Introduction to the Project
A customer was facing escalating costs and delays due to elastomer motor failures. The objective was clear: cut costs, reduce downtime, and complete the well in one seamless run. Full-Metal-Power answered the call with a robust metal-to-metal motor designed to handle the demanding 5 7/8” horizontal section, equipped with a Rotary Steerable System (RSS) and triple-combo LWD to reach total depth (TD) in a single, uninterrupted run.

The Challenge
Drilling a 5 7/8″ horizontal wellbore in high-density water-based mud (WBM) isn’t easy, especially with elastomer motors that break down under stress, drive up operational costs, and need constant re-lining. This job required a motor that could handle aggressive conditions without elastomer-related setbacks, enabling better reliability, lower costs, and faster rates of penetration (ROP).
The Full-Metal-Power Solution
Full-Metal-Power supplied a custom-engineered metal-to-metal motor, built to resist high temperatures, prevent degradation, and maintain consistent performance in high-stress environments. This motor operated efficiently at a flow rate of 280 GPM, continuously drilling from 10,624’ to TD at 18,537’ without any need for replacements or re-lining. The motor’s durability kept drilling steady, delivering the speed and direction required without a single hiccup.
"Switching to Full-Metal-Power’s metal-to-metal motor was a game-changer. We cut down on operational costs, eliminated constant re-lining, and boosted our rate of penetration beyond anything we’d achieved with elastomer motors. Full-Metal-Power delivered reliable performance from start to finish, no interruptions, no setbacks—just the speed and durability we needed to get the job done right."

Run Summary and Key Metrics
- Total Depth (TD) Reached: 18,537’ (7,913’ drilled in a single run).
- Total Drilling and Circulation Hours: 178 hours.
- Flow Rate: Maintained an average of 280 GPM.
This run shattered past records, achieving the highest ROP over the last two years for similar wells previously drilled with elastomer motors. The Full-Metal-Power motor not only boosted efficiency but also proved its endurance under grueling conditions, clearly outshining elastomer-based alternatives.
Results and Benefits
After the run, the motor was disassembled for inspection, showing only minor damage due to handling—no effect on performance. Full-Metal-Power’s technology didn’t just improve drilling speed and reliability; it significantly cut costs associated with elastomer failure, re-lining, and replacements.
Additional Solutions We Can Offer
Full-Metal-Power’s metal-to-metal technology is designed for high-endurance performance, ideal for environments where elastomer motors simply can’t cope. Our motors cut down on replacements, reduce re-lining needs, and keep operational costs low—transforming challenging operations into efficient, cost-effective successes.
Ready to see what Full-Metal-Power can do? Connect with us and bring your drilling operations to a whole new level.