Steerable drilling motors still dominate US shale drilling applications. Shale well construction is commonly planned with monobore vertical, high dogleg-severity (DLS) curve and lateral sections. Limitations arise in each portion of the wellbore because one single bottomhole assembly (BHA) does not provide optimal results; hence, trips are required to optimize the BHA.
The main disadvantage with existing steerable drilling motors is the requirement for high bend-angle settings to drill the high DLS curve portion of the wellbore. The geometry of a high bend-angle motor is only optimal for slide drilling the curve, it is not optimal for drilling the vertical and lateral portions of the wellbore. While drilling the vertical and lateral portions of the well, surface RPM (revolutions per minute) must be limited to reduce the cyclic bending fatigue on the large external bend. Not to mention poor wellbore quality while rotary drilling with a large external bend.
To overcome this issue, a new geometry design was required. The new-generation motor uses a tilted internal drive mandrel aligned with a small external bend. This combination delivers the best of both worlds, providing high DLS capability while slide drilling and high surface-RPM capability while rotary drilling (because of the small external bend).
Compact embedded drilling dynamics data recorders were used to validate the dynamic improvement of the new steerable-drilling-motor geometry versus older-style geometry with large external bend. The embedded sensors recorded at-point dynamics of shock and torsional response providing detailed comparative data sets during the development phase.
The new-generation steerable-drilling-motor technology utilizes point-the-bit rotary-steerable-system (RSS) methods (for example, a tilted mandrel) with conventional steerable-motor methods (for example, an external bend). The combination of the internal tilt and external bend (aligned together) provides a completely new geometry for a steerable motor. This new geometry is beneficial for high DLS sliding capability, high surface-RPM rotary drilling and improved borehole quality (slide/rotate transition and rotary mode).
This new steerable drilling motor with enhanced geometry was utilized to prove delivery of vertical/curve/lateral in one run, consistent DLS through the curve and improved tracking in the lateral. The results from development testing (comparing to older-geometry motors) will be described in this paper.