should provide extended, reliable operation with minimal wear.
As no drilling fluid is used to lubricate the drilling motor bearings, all fluid can be directed to
the bit for maximized hydraulic efficiency. This provides for improved bottom-hole cleaning,
resulting in increased penetration rates and longer bit life. The mud lubricated designs
typically use tungsten carbide-coated sleeves to provide the radial support. Usually 4% to
10% of the drilling fluid is diverted pass this assembly to cool and lubricate the shaft, radial
and thrust bearings. The fluid then exits to the annulus directly above the bit/drive sub.

Gear Reducer Assembly

An alternative to the type low speed drilling motor is the gear reduced design. It utilizes a
gear reduction assembly within the sealed bearing section in combination with a 1:2 lobe
power section. This patented design reduces the speed of rotation by a factor of three while
increasing the torque by the same multiple. The benefit with this design is increased stability

in the bit speed for different differential pressures, and improved hydraulic efficiency out of
the power section.

Kick Pads
Most drilling motors can incorporate wear pads directly above and below the adjustable
bend for improved wear resistance. Eccentric kick pads can also be used on most motors
ranging from 121 mm (4 3/4) to 245 mm (9 5/8) in size. This kick pad is adjustable to match
the low side of the motor to increase build rate capabilities. It will also allow lower adjustable
settings for similar build rates, thereby reducing radial stresses applied to the bearing
assembly, and permit safer rotation of the motor. They can be installed in the field by
screwing them onto specially adapted bearing housings.

Stabilization
Bearing housings are also available with two stabilization styles, integral blade and screwon. The integral blade style is built directly onto the bearing housing and thus cannot be
removed in the field. The screw-on style provides the option of installing a threaded stabilizer
sleeve onto the drilling motor on the rig floor in a matter of minutes. The drilling motor has a
thread on the bottom end that is covered with a thread protector sleeve when not required.
Both of these styles are optional to a standard bladed bearing housing.

Drilling Motor Operation

In order to get the best performance and optimum life of drilling motors, the following
standard procedures should be followed during operation. Slight variations may be required
with changes in drilling conditions and drilling equipment, but attempts should be made to
follow these procedures as closely as possible.

Assembly Procedure & Surface Check Prior to Running in Hole

Most motors are shipped from the shop thoroughly inspected and tested, but some
initial checks should be completed prior to running in hole. These surface check
procedures should only be used with mud drilling systems. To avoid potential bit,
motor, and BOP damage, these preliminary checks should be completed without a bit
attached. A thread protector should be installed in the bit box whenever moving the
motor, but must be removed before flow testing.
1. The correct lift sub must always be installed and used for moving the tool on or off the

2.

rig floor, and for lifting the tool into position for make-up. Also be sure the connection
between the lift sub and the drilling motor is tight. To lift the drilling motor to the rig
floor, use a tugger line secured around the lift sub. Pick up the drilling motor with the
elevators and set it into the slips of the rotary table. Install the dog collar/safety
clamps. The lift sub supplied with the drilling motor should only be used for lifting the
drilling motor. The capacity of the lift sub is restricted to the weight of the drilling
motor and should not be used for any other purpose. Only apply rig tongs on the
identified areas of the drilling motor. All connections marked NO TONGS of the
drilling motor are torqued in the service shop. Further make-up on the rig floor is not
necessary, and if attempted may cause damage.
Remove the lift sub and connect the kelly to the drilling motor, remove the safety

3.

4.

5.
6.

7.

8.

9.
10.

clamp, and lift the drilling motor out of the slips. Remove the thread protector from the
bit box and inspect the threads for damage.
Lower the drilling motor until the dump sub ports are below the rotary table, yet still
visible. CAUTION: The dump sub valve will remain open until there is enough fluid
pressure to close it. Therefore, the drilling motor should be lowered until the ports are
below the rotary table. This will prevent the initial flow of drilling fluid from spraying on
the rig floor.
Slowly start the pumps and ensure drilling fluid is flowing out of the dump sub ports.
Increase the flow rate until the dump sub ports close, and drilling fluid stops flowing
out. Make note of the circulation rate and standpipe pressure. CAUTION: Do not
exceed the maximum recommended flow rate for this test.
Lift the drilling motor until the bit box becomes visible. It should be rotating at a slow,
constant speed. Listen to the bearing section of the drilling motor for excessive
bearing noise, especially if the tool has been used previously without being serviced.
Before stopping the pumps, the drilling motor should be lowered below the rotary
table. Ensure that drilling fluid flows out of the dump sub ports after shutting down the
pumps. It is possible that the dump sub valve remains closed after this test due to a
pressure lock. If this occurs, no drilling fluid will flow out of the ports. To remove the
pressure lock, bleed off some stand pipe pressure and the valve will open. The
surface check should be as short as possible; since it is merely to ensure that the
drilling motor is rotating.
After this surface check, the bit should be attached to the motor using a bit-breaker,
while holding the bit box stationary with a rotary tong. Be sure to avoid contacting the
end cap directly above the bit box with the tong dies. It is recommended that you
never hold the bit box stationary and rotate the drilling motor counter-clockwise, or
hold the drilling motor stationary and rotate the bit box clockwise. This could possibly
cause the internal drilling motor connections to back off and damage it. Although
rotating in the opposite direction will result in drilling fluid to be pushed out the top
end, the internal connections will not be at risk of disconnecting. Get wet or damage
motor.
If the drilling motor has been used previously, an overall inspection should be
completed. Inspect for seal integrity by cleaning the area above the bit box and
visually checking for lubricating oil leakage or seal extrusion. General visual
inspection of the entire drilling motor should be carried out to check for missing oil
plugs, housing damage, or loose connections.
Set the adjustable assembly to the desired bend. The instructions for this procedure
depend upon the motor manufacturer and should be adhered to. Ensure the rig tongs
can generate the required make-up torque the motor.
If a float sub is used, it should be placed immediately above the drilling motor.

Tripping In Hole
Generally, a drill string with a drilling motor can be run into the hole like a standard bottom
hole assembly. The drilling motor is rugged, but care should be taken to control travel speed
while tripping into the hole. The drill string should be tripped with the blocks unlocked and
special care must be taken when passing the B.O.P., casing shoe, liner hanger, bridges and
nearing bottom. Tight spots should be traversed by starting the pumps and slowly reaming
the drilling motor through. When reaming, the drill string should be periodically rotated to
prevent sidetracking. Great care should be taken during these operations.

When tripping to extreme depths, or when hole temperatures are high, periodic stops are
recommended to break circulation. This prevents bit plugging and aids in cooling the drilling
motor, preventing high temperature damage.
Fluid should not be circulated through a drilling motor inside casing if a PDC or diamond bit
is being used, as this may damage the bit cutters.
If a dump sub assembly is not used and the pipe is not being filled while tripping in, the back
pressure on the power section will cause the rotor to turn in reverse. This could cause
internal connections of the drilling motor to unscrew. Stop and break circulation before
putting drilling motor on-bottom. Failure to do so could plug jets and/or damage the drilling
motor.

Drilling
After the assembly has been tripped to the bottom of the hole, drilling motors should
be operated in the following manner:

1. With the bit 1-2 meters (3-6 feet) off bottom, start the pumps and slowly increase the
flow rate to that desired for drilling. Do not exceed the maximum rated flow rate for
the drilling motor.
2. Make a note of the flow rate and the total pump pressure. Note that the pressure may
exceed the calculated off bottom pressure due to some side load effects between the
bit and the hole diameter.
3. After a short cleaning interval, lower the bit carefully to bottom and slowly increase
the weight. Torque can be affected by a dirty, uncirculated hole and the hole should
be adequately cleaned prior to orienting the tool. Fill maybe cleaned out of the
wellbore by slowly rotating the drilling motor or by staging the drilling motor full circle
30o to 45o at a time. This prevents ledge buildup and side tracking.
4. Orient the drill string as desired and slowly apply further weight onto the bit. Pump
pressure will rise as the weight on bit is increased. Record the change in system
pressure between the off bottom and on bottom values. This will be the differential
pressure. Try to drill with steady pump pressure by keeping a steady flow rate and
constant weight on bit.
5. Adding weight on bit will cause both the differential pressure and torque to increase.
Similarly, reducing weight on bit will reduce both the differential pressure and the
torque. Therefore, the rig pressure gauge enables the operator to monitor how the
drilling motor is performing, as well as a weight on bit indicator.
6. Applying excessive weight on bit may cause damage to the on-bottom thrust
bearings. Similarly, applying excessive tension while stuck may cause damage to the
off-bottom thrust bearings. Refer to the manufacturer specifications for the
recommended maximum loads for these conditions.
7. Optimum differential pressure can be determined by monitoring motor performance,
penetration rate, and drilling requirements. Also, maintaining a constant weight on bit
and differential pressure assists in controlling orientation of the drill string.

Reactive Torque
Drilling motors drive the bit with a right-hand (clockwise) rotation. As weight is added to the
bit, reactive torque acting on the drilling motor housing is developed. This left-hand (counterclockwise) torque is transferred to the drill string and may cause the joints above the motor
to tighten. Reactions of this type increase with larger weight on bit values and reach a
maximum when the motor stalls. This reactive torque also affects the orientation of the motor
when it is used in directional drilling applications. Therefore, this reactive torque must be

taken into account when orienting the drilling motor from the surface in the desired direction.
As a rule-of-thumb 4 drill pipe will turn 10o
for every 300m (1,000).
Determining the amount of torque generated by the motor and using drill pipe twist tables
can also produce a rough determination of the torsional angle of the drill string. By
measuring the on-bottom and off-bottom pressure, the differential pressure can be
determined. With this value use the torque performance charts for the motor to determine
the approximate downhole torque generated. Utilizing the following drill string twist table will
estimate the amount of reactive torque.

Critical Rotary Speed

Motor sections are available in a number of configurations. These different designs are
identified by the number of lobes on the rotor and cavities in the stator. For example a 4/5
power section has 4 lobes and 5 cavities. With every rotation made by the rotor, there are
eccentric motions about the radius of the rotor equal to the number of lobes. So a 4/5 power
section would go through 4 eccentric movements for every rotation. In all multi-lobed tools,
regardless of size or configuration, the critical tolerance for this eccentric movement is 1000
cycles per minute. Exceeding this critical tolerance sets up three degenerative cycles in the
tool:
The high oscillation factor combined with the inherent friction of the rotor contacting
the stator results in excessive heat generation in the stator molding. Oscillations
above 1000 cycles per minute may result in temperatures sufficient to cause
hysteretic failure of the stator molding (elastomer doesnt return to original shape).
Vibration frequencies are introduced by the high oscillation rates that can contribute

to mechanical failures in motor components other than the rotor and stator. It is not
known if these vibrations are harmonic or random however, it is logical to assume that
some degree of resonance would be present in the frequency.
The centrifugal force of the rotor in an over-speed condition combined with the
diminished compressive strength of a stator in hysteretic failure, accentuate the
eccentric motion (run out) of the rotor. The result is an expontenial increase in the
degenerative effects of the condition.

Drilling Motor Stall

Stalling usually occurs when the application of excessive weight on bit or hole sloughing
stops the bit from rotating and the power section of the drilling motor is not capable of
providing enough torque to power through. This is indicated by a sudden sharp increase in
pump pressure. This pressure increase is developed because the rotor is no longer able to
rotate inside the stator, forming a long seal between the two. If circulation is continued, the
drilling fluid forces its way through the power section by deflecting the stator rubber. Drilling
fluid will still circulate through the motor, but the bit will not turn. Operating in this state will
erode and possibly chunk the stator in a very short period of time, resulting in extensive
damage. It is very important to avoid this operating condition.
When stalling occurs, corrective action must be taken immediately. Any rotary application
should be stopped and built up drill string torque released. Then the weight on bit can be
reduced allowing the drill bit to come loose and the drilling motor to turn freely. If the pump
pressure is still high, the pumps should then be turned off. Once again, failure to do this will
result in the stator eroding until the drilling motor is inoperable.
Other conditions can be occurring downhole that indicate the motor is stalling. On
underbalanced wells when the motor is being supplied with too low a combined equivalent
flow rate will not drill (see later discussion on two-phase flow tests). Under gauge bits or a
badly worn heel row of cutters on the bit can also make the motor stall.

Bit Conditions
The bit speeds developed when drilling with a drilling motor are normally higher than in
conventional rotary drilling. This application tends to accelerate bit wear. When drilling with a
drilling motor and simultaneously rotating the drill string, it is important to avoid locking up
the bit and over running the drilling motor with the rotary table. A locked bit will impart a
sudden torque increase in the drilling motor which can be detected by a sudden, sharp
increase in standpipe pressure. Small pressure fluctuations can also indicate the onset of bit
failure.

Rotating the Drilling Motor

For directional control, we often rotate a drilling motor which has the adjustable assembly set
for a deviation angle. It has been found that rotating the drilling motor set at bends greater
than 1.8 degrees may fatigue the housings of the drilling motor to a point where a fatigue
crack is initiated, and fracture occurs. Additionally, rotation of motors with settings greater
than 1.83 degrees place high radial stresses on the bearing section which may initiate
premature failure. Most motor manufacturers have a policy that drilling motors set at greater
than 1.83 degrees not be rotated. The extent of the damage is very dependent upon the
drilling conditions and formations being drilled. Although fractures from fatigue due to
rotating over 1.83 degrees are a relatively rare occurrence, a risk is still being taken when it
is done. The operator of the drilling motor must be aware of this risk.

It is also recommended that the speed of rotation not exceed 50 RPM. If this value is
exceeded, excessive cyclic loads would occur to the drilling motor housings and possibly
causing pre-mature fatigue problems.

Tripping Out
Prior to tripping out when drilling with conventional mud, it is recommended that the fluid be
circulated for at least one bottoms-up time to ensure that the wellbore has been cleaned
thoroughly.
The tripping out procedures for a drilling motor is basically the same as those for tripping in.
Taking care when pulling the drilling motor through tight spots, liner hangers, casing, casing
shoes, and the B.O.P. is necessary to minimize possible damage to both the drilling motor
and the wellhead components. Rotating may also be done to assist with the removal of the
drill string. The dump sub valve will allow the drill string to be emptied automatically when
tripping.
Although the drill string will drain when tripping out, the drilling motor itself may not. Once the
drilling motor is at surface, rotating the bit box in a counter-clockwise direction will naturally
drain the drilling motor through the top. This is recommended before laying down the motor
since aggressive drilling fluids can deteriorate the elastomer stator and seals. When
possibly, fresh water should also be flushed through to ensure thorough cleaning of the
drilling motor. Also, clean the bit box area with clean water and install a thread protector into
the box connection.
Rotating the bit box in a clockwise direction will naturally drain the drilling motor through the
bottom, but one of the internal connections could break and unscrew. For this reason, it is
not recommended to rotate it in this manner.

Surface Checks After Running in Hole

Before laying down a drilling motor, it should be inspected in the event that it is required
again before servicing. Listen for indications of internal damage when draining the drilling
motor. Inspect the seal area between the bit box and the bearing section for lubricating oil
leakage, and check the entire drilling motor for loose or missing pressure plugs. If there are
any concerns with the drilling motor, it should be laid down for servicing.

Drilling Fluids
Most drilling motors are designed to operate effectively with practically all types of drilling
fluids. In fact, the stator or power-section of most PDMs are supplied by the same one or
two manufacturers with the same general elastomer type. Successful runs have been
achieved with fresh or salt water, oil based fluids, fluids with additives for viscosity control or
lost circulation, and with nitrogen gas. However, some consideration should be taken when
selecting a drilling fluid, as elastomer components of the drilling motor are susceptible to
pre-mature wear when exposed to certain fluids especially under higher temperatures.
Hydrocarbon based drilling fluids can be very harmful to elastomers. A measure of this
aggressiveness is called the Aniline Point. The Aniline Point is the temperature at which
equal amounts of the hydrocarbon and aniline become miscible. This temperature is an
indication of the percent of light ends (aromatics) present in the hydrocarbon. It is
recommended that the aniline point of any drilling fluid not be lower than 70 to 94.5o C (158
to 200o F), depending upon stator manufacturer. The lower the aniline point the higher the

percentage of elastomer damaging high-ends in the hydrocarbon fluid. Also, the operating
temperature of the drilling fluid should be lower than the aniline point. Operating outside
these parameters tends to excessively swell elastomers and cause premature wear, thus
reducing the performance of the motor. In cases where hydrocarbon based fluids are used it
is recommended that stators material or designs that account for the elastomer swelling be
used (HSN or changed interference of stator/rotor.
Drilling fluids with high chloride content can cause significant damage to internal
components (chrome plated rotors). When these components become damaged, the drilling
motors performance is dramatically reduced.
Lost circulation materials can be used safely with drilling motors but care must be taken to
add the material slowly to avoid plugging the system. (Good rule of thumb is no more than
2.5 lbs/barrel). If coarse lost circulation material is required a circulating sub should be
installed above the motor assembly to by-pass the motor.
The percentage of solids should be kept to a minimum. Large amounts of abrasive solids in
the drilling fluid will dramatically increase the wear on a stator. It is recommended that the
sand content be kept below 2% for an acceptable operational life. A solids content greater
than 5% will shorten rotor and stator life considerably.
For the above reasons, it is extremely important to flush the drilling motor with fresh water
before laying it down, especially when working with the types of drilling fluids described
above. Failure to do so will allow the drilling fluid to further seriously deteriorate components
to the drilling motor long after it has been operated. The solids can also settle out in the
motor and in the worse case lock the motor up.

Temperature Limits
The temperature limits of drilling motors again depend on the effect of different fluids and
temperatures on the components made of elastomers. Generally, standard drilling motors
are rated for temperatures up to 105o C (219o F). At temperatures above this, the
performance characteristics of elastomers are changed, resulting in reduced life expectancy.
When exposed to higher temperatures, the elastomers swell, creating more interference
than desired, wearing the parts out prematurely. The strength of the elastomers is also
affected. When drilling in wells with temperatures greater than 121o C (250o F) it is important
to maintain circulation to minimize the temperature the stator liner is subjected to.
To compensate for these elastomer changes, special materials and special sizes of
components are used. This results in drilling motors that are specifically assembled for high
temperatures. These special order drilling motors may be operated in temperatures up to
150o C (300o F) and higher. The rubber in the stator is specially selected for more clearance
at higher temperatures to minimize interference. Therefore, at lower temperatures, the stator
elastomer will not seal adequately on the rotor and fluid bypass will occur. Therefore, it is
important that the drilling motor be used in the conditions it is designed for in order to
operate as required.
To compensate for these elastomer changes, special materials and special sizes of
components are used. This results in drilling motors that are specifically assembled for high
temperatures. These special order drilling motors may be operated in temperatures up to
150o C (300o F) and higher. The rubber in the stator is specially selected for more clearance
at higher temperatures to minimize interference. Therefore, at lower temperatures, the stator
elastomer will not seal adequately on the rotor and fluid bypass will occur. Therefore, it is
important that the drilling motor be used in the conditions it is designed for in order to
operate as required.

Hydraulics
The use of a PDM in the drill string changes the hydraulic calculations and should be
considered. Various factors have to be taken into account. These are:
1. Range of flow rates allowable: Each size and type of PDM is designed to take a certain
range of volumes of fluid.
2. No-load Pressure Loss: When mud is pumped through a mud motor which is turning
freely off-bottom (i.e. doing no work) a certain pressure loss is needed to overcome the
rotor/stator friction forces and cause the motor to turn. This pressure loss and motor RPM
are proportional to flow rate. Their values are known for each size and type of PDM. The noload pressure loss is usually no greater than 100 psi.
3. Pressure Drop across the Motor: As the bit touches bottom and effective WOB is applied,
pump pressure increases. This increase in pressure is normally called the motor differential
pressure. Motor torque increases in direct proportion to the increase in differential pressure.
This differential pressure is required to pump a given volume of mud through the motor to
perform useful work. For a multi-lobe motor, it can be 500 psi or even more.
4. Stall-out Pressure: There is a maximum recommended value of motor differential
pressure. At this point, the optimum torque is produced by the motor. If the effective WOB is
increased beyond this point, pump pressure increases further. The pressure across the
motor increases to a point where the lining of the stator is deformed. The rotor/stator seal is
broken and the mud flows straight through without turning the bit (blow-by or slippage). The
pump pressure reading jumps sharply and does not vary as additional WOB is applied. This
is known as stall-out condition.
Studies have shown that the power output curve is a parabola and not a smooth upward
curve, as originally thought. If the PDM is operated at 50%-60% of the maximum allowable
motor differential pressure, the same performance should be achieved as when operating at
90% of differential. The former situation is much better however, there is a much larger
cushion available before stall-out. This should result in significantly longer motor life.
The greater the wear on the motor bearings, the easier it is to stall-out the motor. It is useful
to deliberately stall out the PDM briefly on reaching bottom. It tells the directional driller what
the stall-out pressure is. He may want to operate the motor at about 50% of stall-out
differential pressure. In any case, he must stay within the PDM design specifications.
It is obvious that, if the pump pressure while drilling normally with a mud motor is close to
the rigs maximum, stalling of the PDM may lead to tripping of the pop-off valve. This should
be taken into account in designing the hydraulics program.
Rotor Nozzle: Most multi-lobe motors have a hollow rotor. This can be blanked off or jetted
with a jet nozzle. When the standard performance range for the motor matches the drilling
requirements, a blanking plug is normally fitted.
The selection of the rotor nozzle is critical. Excessive bypass will lead to a substantial drop
in motor performance and, consequently, drilling efficiency. If a rotor nozzle is used at lower
flow rates, the power of the motor will be greatly reduced.
From the above, it is clear that careful planning of the PDM hydraulics program is required.

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