CASE STUDIES

(most recent at top)

7.00-in. RE|FLEX Motor Gets It Done in North Dakota

(case study no. 0025)

OVERVIEW 

Location: Wolf Bay Field, North Dakota
Well/Run Type: Vertical
Total Depth Drilled: 11,963 ft (3,646m)  / 8.75” hole
Circulating / Drilling Hours: 69.5 hrs
Products / Services: InFocus 7.00-in RE|FLEX Premium Drilling Motor w/7:8 Lobe 5.7 Stage
                                      elastomer power section. 
                                      Operator was NEWSCO

Date: March - April 2019

OBJECTIVES

Successful field trial of the 7-in RE|FLEX motor, using a 7:8 Lobe 5.7 Stage elastomer-based power section. 

 

RESULTS

RE|FLEX Premium Drilling Motors contain double-shouldered connections to handle the torque requirements of tomorrow’s power sections.  Recently, an InFocus 7.00-in RE|FLEX Premium Drilling Motor was sent to drill a vertical well in North Dakota. This provided a great testing ground for InFocus’ beefed up 7.00-in bearing section paired with a 7:8 Lobe 5.7 Stage elastomer-based power section.

Run 1 of 3:  The tool was in the hole for almost 52 hours and drilled 6,072 feet (1,851 m). While drilling, the motor easily handled torque ranges of 4,000 - 12,975 ft-lbs (5,420 - 17,590 N-m). It was pulled to replace the bit.

Upon return to the InFocus facility, the 7.00-in RE|FLEX was inspected, with special attention paid to our new patent-pending driveshaft design. As expected, the drive assembly (as well as the rest of the tool) was unphased by this drilling environment. The tool was re-assembled and returned to the customer in the same field three days later. 

Run 2 of 3:  Tool was downhole for 19 hours and drilled 1,676 feet (510m).

Run 3 of 3:  The 7.00-in RE|FLEX reached planned total vertical depth after being downhole for an additional 39.75 hours, drilling 4,215 feet (1,285m). 

The average ROP was 111.4 feet/hour (34 meters/hour). 

OPERATIONAL NOTES

 - BHA -

•  HWDP
•  Hydro Mechanical Drilling Jar
•  HWDP
•  Crossover
•  Drill Collar
•  Non Mag Flex Monel Drill Collar
•  Non Mag Flex Monel Tool Carrier
•  UBHO Sub
•  7.00-in InFocus RE|FLEX Premium Drilling Motor w/7:8 Lobe 5.7 Stage elastomer power section
•  8 3/4-in. PDC Bit

N2 run_thm.png

2-7/8” AMP Sand Cleanout w/Nitrogen - Grande Prairie, Alberta, Canada

(case study no. 0022)

OVERVIEW 

Location: Grande Prairie, Alberta
Well/Run Type: Oil & Gas cleanout run using Nitrogen (N2)
Run Length: Cleanout to 4500 meters
Circulating / Drilling Hours: 69.5 hrs
Products / Services: InFocus 2.875” Drilling Motor w/AMP - All Metal Power section
Operator: Tartan Energy Group, Grande Prairie, Alberta

OBJECTIVES

The objective of this run was to circulate through sand bridges that were cutting off gas production.

 

RESULTS

An InFocus AMP - All Metal Power section was brought in to aid the Operator with this cleanout. The Operator did small sweeps, not trying to be aggressive to avoid the coil getting stuck behind the BHA. The Operator would tag sand bridges and do small wiper trips, circulating sand up and out of the well. It took 3 days to reach TD of 4500m following this practice. 

100 l/min of fresh water and up to 50 SCM of nitrogen was pumped through the tool for 69.5 straight hours. As a bypass tool was not run above the AMP, all fluid and gas was pumped through the motor, which completed the entire run.

Upon return to InFocus, the motor was serviced and then Dyno tested. Post-run performance verification aligned perfectly to the benchmark pre-run Dyno verification.

BENEFITS

The Operator was able to utilize high N2 rates throughout this run with no damage to the power section.
This particular AMP now has 220 combined run hours on it as of this writing.

OPERATIONAL NOTES

 - BHA -

•  Coil Connector

•  Bi-directional Jar

•  MHA (dual float, disconnect, circulation sub)
•  InFocus AMP Motor, 9:10 Lobe 3.8 Stage
•  Pineapple Mill

N2 run_thm.png

2-7/8” AMP Wellbore Cleanouts - Leduc, Alberta, Canada

(case study no. 0021)

OVERVIEW 

Location: Leduc, Alberta
Well/Run Type: Oil & Gas Confirmation Runs
Run Length: Consecutive Runs (#1) 3740 meters & (#2) 3550 meters
Circulating / Drilling Hours: 14 hrs
Products / Services: InFocus 2.875” Drilling Motor w/AMP - All Metal Power section
Operator: Blacksmith Oil Tools, Medicine Hat, Alberta

OBJECTIVES

The reason for a confirmation run (toe tag) is to avoid tool/cement/well problems while there is a frac crew on location. Wells were 4.5” - kicked off at 900m, and are at a 90° angle from ~ 1400m to TD.

 

RESULTS

The client recently used a conventional motor on an identical job, so this was a great time to try an AMP to determine pressure differences. Operator noted, “... there are times that we can be maxed out with circulating pressure with 2” coil tubing and 6000m of coil on the reel. You can’t cycle coil above 28,000 kPa because of the affect on coil fatigue.” 

“We pumped about 80 m3 of straight clean fluid on each well for a total of 160 m3. On the job we pump 100 l/min (26.4 gpm) in the vertical and then pick up our rate to 200 l/min (52.8 gpm) in horizontal. Once TD’d we pick up to 450 l/min (119 gpm) to do a bottoms up. Then reduce rate back down to a minimum. Encountered a 1m stringer on the first well.” Upon return to InFocus, the tool was immediately put on the Dyno. Both pre- and post-dyno results were consistent.

OPERATIONAL NOTES

 - BHA -

•  2-3/8” Internal Coil Connector
•  DFCV (Double-Flapper Check Valve)
•  InFocus AMP Motor, 9:10 Lobe 3.8 Stage
•  Fishneck / Pineapple Mill

cs_0021.png

BENEFITS

Operator - “The motor wasn’t as hard to handle as I expected due to the extra weight [up to 50 lbs]. I would say the nicest surprise was to be able to easily drain the motor before removing it from coil so no one below gets soaked. This is a big problem in the winter. All in all, great job on the motor and I’m looking forward to using it further!”

2-7/8” AMP Third Party Dyno Test

(case study no. 0020)

OBJECTIVES

In May of 2018, to independently validate the new 2-7/8 AMP, InFocus Energy Services conducted 3rd party dyno testing of the power sections at a third party provider in Red Deer, AB. The objective was to demonstrate repeatable high torque and extended run time performance of InFocus Energy’s 2-7/8” AMP (ALL METAL POWER) sections.

cs_0020.png

This test was successful and well received by all parties present. This testing provided valuable 3rd party data on the performance, durability and wear characteristics of the power sections. Dyno test data was provided by the third party provider.

 

TEST PROCEDURE

1. Initial runs were done with no brake load to confirm operating parameters and establish the no load RPMs at different flow rates. This established the No Load Bit Speed range of 251 – 524 RPM, with corresponding flow rates of 68 – 144 GPM.

2. 1st Load run – 100 GPM Flow Rate
(a) This started at a flow rate of 65 GPM, and a diff pressure of 800 psi. Produced a stable torque of 375 lb-ft and was held for 15 minutes before increasing flow rate to 100 GPM.
(b) 100 GPM: the brake load was gradually increased over 25 minutes, with steadily increasing torque values 740 lb-ft at a diff pressure of 1,570 psi.

3. 2nd Load run – 66 GPM flow rate
(a) This test was started at a flow rate of 100 GPM, and the motor was held at 765 lb-ft for 10 minutes. Flow rate was then dropped to 80 GPM.
(b) The stable load was 410 lb-ft at a diff pressure of 900 psi. This was steadily increased over 25 minutes until a torque of 890 lb-ft was reached at a diff pressure of 1,950 psi.
(c) This 890 lb-ft load was held for over 30 minutes at a speed of just under 100 RPM with no drop in performance or change in diff pressure.

 

Tests were very successful and proved the AMP power section

can operate at a variety of load conditions, and can transition

easily between loading conditions, all while putting out very

high torque for it’s size in a sustained (>30min) high load test.

Data from the 2nd load run, where maximum torque of

890 lb-ft was achieved and sustained, is plotted in Figure 1.

POST-RUN DIMENSIONAL INSPECTION

Aside from testing the performance of the power section, the second goal of these dyno tests were to see the dimensional change of the of the 2-7/8” AMP power section after a sustained high-torque run. This was done with a combination of visual inspection and laser scan comparison before and after dyno testing.
 

Visual Evaluation of Rotor Profile
Contact appears to have occurred along one side of the profile of the rotor lobe, and in some locations extended to the rotor lobe tip. This is the side where the rotor rolls into the stator. This contact patch does not appear to have any divots or dents or even a step change in lobe thickness. The rotor profile still feels smooth and looks like the contact is more of a polish than any appreciable wear.

NOTE: The rotor was manufactured to a milled finish, resembling “snake skin”. The scaling seen is from the manufacturing process and not from dyno testing.

Visual Evaluation of Stator Profile

The stator (Figure 4) was evaluated via visual inspection with a borescope, as well as tactile evaluation. Contact appears to be on the flanks on either side of the stator minors, where the rotor makes rolling contact with the stator. The contact patches are smooth, and free of divots and dents. The edges of the contact patches are gradual and no step changes or indents are visible. This wear pattern is consistent through most of the stator. As seen on the rotor, this contact appears to be mostly polish rather than any appreciable wear.

Laser Scans
To quantify the contact and dimensional change seen in the visual inspection, laser scan data was used to evaluate profile change caused by testing.

Laser scans were taken at 2 points in the life of the rotor. Sequence of events follows:
1. Rotor was manufactured
2. 1st laser scan taken to verify geometry
3. Rotor was sent for treatment (adds approximately 0.002” to the entire profile)
4. Motor was assembled, and dyno tested
5. 2nd laser scan taken to evaluate change after dyno testing
6. Laser scan data from both scans was imported into SOLIDWORKS, converted from mesh to solid geometry, and compared to nominal profile.

Post Test Data Analysis
For both laser scans, a 4-6” representative section of the rotor was scanned, then imported into SOLIDWORKS, converted from mesh to solid, and then cross sections were taken and compared to the nominal profile.

NOTE: It is important to note that the points are imported as a polygon mesh from the laser scan data, so there is some rounding error as the curvature of the tips are connected straight line segments rather than true, clean arcs. The initial laser scan, taken directly after manufacturing, showed the minors to be exactly on size, and the majors very slightly under the maximum nominal dimension. This was consistent across most of the lobes and fell within the acceptable tolerance.

The post-dyno laser scans help quantify what was seen in the visual rotor inspection. The minors and the flanks saw no wear, and scans show them to be approximately 0.002” thicker than in the first scan. This is consistent with the expected growth due to rotor treatment. The dimensional change on the majors varied between lobe and profile location, but was generally between 0.001 – 0.002”. On most lobes this contact was preferential to one side of the major, which again lines up with the visual inspection and the side of the major that would roll into the stator.

The post-dyno laser scans help quantify what was seen in the visual rotor inspection. The minors and the flanks saw no wear, and scans show them to be approximately 0.002” thicker than in the first scan. This is consistent with the expected growth due to rotor treatment. The dimensional change on the majors varied between lobe and profile location, but was generally between 0.001 – 0.002”. On most lobes this contact was preferential to one side of the major, which again lines up with the visual inspection and the side of the major that would roll into the stator.

High Flow Rate @ 0 load
The AMP power section is capable of very high flow rates at low load. This is advantageous when drilling/milling plugs and ports. The higher annular velocity improves cutting removal and milling/drilling efficiency. The initial No Load dyno runs demonstrated RPM in the range of 251 – 524 RPM, with corresponding flow rates of 260 lpm – 535 lpm (68 – 144 GPM). After data processing and extrapolation, the published No Load Bit Speed of 183 RPM – 550 RPM were established over flow ranges of 189 LPM – 568 LPM (50 - 150 GPM)


Stall Resistant 

Looking at the performance curve for the 2-7/8” AMP, it appears that the RPM curve for the AMP power section does not see a dramatic drop-off like is seen in traditional power sections. During the 3rd party dyno testing, the test was run to maximum pump capacity without being able to stall the power section.


REFERENCES
IFES-MOT-SPEC-0019 REFLEX 2875_73mm 91038

First Successful Deployment of 2-7/8” AMP - Canada
(case study no. 0019)

Overview
Location: Fort MacMurray, Alberta
Well Type: Water Injection
Run Length: 1250 meters
Circulating / Drilling Hours: 30 hrs
Products / Services: InFocus 2.875” Drilling Motor w/AMP - All Metal Power section

cs_0020.png

Objectives
Screen cleanout on water injection wells that had sanded off. Pumped 0.5 m3/min of fresh water during cleanout operations. Once completed, wells were then displaced with Nitrogen @ 20 m3/min.

Results
Achieved objective of cleaning and freeing debris over Operator’s intended interval. Well was put back into production.


Benefits
There was no dimensional wear or damage to the motor or power section. A considerable cost-saving to the Operator was achieved since the same tool was used to complete multiple consecutive wells. Typically, a stator re-line would have been required to reduce the amount of failure that occurs in this type of application. The 2-7/8” All Metal Power section used was ready to return to the field after a quick service.

Contact an InFocus representative for more information

 

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