Success stories

Full-Metal-Power’s Breakthrough in Horizontal Well Drilling

"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.

Horizontal well drilling - Full-Metal-Power

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.

Horizontal well drilling - Full-Metal-Power

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.

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.