Department of Petroleum Engineering

Indian Institute of Technology (ISM), Dhanbad – 826004

VI Semester B.Tech Petroleum Engineering 2023-24
Lecture 4 / 2023-24
(For internal circulation only)

DOWN HOLE MOTORS

POSITIVE DISPLACEMENT MOTOR AND TURBODRILL
BY

Prof. A.K.Pathak
Department of Petroleum Engineering
Indian Institute of Technology (Indian School of Mines), Dhanbad
E-mail: akhilendra56@iitism.ac.in

POSITIVE DISPLACEMENT MOTORS

In search of alternative to conventional rotary
drilling where the entire drill string is rotated
from surface, various types of down-hole
motors have been proposed. Drill string
rotation can be eliminated, by having a motor
placed down hole to drive the bit by hydraulic
power. After second world war, Smith tool Co.
developed a down hole motor known as
Positive Displacement Motor (PDM) 1950. It
was basically consisted of a steel spiral shaft,
which rotated with a rubber sleeve stator. As
mud was pumped between the spiral shaft and
the stator the shaft rotated clock wise and
turned the bit. The hydraulic power of the mud
in terms of pressure and flow rate was
converted to mechanical power at the bit in
terms of rotational speed and torque. The PDM
provides faster RPM at the bit then
conventional rotary methods.
During 1970s more service companies
like Schlumberger, Baker and Christensen
developed different PDMs in improved form for
longer use for 100-200hours. Both single and
multi-lobe models are being used now a days
for straight hole drilling, Kick offs, side tracking
and coring purpose.
Motor Description
i. Dump Valve:
To prevent the motor rotating while
running in to the hole or pulling out of the
hole, a by-pass valve or dump valve is
installed at the upper end of the motor.
This valve has radial ports those remain
open when pump is shut during tripping.
During drilling the increased mud
pressure, a piston pushes a sleeve down
to cover and seal off the ports. Whenever
the limps are shut off a spring forces the
sleeve upward, opening the ports again.
Dump valve

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24

ii. Motor Section:

Rotor: The rotor is a steel shaft of spiral
form. For a single lobe the cross section of
the shaft is circular. It is free at the top but
attached to the universal joint at the bottom.
Stator: The stator is moulded rubber sleeve,
which forms a spiral passage way to
accommodate the rotor. The rubber sleeve is
fixed to the steel body of the motor. When the
rotor is fixed inside the stator the difference in
geometry between two components create a
series of cavities, when mud requires a path
between the rotor and stator. In doing so the
mud displaces the shaft forcing it to rotate
clock wise as the mud continues to flow
through the passage way.
Motor Section: Stator and Rotor
iii. Lobe Configuration of PDM:
In a single lobe motor the flow area
is relatively large, allowing a faster
flow and hence a faster speed of
rotation. In a multi-lobe motor, there
can be up to 10 cavities in the stator
and 9 lobes on rotor. Thus flow area is
reduced and hence speed of rotation is
also reduced. Torque developed at the
bit however is quite high. PDMs are
available of ½ , ¾ , 5/6 , 9/10 lobes
configurations.

Lobe Configuration of PDM

iv. Stage and Rotor Pitch of PDM:

To increase the power and torque delivered by PDM the number of PDM stages can be
increased. There are normally 3 stage in the motor section but by welding two rotors together
this can be increased up to 6 stages. To achieve more power output the overall length of the
PDM must be increased.

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24

Stage and Rotor Pitch of PDM

v. Bearing Assembly of PDM:
The durability of bearing determines the
operating life of the motor. The bearing
assembly fulfils two functions. (a) It transmits
the axial load to the bit. This is achieved
through thrust bearing of several sets. (b) It
maintains central position of the drive shaft to
ensure smooth rotation. This is achieved by
radial bearing which are of sleeve type made
of elastomer material.

Bearing Assembly of PDM

vi. Universal Joint:

Since the shaft is rotating eccentrically the

lower end must be connected to a universal
joint. This joint converts the eccentric motion
to the co-centric motion which is transmitted
to the bit. Various type of flexible joints can
be used but a simplest joint is a ball joint
lubricated by grease. A rubber sleeve, around
the joint prevents mud contamination.

Universal Joint of PDM

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
Performance Characteristics:
The energy supplied by the drilling fluid is used to rotate the helical shaft, which in turn rotates
the bit. The speed of rotation n can be determined from:
n = Q/ A.L A = (π dr2 /4) + 2 e.dr - (π dr2 /4) A = 2 e.dr
n = Q / 2 e.dr . L = 123 Q / 2 x 7.48 e.dr.L
n = 115.5 Q / (e.dr.L) (1)
Q = flow rate in GPM e = eccentricity in inch.
.dr = shaft diameter in inch L length of stages inch.
A = available flow area between stator and rotor
The in put power developed can be calculated from:
Pi = Q . ΔP / 1714 (2)
ΔP = Pressure drop per stage in psi.
The out put power developed can be calculated by:
Po = (1.904 x 10-4 ) T . n (3)
The torque developed is:
T = 2.653 X 10-2 e. dr. L. ΔP (4)
The efficiency of the motor is the ratio of out put power to the in put power of the motor. This
factor include (a) the internal fluid leaks along with the contact surfaces, which increase due
to wear. (b) frictional-losses in the bearing and universal joint and
Drilling with PDM
The pre tested motor is run along with BHA in the hole with a bent sub above the motor for
providing build up rate.
- Once on bottom the motor should be picked up 1 – 2 ft. up before starting the pump. The off
bottom circulation pressure should be noted. The motor is then lowered and the drilling can
be commenced.
- As WOB is applied, the surface pressure will increase. WOB and pump pressure should not
exceed then the manufacturer’s specification. If too much WOB is used the pump pressure
reaches at maximum at which motor stalls and stops drilling. In this condition the motor must
be picked up off the bottom and the surface pressure should return to the original circulating
pressure.
- During drilling, if the flow rate and pump pressure are kept constant, the torque and RPM
should also be constant unless there is formation change.
- A gradual lowering of the surface pressure indicates that more WOB should be used.
Warning Signals of Problems:
- A sudden rise in surface pressure usually indicates that the motor has stalled. If the motor is
kept in stalled condition serious damage will occur in stator preventing a proper seal between
the stator and rotor. If this happens, the motor have to be tripped out of the hole and replaced.
- In creased surface pressure may also caused by mud clogging and jamming the bearings.
- Bit wear may be indicated by repeated stalling of the motor. A plugged nozzle will cause a
more gradual increase in surface pressure.
- As the stator bearings become worn the pressure drop through the motor decreases. This
can be detected by observing a reduction in surface pressure at which the motor stalls.

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24

TURBODRILLS

The turbodrills offers several advantages over rotary

drilling for straight holes:
- Rotary torque was developed at the bit where it
was actually required.
- The turbodrill could develop more power than the
rotary system.
- The turbine could produce much faster speed.
- Since the drill string did not have to rotate there
was less wear on the drill pipe and casing.
- The turbo drills can be used for both straight wells
and deviated wells.
- The major application of the turbodrill is to drill long
tangential section of the directional wells.

Turbodrills

MOTOR DESCRIPTIONS
Stator and Rotor:
The turbine-motor, consist of a series of rotors
and stators. The rotors are blades mounted on
a vertical shaft while stators are fixed on the
body of the turbodrill. Each rotor and stator
pair is called a stage. The number of the
stages may be 25 to 250 depending up on
application. The pressure drop through each
stage should be constant. The number of
stages is therefore, limited by the total head
available. Each stage also contributes an
equal share of the total torque and total power
developed by the turbine.

Stator and Rotor Configuration of Turbodrill

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24

Flow pattern and operation of Turbodrill

As the mud is pumped through the turbine, the stator deflects the flow of the mud against the rotors
forcing them to turn clockwise direction. The upper end of the shaft is free while the lower end is
connected to the bit. The turbine blades are made of the Carbon steel having small percentage of
Chromium alloy. The blades may be positioned within an inner and outer ring to form a wheel. The
profile of the blades has an important effect on the pressure drop through the tool and overall
performance of turbine.

The minimum clearance of the turbine between rotor and stator is of the order of mill meters. Any
solid particle in the mud could easily cause clogging of the motor. A sand content of 2 % or more
could also cause excessive wear of the turbine blades. Lost circulating materials cannot be allowed
through the turbine and must be diverted through a circulating sub installed above the turbine for the
purpose.

Bearing Assembly:

There are two type of bearings. Thrust

bearings are used to with stand the axial
loads, while the radial bearings centre the
shaft during rotation. After passing through
the stages of turbine a small percentages of
flow is diverted through the lower bearing of
lubrication.

Bearings of a Turbodrill
Thrust Bearings: These resists the axial load exerted on the turbine. The simplest type of
thrust bearing consists of metal discs which slides on a bearing surface of elastomer or
synthetic rubber. The metal disc is attached to the shaft while elastomer is fixed to the bearing
supports on the onside of the body tool. There are also channels through which the drilling
fluid lubricates the bearing. The resisting torque developed in the thrust bearing is the function
of the axial load and coefficient of friction.. Thrust bearing can be located between the motor
section and the bit, thus isolating turbine blades from vibration and shock loads. In multi stage
turbines thrust bearing may be installed within each section.
Radial bearings: Radial bearings centralise the drive shaft. Elastomer pads on both inside of
the bearing support and a metal sleeve on the shaft are fitted such that a small clearance 0.5
mm exists between them. This type of bearing is also lubricated by mud.
Lower Bearing: The function of lower bearing is to centralise the lower part of the drive shaft
and to resist the bending stresses exerted on the turbine while drilling.

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
PERFORMANCE CHARACTERISTICS

Fluid flow through stator and rotor of a Turbodrill

The turbodrill is an axial flow machine where fluid energy is transferred to the rotor shaft.
There is no appreciable radial flow since the radius remains constant through out the
operation.
The absolute velocity of the fluid as it passes through the turbine can be diverted in to two
components: (a) parallel to the axis YY is denoted by Vy, and (b) tangential component IS Vt.
It is only tangential component that does the useful work of turning the rotor. As the mud
enters the turbine, it is deflected by the stator. Although there is a change in direction but no
work is done by the fluid on the stator because the stator is fixed.
Let Vt denote the initial velocity as the fluid strikes the rotor. The angle at which V1 acts with
respects to the direction of rotor movement is α1. Similarly the final velocity of the fluid be V2
acting at angle α2. From the vector diagram it can be seen that

Vt1 = Vy1 Cot α1 and Vt2 = Vy2 Cot α2 (5)

Since Vy1 = Vy2 = Vy for the continuity of axial flow the turbine the change in velocity can be
written as:
Vt2 - Vt1 = Vy (Cot α2 - Cot α1) (6)

The torque (T) produced by this force is given by:

F . = ρ . Q . (Vt2 - Vt1) (7)
T = F . r = ρ . Q . r . (Vt2 - Vt1) (8)
Power (P) can be determined from
P=T.ω (9)
Where ω is angular velocity in radians per seconds.

The tangential velocity of rotor blade is Ut that can be –

Ut = ω . r (10)
P = ρ . Q . (Ut2 . Vt2 - Ut1 . Vt1) (11)

To obtain pressure drop through turbine (ΔP) the power is divided by mass flow rate giving –
ΔP = ρ . (Ut2 . Vt2 - Ut1 . Vt1) (12)

Since r is constant Ut = Ut1 = Ut2 and the equations for torque, power and pressure drop
becomes as follows:
T = ρ . Q . r . (Vt2 - Vt1) (13)
P = ρ . Q . Ut (Vt2 - Vt1) (14)
ΔP = Ut. ρ (Vt2 - Vt1) (15)

T , P and ΔP are directly proportional to the mud density (ρ) therefore –

T α Q2 , P α Q3 and ΔP α Q2. These relations can be used to calculate the new
performance under altered parameters in field at the time of use -
T2 = T1 ( Q2 / Q1)2 . (ρ2 / ρ1) (16)
P2 = P1 ( Q2 / Q1)3 . (ρ2 / ρ1) (17)
ΔP2 = ΔP1 ( Q2 / Q1)2 . (ρ2 / ρ1) (18)

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24

In assessing the performance of a turbodrill it is important to consider how certain key parameters
are changing with respect to rotational speed. The maximum rotational speed occurs when there is
no resistance to the flow of fluid through the turbine. This is known as “runaway speed” and
corresponds to zero resisting torque. At the other extreme the turbine stalls when the rotors are
prevented from turning. The resisting torque therefore reaches a maximum between torque and
speed is approximately linear. The equation of this straight line can be expressed as-
T=mn+c
Stalling torque (TS)
Where gradient m = - [-----------------------------------]
Runaway speed (nR)
And the intercept (c) is Ts
c = Ts
The torque (T) can be given as –
T = - (Ts / nR) + Ts
T = Ts [ 1 – (n / nR) ]
The power (P) developed by the turbine is –
P=T.ω
ω = (2π / 60) . n
P = T . π . n / 30
Substituting for T gives
π.n n
P = [-----------] . [Ts - (1 - ---------)]
30 nR

π . Ts π . Ts
P = [-----------] . n - [----------] . n2
30 30 nR

π . Ts 2 . π . Ts . n
(dP/dn) = [-----------] - [-----------------------] = 0
30 30 nR

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24
The optimum rotational speed (no) can be

no = nR / 2 (19)
The maximum power is therefore obtain when
the rotational speed is exactly half of the
runaway speed
T = TS {1 – (n / nR)} (20)
P = (π . n / 30) TS {1 – (n / nR)} (21)
nO = nR / 2 (22)
PI = Q . ΔP / 1714 (23)
PO = T.n / 5252 (24)
η = PO / PI (25)
Performance curve of a Turbodrill

Short Answer Questions

1. What is a PDM and for what it is used?

2. What are components of drill string of curvature drilling using PDM.
3. What are the components of a PDM?
4. What is a Bent sub and how it differs than a normal Pin-Pin adapter?
5. What is a Dump Valve and for what it is use?
6. What is A Universal joint and for what it is used?
7. What do you mean by Lobe of a PDM?
8. What is a stage of PDM is Pitch of PDM?
9. What are the components of Bearing Assembly of a PDM and what are their
functions?
10. Define the speed and torque of PDM
11. What are the symptoms of the non-functioning PDM in the well?
12. What are the stator and rotor of a PDM?
13. What is a Turbodrill and how it differs than a PDM
14. Describe the drilling procedure with Bottom drive system.
15. Define “Runaway speed” and “Stalling torque” of turbodrill.
16. Describe the stator and Rotor of a turbodrill.

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 Department of Petroleum Engineering
Indian Institute of Technology (ISM), Dhanbad – 826004
VI Semester B.Tech Petroleum Engineering 2023-24

TUTORIAL SHEET (POSITIVE DISPLACEMENT MOTORS)

Q.1: In a single lobe PDM the motor dia 2.5 inch, the eccentricity 1.125 inch and the
length of one motor section is 48 inch. At a flow rate of 550 GPM the total pressure
drop through motor is 480 psi. If the motor efficiency is 80% Calculate the rotational
speed, the torque developed by the motor and the power output of the motor.

Q.2: From the manufacturer specification a 3 stage single lobe PDM has a rotor
diameter of 4.555 inch, eccentricity 1.5 inch and a rotor pitch of 62 inch. The available
torque is 5666 ft-lbf, calculate the pressure drop per stage in the motor.

Q.3: While drilling with a PDM at a flow rate of 200 GPM the maximum pressure drop
from the manufacturer table is 360 psi using an MWD tool the actual downhole
measurements are obtained as follows –
Torque = 460 ft-lbf, speed = 380 rpm. Calculate the efficiency of motor.

Q.4: For a 9 ½ inch single lobe PDM whose rotor diameter is 2.5 inch, length of one
stage is 50 inch and eccentricity is 1.125 inch plot power versus pressure drop for 200
– 400 psi for a range of speed 100 – 200 rpm.

Q.5: In planning a kick off the operator has selected the following parameters-
Flow rate = 550 GPM, Bit speed = 150 rpm, ΔPb = 900 psi.
Drill string + annulus pressure drop = 1800 psi
Maximum surface pressure = 3000 psi
The down hole motors which are available select the motor which fits these
requirements and calculate the power output.

TUTORIAL SHEET (TURBODRILL)

Q.1: At a flow rate of 600 GPM a turbodrill produces a torque of 3589 ft-lbf of 665 rpm.
Calculate power output and total pressure drop if efficiency is 70%.

Q.2: Specifications of a Turbodrill

ρ1 = 10 ppg Q1 = 500 GPM P1 = 263 Hp ΔP1 = 1285 psi
T1 = 2492 ft.-lbf n1 = 554 rpm
Calculate new performance with ρ2 = 12 ppg Q2 = 700 GPM

Q.3: During a lab test a turbodrill has the stalling torque 1800 ft-lbf and the runaway
speed 1500 rpm. Plot the T Vs n and P Vs n curves and determine the optimum speed
and maximum power output.

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