Success stories

Eliminating Elastomer Failures with Full-Metal-Power

“Switching to Full-Metal-Power’s metal-to-metal motor transformed our operation. We cut rig days, eliminated elastomer failures, and achieved consistent performance under conditions that would’ve sidelined other motors. It’s a game-changer for efficiency and cost savings.”

Eliminating Elastomer failures - Full-Metal-Power case

Introduction to the Project

The customer needed a reliable solution to eliminate elastomer failures that were driving up operational costs and extending drilling times. These elastomer-related issues resulted in frequent downtime and added unnecessary rig days, making it challenging to maintain efficient operations. Full-Metal-Power deployed a metal-to-metal motor designed to withstand demanding downhole conditions, with the goal of completing a 5 7/8” horizontal wellbore in a single, uninterrupted run.

Eliminating Elastomer failures - Full-Metal-Power case

The Full-Metal-Power Solution

To maximize efficiency, Full-Metal-Power paired its metal-to-metal motor with Rotary Steerable technology and triple combo LWD (Logging While Drilling). The motor achieved a 7,913-foot run, drilling to a total depth (TD) of 18,537 feet at an average flow rate of 280 GPM. Unlike elastomer power sections, which had repeatedly failed over the past two years in similar operations, the Full-Metal-Power motor maintained a high ROP (Rate of Penetration), outperforming traditional elastomer motors in both speed and resilience. This deployment allowed the customer to avoid the need for frequent re-lining and other elastomer-related downtime, proving the motor’s superior performance and reliability.

The Outcome

  • Operational Efficiency: The operation was completed in 178 hours of drilling and circulation, reducing the time spent on-site and cutting down rig days. The high ROP enabled the customer to achieve TD faster than previous runs with elastomer-based motors.
  • Durability: On post-run inspection, only minor surface damage was noted on the motor, attributed to handling rather than performance wear. This resilience underscored the motor’s ability to perform consistently in harsh conditions, unlike elastomer motors that degrade and fail under similar stresses.
  • Cost Savings: By removing elastomer-related failures from the equation, the operation saw substantial cost savings. Reduced downtime, fewer rig days, and minimized maintenance needs all contributed to lowering overall operational expenses.

Conclusion

Full-Metal-Power’s metal-to-metal motor delivered a robust, cost-effective alternative to elastomer motors, proving its value in challenging well environments. Its resilience against wear and consistent high performance under demanding conditions allowed the customer to achieve operational targets with greater speed and efficiency. This case demonstrates how Full-Metal-Power’s technology not only solves common elastomer issues but also sets a new standard in high-performance drilling.

Interested in transforming your drilling operations? Connect with Full-Metal-Power and discover a future without elastomer failures.

More case studies

Proven performance in 37 countries

Proven in 37 countries, Full-Metal-Power’s metal-to-metal tech doesn’t just perform—it dominates. From geothermal to oil and gas, we eliminate elastomer failures and push efficiency to new heights, making sure your operations run harder, faster, and smarter, no matter the challenge.