High-power downhole motor

New high power motors are being developed by the Gas Research Institute (GRI) in an attempt to reduce drilling costs in deep gas wells. Conventional 2 3/8-in. (60-mm) and 3 3/8-in. (86-mm) motors operated in overpowered conditions (i.e., high flow rates and high differential pressures) drill 2 to 3 times faster than conventional motors. A new high-power 3 3/8-in. (86-mm) motor is being developed that utilizes additional stages and tighter interference between the rotor and stator to increase motor pressure drop, torque, and power output. This new high-power motor delivers up to 238 hp (177 kW) compared to 50 hp (37 kW) for a conventional 3 3/8-in. (86-mm) motor operating at rated operating conditions. Temperature probes showed that temperatures in different stages of motors vary considerably, showing that some sections do more work than others. A better understanding of temperatures within the stators is needed because thermal degradation and ``chunking`` of the rubber is a leading cause of failures in motors operating at high power levels. These tests were very encouraging, demonstrating the feasibility of developing reliable, high-power motors.