CJ Directional Services Motor Handbook 11-7-14

Motor Handbook

Table of Contents

The purpose of this handbook is to provide technical information to successfully operate our

fleet of downhole drilling motors. It is a reference guide only; interpretation and application

of the information is the responsibility of the user. The information contained herein is subject

to change without prior notice.

Motor Handbook

November 2014

1© 2014 C&J Energy Services, Inc. All rights reserved.

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Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Motor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Selecting a Power Section . . . . . . . . . . . . . . . . . . . . . 7Power Section Operational Issues . . . . . . . . . . . . . . . 9Drilling Fluid Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Configurations and Performance . . . . . . . . . . .10-17

Fishing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Tong and Torque Diagram . . . . . . . . . . . . . . . . . . . .19

Driller Information . . . . . . . . . . . . . . . . . . . . . . . . . 20Rig Floor Motor Test - Before Tripping in Hole . . . . 20Tripping In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Drilling With the Tellus Motor . . . . . . . . . . . . . . . . . 22Tripping Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Circulating Pressure Irregularity . . . . . . . . . . . . . . . 23Motor Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Changes in Standpipe Pressure . . . . . . . . . . . . . . . . 25Changes in On- and Off-Bottom Drilling Pressure . . 26

Bit Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27-28

Table of Contents

© 2014 C&J Energy Services, Inc. All rights reserved.

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Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Motor Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Motor Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Selecting a Power Section . . . . . . . . . . . . . . . . . . . . . 7Power Section Operational Issues . . . . . . . . . . . . . . . 9Drilling Fluid Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Configurations and Performance . . . . . . . . . . .10-17

Fishing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Tong and Torque Diagram . . . . . . . . . . . . . . . . . . . .19

Driller Information . . . . . . . . . . . . . . . . . . . . . . . . . 20Rig Floor Motor Test - Before Tripping in Hole . . . . 20Tripping In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Drilling With the Tellus Motor . . . . . . . . . . . . . . . . . 22Tripping Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Circulating Pressure Irregularity . . . . . . . . . . . . . . . 23Motor Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Changes in Standpipe Pressure . . . . . . . . . . . . . . . . 25Changes in On- and Off-Bottom Drilling Pressure . . 26

Bit Grading . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27-28

C&J’s directional technology is powered by advanced drilling motors and directional tools from Tellus.

Acquired in 2013, Tellus provides industry-leading technology that helps operators drill faster, steer the bit accurately and keep the drill string in the long horizontal zones common in shale plays. All Tellus tools and systems are designed and tested in house by experienced technicians and engineers at C&J’s Research and Technology Center.

Some of the advantages obtained from the use of our motors are:

Better hole deviation control.

Increase in rate of penetration.

Reduced drill string failure rate.

Reduced casing and drill pipe wear.

Reduced wear of components above the rotary table.

Introduction

© 2014 C&J Energy Services, Inc. All rights reserved. 3

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Table of ContentsMotor Features

• Patented bearing section: By integrating the bearing and bent housing section into one internal offset design, Tellus has developed the shortest bit-to-bend motor in the industry.

• Customizable rotor/stator configurations: These configurations optimize drilling based on the formation and bit.

• PDC bearings: Featuring an on-and-off bottom design, these bearings can handle increased loading during both drilling and back reaming. They can apply higher WOB with less wear, to deliver consistent drilling for extended downhole operation.

• Rugged drive shaft: The shaft allows greater torque transmission to bit, limited only by the power section and not affected by the motor.

• Double-shouldered pin connections: These connections handle 30 to 40 percent more torque than standard connections, with less chance of backing off.


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Table of Contents

• Top sub: This component is used as a crossover between the motor assembly and the drillstring.

• Rotor catch sub: This retaining device is used to minimize the possibility of losing motor components if a connection breaks or becomes disconnected.

• Power section: All Tellus motors operate using a positive displacement power section. Its function is to convert a portion of the hydraulic energy of the drilling fluid into mechanical energy. The components of the power section are the rotor and the stator.

• Drive shaft coupling: This component converts the eccentric motion of the rotor into rotary motion and transmits the torque and the rotary motion to the bit.

• Fixed housing: This housing connects the stator housing to the bearing housing.

• Bearing pack assembly: the main components are the bearing mandrel, thrust and radial bearings, and the flow restrictors.

• Bit box: the only external component which has rotary motion independent of the rotational motion of the drill string. The drill bit is assembled directly into the bit box.

Motor Components


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6

Table of ContentsBackground

Mud motors increase the levels of RPM and torque while drilling, and are used to drive the bit. The motors increase ROP and take rotational loads off the rotary table, reducing wear on the drill string and topside rotating components.

Mud motors operate on the principle of the positive displacement pump. Fluid flows through the power section and the helical gap of the rotor within the stator, creates sealed cavities like a piston pump, and pushes the rotor in an eccentric pattern within the stator. When the bit is on bottom, flow is restricted increasing the pressure (force) that turns the rotor; this is known as differential pressure.

As the rotor moves eccentrically, it spins a drive shaft attached on one side to the rotor; the other to the bit shaft. The bit rotation and torque are directly related to the power section. The lower section of the motor serves to couple the forces from the fluid pumped into the power section to the head of the bit. The motor must be capable of extreme levels of loading and fatigue resilience, and is, in some cases, responsible for steering.

Rotation Flow

Positive Displacement Motor

Positive Displacement Motor


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Table of Contents

Selecting a Power Section

When selecting a power section, consider these factors:• RPM desired

- Off -bottom Rev/Gal * Gal/min (gpm) + Rotary Table Speed = Total RPM off-bottom

• WOB desired• Flow rate• Rig capabilities

Power sections are highly dependent on the formation and bit . Power sections have three standard types of variations:1 . Size (OD) 2 . Number of lobes

The higher the number of lobes selected, the higher the torque will be.

3 . Number of stagesThe number of stages refers to the number of full turns from one end to the other. Adding more stages produces more torque. Reducing the number of stages increases RPM but produces less torque.• High bottom hole temperature (BHT) requires

a decreased rotor/stator fit due to swell of the motor rubber under higher temperatures, tightening the fit as the motor heats up.

• Torque is related to the angle of the fluid wedge that drives in the top end of the motor; the smaller the wedge angle, the larger the force that is produced. The wedge angle depends on lobe configuration and stage length and is not directly proportional to the number of stages.

Background


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4:5High rpm

Low torque

7:8Low rpm

High torque

5:6

Increase fluid flow [flow rate]Increase

RPMLower number of lobes

Decrease volume of cavity [specific to company design]

Increase fluid pressure [differential pressure]Increase TorqueHigher number of lobes

Increase volume of cavity [specific to company design]

The rotor and stator must have the same number of stages and be approximately the same size, and the rotor must have one less lobe. Otherwise, interference will prevent either installation or intentional operation.

Selecting a Power Section

Extra stages offer a wider pressure range, higher differential capabilities, resulting in higher torque. It also improves dynamic seal but is limited by an increase in friction and thus a reduced life.


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Power Section Operational Considerations• Slip refers to high pressure fluid leaking through

sealed areas, which reduces RPM. • Stall is a point above maximum pressure seen as

a sudden increase in differential pressure, during which all of the fluid blows through the seal areas. Power sections with higher maximum pressure use a tighter R/S fit; however this tighter fit significantly reduces the life of the motor. Stall frequently occurs with excessive WOB. Operating with excessive WOB may possibly chunk the stator.

• Temperature or drilling fluid additives may cause stator elastomers to swell. LCM may plug the motor.

• Chunking and debonding cause reduced performance and failure. Recommend tripping out of hole (TOOH).

Drilling Fluid FactorsFactors that could negatively affect the performance or longevity of a power section • Level of pH: A pH<4 or >10 can damage the

power section or erode plated motor components and rubbers. After using acidic fluids, flush motor after TOOH.

• Sand content: Higher sand content increases the number of particulates, which increases erosion.

• Chlorine content (Chlorine of > 30,000 ppm): Chlorine decomposes the stator rubber.

• Amount of mud weight: Higher MW is indicative of larger number of particulates, which increases erosion.

• LCM• Operating temperature below the aniline point

for oil-based mud: The lower the aniline point (oil’s aromatic content), the greater the amount of swell the elastomer may undergo.


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10

Configurations and Performance

6 3/4 in. Tellus Drilling Motor - 4:5-7.0 Stage

SpecificationsPhysical Data (U.S. Units)

Motor O.D. (in.) 6 3/4

Lobe Configuration 4:5/7.0

Overall Length (ft) 28.5

Length to Stabilizer Center (If Stabilized (ft) 22 in.

Weight (lbs) 2,340

Bit Size Range (in.) 7 7/8 in. to 9 7/8 in.

Top Sub Connection 4 1/2 X H

Bit Box Connection 4 1/2 REG

Recommended Operating Range

Flow Range 300 gpm-600 gpm

No Load RPM 152-304

Displacement 0.51 revs/gal

Maximum Working Pressure 1,476 psi

Maximum Off-BTM Pressure 102 psi

Maximum Operating Torque 6,566 ft-lbs

Maximum Operating Pressure = Maximum Working psi - Maximum Off-BTM psi

For maximum life do not exceed 1,374 psi differential.


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6 3/4 in. 4:5 Lobe 7.0 Stage HP Group 0



Spec

ificati

on sh

eet fo

r:6 3

/4” 4:

5 Lob

e 7.0

Stag

e HP

Grou

p 0

Mode

l Num

ber

PV67

5470

-HP-

0

Theo

retic

al Pe

rform

ance

With

Wate

r at O

pera

ting T

empe

ratur

e

(in)

Loos

e

(in)

(in)

(in)

(lbs)

833.

0

6.75

5.50

7.50

214.

63.

520

2.5

PV F

luid

Pro

duct

s

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Table of ContentsConfigurations and Performance






Length to Stabilizer Center (If Stabilized) (ft) 22 in.

Weight (lbs) 2,230






No Load RPM 91-182








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Spec

ificati

on sh

eet fo

r:6 3

/4” 6:

7 Lob

e 5.0

Stag

e HP

Grou

p 0

Mode

l Num

ber

PV67

5650

-HP-

0

Theo

retic

al Pe

rform

ance

With

Wate

r at O

pera

ting T

empe

ratur

e

(in)

Loos

e

(in)

(in)

(in)

(lbs)

775

6.75

5.50 NA

7.25

200.

03.

763

3PV

Flu

id P

rodu

cts

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Weight (lbs) 2285






No Load RPM 44-89


Maximum Working Pressure 621 psi




For maximum life do not exceed 405 psi differential.


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6 3/4 in. 7:8 Lobe 3.3 Stage (Slow Speed) TR Group 0


Mode

l Num

ber

PV67

5733

-TR-

0

Theo

retic

al Pe

rform

ance

With

Wate

r at O

pera

ting T

empe

ratur

e

Spec

ificati

on sh

eet fo

r:6 3

/4” 7:

8 Lob

e 3.3

Stag

e (Sl

ow S

peed

) TR

Grou

p 0

PV F

luid

Pro

duct

s

(in)

Loos

e

(in)

(in)

(in)

(lbs)

931

6.75

5.50 NA

8.00

245.

03.

995

5

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Weight (lbs) 2160






No Load RPM 72-144








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Spec

ificati

on sh

eet fo

r:6 3

/4” 7:

8 Lob

e 5.7

Stag

e HP

Grou

p 0

Mode

l Num

ber

PV67

5757

-HP-

0

Theo

retic

al Pe

rform

ance

With

Wate

r at O

pera

ting T

empe

ratur

e

(in)

0.00

3Co

mpr

essio

n

(in)

(in)

(in)

(lbs)

974.

0

6.75

5.50

0.00

8.00

260.

04.

150

4

PV F

luid

Pro

duct

s

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Fishing Diagram

AK

Top

Sub

Powe

r Sec

tion

Trans

missi

on S

ectio

nBe

aring

Sec

tion

J

H

Z

X

GD

FB

0.0

Float

Sub

U

Y

TR

P

N

M

L

E

C

Roto

r Cat

chPo

wer S

ectio

nTra

nsmi

ssion

Sec

tion

Drive

Sha

ft

0.0


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20,000 ft-lbs

20,000 ft-lbs

25,000 ft-lbs

31,000 ft-lbs

21,000 ft-lbs

PDC Section

Bit Box

Sleeve/ Stabilizer

Drive Housing

Power Section

Top Sub

Float Sub

Tong

Tong

Tong

Do Not Tong Tong only if needed to remove or install sleeve or stabilizer .

Do Not Tong

Tong and Torque Diagram


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Driller Information

Rig Floor Motor Test - Before Tripping in Hole

Before running the motor in the hole, the motor should be tested while on the surface.

Performing the Test

• Remove the top sub and bit box thread protectors.

• Using a lift sub, pick up the motor and set it in the slips. Install a proper safety clamp and proceed to remove the lift-sub.

• Attach the kelly or top drive to the motor and remove the safety clamp.

• Lower the motor inside the hole until the gap between the top of the bit box and the bearing housing is below the flow nipple.

• Start the pumps and gradually bring the flow rate up to the desired limit. Make a note of the flow rate and the system pressure. It may be beneficial to increase the flow rate in several increments while noting the standpipe pressure each time.

• The motor vibrates vigorously at higher flow rates. This vibration is one of the characteristics of the positive displacement motors and should not be a cause for concern.

• The test is considered satisfactory if there are not any substantial flow and pressure fluctuations.

• If satisfied the motor is ready to trip into the hole, set the motor in the rotary table and place a safety clamp around top sub of motor before making up the bit. Then continue making up the next part of the BHA.


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Tripping In

• Break circulation while tripping in the hole to fill the drill pipe every 3,000 feet (fill every 2,000 ft. if mud temperatures are >/+ 200 °F). Pumping should be at a slow rate and should last long enough to allow the fluid to reach the power section.

• It is our recommendation to use at least one float valve in the bottom hole assembly to keep fluid from flowing into the motor from the opening at the bit.

• Tellus motors are equipped with a top sub that is bored for float valve insertion. If the use of a float valve is not practical, keep the drill string full at all times and trip in slowly. When stopping to fill the pipe and break circulation, take pressure readings at a flow rate close to the operating flow rate after the pipe has filled completely.

Driller Information


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Driller Information

Drilling With the Tellus Motor• After reaching the bottom of the hole, with the bit

off bottom, start the pump and slowly increase the flow rate to the desired level.

• Once circulation is established, record the standpipe pressure reading, which will be higher than the one recorded on the surface.

• If rotation of the drill string is desired, start rotating the drill string at this point.

• Slowly lower the motor to the bottom of the hole and apply weight to the bit. An increase in the standpipe pressure will be noticed and should be recorded.

• Continue to add weight to the bit and adjust rotary RPM as necessary. The difference between the on-bottom pressure and off-bottom pressure is known as the differential pressure. The pressure level should be recorded and watched closely as drilling operations continue. Consult the specifications of the motor in the Specifications section of this manual for the various motor performance characteristics.

Tripping Out• When the motor reaches the surface, flush the tool

with clean water by placing a water hose into the top sub.

• The float valve will need to be removed before running water into the top sub.

• Slowly rotate the bit box in a clockwise direction until the discharge is clear. If the bit box is locked up or there has been external damage to the motor, lay the motor down and replace all thread protectors prior to shipping.


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Cause Solution

Plugged motor or bit

Stop pumps. Restart pumps and vary flow rates. Reciprocate string. Slowly rotate motor.

Bit side-loading Drill ahead slowly to relax tool assembly – watch for change of formation.

If none of the solutions work or there is backflow [with no float valve] in making up connections, debris may be blocking drill string. May require full trip.

Cause Solution

Lost circulation Follow lost circulation procedures

Drill-string washout

Pull out of hole. Check string.

Decrease in Pressure

Describes common drilling issues and offers solutions; this is not a substitute for drilling experience.

Circulating Pressure Irregularity

Increase in Pressure

Troubleshooting


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24

Table of Contents

Motor Stall

Symptoms

High standpipe or on-bottom pressureNo ROP + high SPP

Solution

Immediately stop rotary, pull off bottom, add weight-on-bit (WOB) carefully to restart

Bit Issues

Differential pressure spike – indicative of rolling a cone, back off WOB and trip for bit change [likely on worn bits with > recommended hours]

Troubleshooting


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Table of Contents

Standpipe Pressure

Rotary Torque

Cause Solution

Decrease

DecreaseHarder formation

Optimize ROP. Continue drilling

NormalString washout

Immediately take off-bottom and trip out to check

IncreaseStabilizers reaming

Continue with caution. If unsatisfactory, pull bit

Increase

Decrease Bit ballingLift off bottom, reciprocate. Wash away balling material [circulate, pump a sweep]

Bit wear Either continue drilling or pull bit

Increase Motor StallImmediately stop rotary, pull off bottom, restart cautiously

Bearings locked

Lift off bottom, check pressure, try to drill off without rotary

Variable Variable Junk in hole Attempt to wash junk. Fish if necessary.

Changes in Standpipe Pressure

Troubleshooting


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26

Table of Contents

Flow

rat

eO

ff-

botto

m P

On-

botto

m P

Indi

cate

d W

OB

Rota

ry

Torq

ueRO

PC

ause

Solu

tion

Nor

mal

N

orm

alH

ighe

rN

orm

alH

ighe

rN

one

Mot

or s

talle

dPi

ck u

p dr

ill-s

trin

g

Low

erRo

ller

cone

bit

bear

ing

lock

ing

Trip

out

for

bit

Low

erN

orm

alLo

wer

Low

erBi

t cut

ter

wea

rEv

alua

te e

cono

mic

s; T

rip o

ut fo

r bi

t

Dril

l-str

ing

hang

ing

up R

eact

ive

torq

ue lo

wer

(orie

nted

mod

e)W

ork

drill

-str

ing

Hig

her

Low

erD

rill-s

trin

g ha

ngin

g up

Wor

k dr

ill-s

trin

g; R

eam

(rot

ary

mod

e)

Low

erLo

wer

Nor

mal

Nor

mal

Nor

mal

Lost

circ

ulat

ion

Lost

circ

ulat

ion

proc

edur

e

Low

erSu

rfac

e eq

uipm

ent w

asho

utC

heck

sur

face

equ

ipm

ent

Dril

l-str

ing

was

hout

Trip

out

look

ing

or w

asho

ut

Wor

n po

wer

sec

tion

TOO

H

Low

erH

ighe

rG

as K

ick

Wel

l con

trol p

roce

dure

Hig

her

Hig

her

Nor

mal

Nor

mal

Nor

mal

Bit p

artia

lly p

lugg

ed, c

uttin

g bu

ildup

aro

und

tool

join

tsSt

op p

umps

- r

ecip

roca

te d

rillst

ring

- re

star

t pum

ps

Dril

l pip

e sc

reen

par

tially

plu

gged

Che

ck a

nd c

lean

sys

tem

Non

eVa

lve

clos

edC

heck

sur

face

sys

tem

Mot

or /

Bit

Plug

ged

Trip

out

Hig

her

Low

erBi

t Sid

e lo

aded

Wor

k dr

ill-s

trin

g (o

rient

ed m

ode)

Re

am (r

otar

y m

ode)

Troubleshooting

Changes in On- and Off-Bottom Drilling Pressure


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Table of Contents

I Inner Cutting Structure (All inner rows)

O Outer Cutting Structure (Gauge row only)

D Dull Characteristics (cutting structure related codes)

Cutting Structure

Inner OuterDull

CharacteristicsLocation

Bearing Seals

GaugeOther Dull

CharacteristicReason Pulled

I O D L B G N/A R

BC = Broken cone NO= No dull characteristic

BF = Bond failure LC = Lost cone

BT = Broken teeth/cutters LN = Lost nozzle

BU = Balled up LT = Lost teeth/cutters

CC = Cracked cone OC = Off center wear

CD = Cone dragged PB = Pinched bit

CI = Cone interference PN = Plugged nozzle

CR = Cored RG = Rounded gauge

CT = Chipped teeth/cutters RO = Ring out

ER = Erosion SD = Shirttail damage

FC = Flat crested wear SS = Self sharpening wear

HC = Heat checking TR = Tracking

JD = Junk damage WO= Washed out bit

WT = Worn teeth/cutters

Bit Grading


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28

Table of ContentsBit Grading

L Location

Roller Cone Fixed Cutter

N = Nose row C = Cone S = Shoulder

M = Middle row N = Nose G = Gauge

G = Gauge row T = Taper A = All areas

A = All row

B Bearing Seals

Non Sealed Bearings

A linear scale estimating bearing life used.

0 - No life used

8 - All life used

Sealed Bearings

E = Seals effective

]F = Seals failed

N = Not able to grade

X = Fixed cutter bit

G Gauge

1 - In gauge

1/16 - 1/16 out of gauge



BHA = Change Bottom Hole Assembly LIH = Left in hole

CM = Condition mud LOG = Run logs

DMF = Downhole motor failure PP = Pump pressure

DP = Drill plug RIG = Rig repair

DSF = Drill string failure TD = Total depth/Casing depth

DST = Drill stem testing TQ = Torque

DTF = Down tool failure TW = Twist off

FM = Formation change WC = Weather conditions

HP = Hole problems

HR = Hours on bit

R Reason Pulled for Run Terminated


cjenergy .com

© 2014 C&J Energy Services, Inc. All rights reserved. CJES-14-046

The purpose of this handbook is to provide technical information to successfully operate our fleet of downhole drilling motors. It is a reference guide only; interpretation and application of the information is the responsibility of the user. The information contained herein is subject to change without prior notice.

Documents

CJ Directional Services Motor Handbook 11-7-14