1. Failure Modes, Inspection process, Component Tracking
Samit Gokhale

2. IADD Monthly Meeting Connection & Mud Motor Issues
NPT
IADD Monthly Meeting
Connection & Mud Motor Issues

3. Static Torque Dynamic Torque Long, long laterals mean…
…lots of torque.

4. Increase MUT beyond API Makeup Torques
That’s tough on our connections. We try to get better results with some tricks:
Increase MUT beyond API Makeup Torques
Increase torque with higher FF thread dope

5. Torque
Compression
Tension
Because the stress gets shared between two places, more torque can be applied.
Compression
Once the second shoulder engages…
Tension

6. Increased repair costs
Double Shouldered connections.
Increased repair costs
Compatibility issues across manufacturers
Mostly sized based on DP configurations
Need for industry standardized double shouldered connections

7. Mud Motor failures because of…

8. Tool Design

9. Component Manufacturing

10. Job Order

11. Component Inspection

12. Assembly & Testing

13. Field Use

14. Component Manufacturing
If you’re using a tool that’s field-proven (like mud motors), it’s unlikely that you’ve stumbled upon a fundamental design flaw.
Tool Design
Component Manufacturing
Job Order
Component Inspection
Assembly & Testing
Field Use

15. Component Manufacturing
While it’s possible that there’s a material problem, those are rare and tend to be obvious.
Tool Design
Component Manufacturing
Job Order
Component Inspection
Assembly & Testing
Field Use

16. Job Order

17. 6-3/4" mud motor
Performance
Motors aren’t all the same, so you should match the tool to the operation.

18. 6-3/4" mud motor
Environment
The motor also has to match the hole. Temperature causes the stator rubber to swell, making the fit tighter. Oil-based fluids also cause swelling.

19. Which means you have to communicate with your end user.

20. Job Order

21. Component Inspection

22. Everything in our industry is used, so inspection is an important way to ensure all our components are serviceable.

24. Tools that have been “inspected” all looks the same, so I have to control the inspection with good procedures.

25. Rig-end connections
Bodies, subs, stabilizers
Stator elastomers (borescope)

26. The shop manual can (and should) address more specific items.
SOP

27. The shop manual can (and should) address more specific items.
SOP

28. Component Inspection

29. Assembly & Testing

30. 6-3/4" mud motor
An example…
Correct number of balls Lubricated well Proper stack height

31. In many cases that only happens when an auditor forces them to do everything exactly as listed in the procedure.
SOP

32. Assembly & Testing

33. Field Use

34. Performance ranges?
Optimum
Maximum
Me!
Minimum

35. Review & Improvement

36. Component Manufacturing
Good procedures get you consistency. What you want is high quality.
Only by feeding failure information back into the system can you encourage continual improvement.
Review & Improvement
Tool Design
Component Manufacturing
Job Order
Component Inspection
Assembly & Testing
Field Use

37. Component Manufacturing
This sounds like it’s a lot of work. Because it is.
Review & Improvement
Tool Design
Component Manufacturing
Job Order
Component Inspection
Assembly & Testing
Field Use

38. Component Manufacturing
Samit Gokhale
T H Hill Associates,
(281) | office
(832) | cell
Review & Improvement
Tool Design
Component Manufacturing
Job Order
Component Inspection
Assembly & Testing
Field Use