The Physics-Based Mud Motor PHM Solution for Enhancing Drilling Efficiency

Improving mud motor reliability is vital in the drilling industry for enhancing drilling efficiency, minimizing environmental impact, and maximizing economic profit. Despite their long history of use, mud motors remain essential in drilling operations, converting hydraulic energy into mechanical force necessary for efficient well drilling. However, their frequent failures result in costly maintenance and operational disruptions, with traditional monitoring methods falling short and leading to suboptimal maintenance practices and unexpected expensive field failures. To address these challenges, we present a pioneering prognostics and health management (PHM) solution designed specifically for mud motors. This innovative approach predicts potential fatigue failures of the mud motor power section by estimating the remaining useful life (RUL), enabling operators to perform timely maintenance and optimize drilling processes. Our developed power section PHM model employs downhole measurements together with a numerical model of the considered power section to predict the RUL of the elastomer, a critical and highly sensitive component within the power section. Our approach, implemented within the PHM model, combines a high-fidelity physics-based model with data-driven techniques, ensuring accuracy and reliability in real-time applications or for post-job maintenance. Field trials conducted in various global locations demonstrate the effectiveness of our solution, which can be seamlessly integrated into drilling platforms to streamline maintenance systems and enhance well construction planning and execution. Our PHM solution represents a significant advancement in mud motor management practices, minimizing uncertainties surrounding RUL to support informed decisions on maintenance reruns, prevent over-maintenance, and reduce costs while improving operational efficiency. This solution signifies a paradigm shift in the oil and gas industry, offering actionable insights to mitigate risks, minimize nonproductive time, and strengthen operational reliability. By delivering precise prognoses of the power section elastomer liner's health, our PHM solution holds the potential to drive substantial cost savings and operational enhancements, marking a pivotal advancement in drilling technology.