EP1892416A1 - Élastomère fortement renforcé pour une utilisation dans des stators de fond de trou - Google Patents

Élastomère fortement renforcé pour une utilisation dans des stators de fond de trou Download PDF

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Publication number
EP1892416A1
EP1892416A1 EP07253324A EP07253324A EP1892416A1 EP 1892416 A1 EP1892416 A1 EP 1892416A1 EP 07253324 A EP07253324 A EP 07253324A EP 07253324 A EP07253324 A EP 07253324A EP 1892416 A1 EP1892416 A1 EP 1892416A1
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EP
European Patent Office
Prior art keywords
stator
range
weight
parts
lobes
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP07253324A
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German (de)
English (en)
Inventor
Michael E. Hooper
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Smith International Inc
Original Assignee
Dyna Drill Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dyna Drill Technologies Inc filed Critical Dyna Drill Technologies Inc
Publication of EP1892416A1 publication Critical patent/EP1892416A1/fr
Withdrawn legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2/00—Rotary-piston machines or pumps
    • F04C2/08—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing
    • F04C2/10—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member
    • F04C2/107—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth
    • F04C2/1071—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth the inner and outer member having a different number of threads and one of the two being made of elastic materials, e.g. Moineau type
    • F04C2/1073—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth the inner and outer member having a different number of threads and one of the two being made of elastic materials, e.g. Moineau type where one member is stationary while the other member rotates and orbits
    • F04C2/1075—Construction of the stationary member
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B4/00—Drives for drilling, used in the borehole
    • E21B4/02—Fluid rotary type drives
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2225/00—Synthetic polymers, e.g. plastics; Rubber
    • F05C2225/02—Rubber

Definitions

  • This invention relates generally to Moineau style power sections useful in subterranean drilling motors, and more specifically relates a drilling motor including an improved elastomer material.
  • Moineau style hydraulic motors and pumps are conventional in subterranean drilling and artificial lift applications, such as for oil and/or gas exploration. Such motors make use of hydraulic power from drilling fluid to provide torque and rotary power, for example, to a drill bit assembly. While downhole drilling motors fall into the general category of Moineau-type motors, they are generally subject to greater working loads, temperatures, and more severe chemical and abrasive environments than Moineau motors and pumps used for other applications. As such, the demands on drilling motor components (rotor and stator components) typically far exceed the demands on the components of other Moineau-type motors and pumps.
  • drilling motors may be subject to a pressure drop (from top to bottom across the motor) of up to 1500 psi at temperatures of up to about 200 degrees C.
  • a conventional stator may exceed 25 feet in length. Achieving suitable processability (e.g., flowability) in order to injection mold the elastomer materials tends to be difficult at such lengths.
  • processability e.g., flowability
  • rubber compounds are known to deteriorate in the presence of hydrocarbons.
  • the power section of a typical Moineau style motor includes a helical rotor disposed within the helical cavity of a corresponding stator.
  • a typical stator When viewed in circular cross section, a typical stator shows a plurality of lobes in the helical cavity.
  • the rotor lobes and the stator lobes are preferably disposed in an interference fit, with the rotor including one fewer lobe than the stator.
  • fluid such as a conventional drilling fluid
  • the rotor may be coupled, for example, through a universal connection and an output shaft to a drill bit assembly. Rotation of the rotor therefore causes rotation of the drill bit in a borehole.
  • Conventional stators typically include an elastomeric helical cavity component bonded to an inner surface of a steel tube.
  • the helical cavity component in such conventional stators is made substantially entirely of elastomer (rubber) and provides a resilient surface with which to facilitate the interference fit with the rotor.
  • the elastomeric material typically includes a Nitrile Butadiene Rubber (NBR) or a variation of NBR referred to as Hydrogenated Nitrile Butadiene Rubber (HNBR) (which is also referred to in the art as Highly Saturated Nitrile (HSN)).
  • NBR and HNBR elastomers are commonly used owing to their chemical resistance, processability, mechanical properties, dynamic properties, and high temperature resistance.
  • NBR and HNBR elastomers are controlled, in part, by the acrylonitrile (ACN) content of the elastomer.
  • ACN acrylonitrile
  • Conventional elastomers used in downhole drilling motors include about 30-40% ACN. Elastomers having less than about 30% ACN typically have compromised chemical resistance, while elastomers having more than about 40% ACN typically have inadequate dynamic properties.
  • Guo discloses an elastomer having a hardness of about 74 on the Shore A scale (ASTM D2240). Guo's teaching is consistent with conventional wisdom in the art, which suggests that rigid elastomers (e.g., those having a Shore A hardness of about 90 as well as other mechanical properties described in more detail below) are not suitable for use in downhole stators due to inherently poor processability.
  • the elastomeric materials in conventional stators typically have a hardness (Shore A) in the range from 65-75.
  • Stators including a comparatively rigid helical cavity component have been developed to address this problem.
  • the use of rigid stator materials has been in part due to the above described conventional wisdom in the art and to the poor processability of known, high modulus rubbers.
  • U.S Patents 5,171,138 to Forrest and 6,309,195 to Bottos et al. disclose stators having helical cavity components in which a thin elastomer liner is deployed on the inner surface of a rigid, metallic stator former. The use of such rigid stators is disclosed to preserve the shape of the stator lobes during normal operations (i.e., to prevent lobe deformation) and therefore to improve stator efficiency and torque transmission.
  • rigid stators have been disclosed to improve the performance of downhole power sections (e.g., to improve torque output)
  • fabrication of such rigid stators is complex and expensive as compared to that of the above described conventional elastomer stators.
  • Most fabrication processes utilized to produce long, internal, multi-lobed helixes in a metal reinforced stator are tooling intensive (such as helical broaching) and/or slow (such as electric discharge machining).
  • rigid stators of the prior art are often only used in demanding applications in which the significant added expense is acceptable.
  • Comparatively rigid (resilient) elastomer helical cavity components are also known in the art (e.g., having a Shore A hardness of about 90).
  • rigid elastomers typically suffer from poor processability and poor dynamic properties, which tends to result in more difficult and costly stator fabrication and a shortened service life of the stator. Therefore, there exists a need for a downhole stator having an improved elastomeric material. In particular, there exists a need for an elastomeric material having improved rigidity while maintaining suitable processability and other properties such as dynamic properties and temperature and chemical resistance.
  • the present invention addresses one or more of the above-described drawbacks of conventional downhole drilling motors.
  • Aspects of this invention include a stator for use in a downhole drilling motor.
  • the stator includes an internal helical cavity component fabricated from an improved elastomeric material formulated to provide both high resilience and good processability.
  • the elastomer material includes at least 15 parts by weight of a phenolic resin plasticizer per 100 parts by weight of the nitrile rubber.
  • the phenolic resin plasticizer preferably further includes a hexa cross linking agent.
  • the elastomer material includes rheological parameters M L in a range from about 1.0 to about 4.0 1b ⁇ in and M H in a range from about 75 to about 110 lb ⁇ in.
  • M L and M H are representative of a minimum and maximum torque as determined according to ASTM D2084 at 380 degrees F with no preheat.
  • Exemplary embodiments of the present invention advantageously provide several technical advantages.
  • exemplary embodiments of the invention advantageously reduce the above described tradeoffs associated with elastomer material selection (in particular in regard to resilience and processability).
  • stators in accordance with this invention may exhibit improved efficiency (and may thus provide improved torque output) as compared with conventional stators without substantially increasing manufacturing costs.
  • stators in accordance with this invention may provide comparable torque output with stators including rigid metallic lobes, but at significantly reduced expense.
  • An additional benefit of exemplary embodiments of the invention is higher temperature capability due to reduced internal heat generation in the center of the lobe. Reduced heat generation also tends to reduce elastomer breakdown in the lobes and thereby prolong service life of the stator.
  • this invention includes a Moineau stator for a drilling motor.
  • the stator includes an outer tube and a helical cavity component deployed substantially coaxially in the outer tube.
  • the helical cavity component provides an internal helical cavity and includes a plurality of internal lobes.
  • the helical cavity component further includes an elastomeric material, the elastomeric material including (i) a 33-3 nitrile butadiene rubber having about 30 percent by weight acrylonitrile and a Mooney viscosity of about 30, (ii) at least 60 parts by weight carbon black per 100 parts by weight of the nitrile rubber, and (iii) at least 15 parts by weight phenolic resin plasticizer per 100 parts by weight of the nitrile rubber, the phenolic resin plasticizer further including a hexa cross linking agent.
  • the elastomeric material including (i) a 33-3 nitrile butadiene rubber having about 30 percent by weight acrylonitrile and a Mooney viscosity of about 30, (ii) at least 60 parts by weight carbon black per 100 parts by weight of the nitrile rubber, and (iii) at least 15 parts by weight phenolic resin plasticizer per 100 parts by weight of the nitrile rubber, the phenolic resin plasticizer further including a
  • this invention in another aspect, includes a Moineau stator for a drilling motor.
  • the stator includes an outer tube and a helical cavity component deployed substantially coaxially in the outer tube.
  • the helical cavity component provides an internal helical cavity and includes a plurality of internal lobes.
  • the helical cavity component is fabricated from an elastomeric material, the elastomeric material including a nitrile rubber having from about 30 to about 40 percent acrylonitrile.
  • the elastomeric material further includes rheological parameters M L in a range from about 1.0 to about 4.0 1b ⁇ in and M H in a range from about 75 to about 110 lb ⁇ in, wherein M L and M H are representative of a minimum and maximum torque as determined according to ASTM D2084 at 380 degrees F with no preheat.
  • this invention includes a method for fabricating a stator.
  • the method includes providing an elastomeric compound including a nitrile rubber having from about 30 to about 40 percent acrylonitrile.
  • the elastomeric compound further includes rheological parameters M L in a range from about 1.0 to about 4.0 1b ⁇ in and M H in a range from about 75 to about 110 lb ⁇ in, wherein M L and M H are representative of a minimum and maximum torque as determined according to ASTM D2084 at 380 degrees F with no preheat.
  • the method further includes injecting the elastomeric compound into a tubular stator housing to form a helical cavity component, the helical cavity component providing an internal helical cavity and including a plurality of internal lobes.
  • elastomeric materials with insufficient resilience undergo excessive deformation at high torque loads (due to the low rigidity of the elastomer), which allows drilling fluid to pass from one cavity to the next without producing any work. The result is a loss in rotor RPM (and therefore drill bit RPM). In severe conditions the rotor can stall in the stator.
  • material properties may be measured to determine the resilience of an elastomeric material. Such properties include, elastic modulus (e.g., at tensile strains of 25 and 100%), compression modulus (e.g., at compressive strains 5, 10, and 15%), and hardness (Shore A).
  • Mooney viscosity e.g., measured according to ASTM D1646
  • Mooney viscosities in the range from about 20 to about 60 are sometimes considered to provide suitable processability.
  • Rheological properties can also be used to determine both the processability and the resilience (rigidity) of an elastomer. For example, the minimum torque, M L , as determined via ASTM D2040, tends to be a good indicator of elastomer processability, while the maximum torque, M H , tends to be a good indicator of elastomer resilience.
  • An elastomer typically has good processability (suitable flowability at conventional injection molding temperatures) when M L is in the range from about 1.0 to about 4.0 lb ⁇ in when measured at 380 degrees F with no preheat.
  • High elastomer resilience is typically indicated when M H is in the range from about 75 to about 110 1b ⁇ in as also measured at 380 degrees F with no preheat.
  • Conventional stators typically have an M H of about 55 lb ⁇ in or less.
  • Increasing tan ⁇ typically indicates increasing viscoelastic behavior and therefore degraded dynamic properties. While there is no universally agreed upon industry standard measurement technique for determining tan ⁇ , the Applicant has found that a 250 degree F tan ⁇ value as determined in an RPA, after cure temperature sweep at a frequency of 10 Hz and a strain of 7% provides a suitable indication of the dynamic properties of a stator elastomer for use in a downhole stator. Tan ⁇ values of less than about 0.25 typically indicate suitable dynamic properties; however, the Applicant has also found that stators employing highly resilient elastomers can accommodate somewhat compromised dynamic properties via reducing the strain in the interference fit between rotor and stator.
  • Drilling motor 60 is coupled to a drill bit assembly 50 in a configuration suitable for drilling a subterranean borehole, such as in an oil and/or gas formation.
  • Drilling motor 60 includes a helical rotor 150 deployed in the helical cavity of Moineau style stator 105. The rotor 150 it operatively positioned in the cavity to cooperate with the plurality of lobes.
  • Applying fluid pressure to the cavity causes the rotor 150 to rotate in cooperation with the lobes in order to allow pressurized drilling fluid that is introduced at an upper end of the stator 105 to be expelled at the lower end and subsequently exhausted from the drill bit into a borehole. Rotation of rotor 150 causes drill bit 50 to rotate in the borehole.
  • Moineau style stator 105 includes an outer stator tube 140 (e.g., a steel tube) retaining an elastomeric helical cavity portion 110.
  • Helical cavity portion 110 is shaped to define a plurality of helical lobes 120 (and corresponding grooves) on an inner surface thereof.
  • the differing helical configurations on the rotor and the stator provide, in circular cross section, 4 lobes on the rotor and 5 lobes on the stator. It will be appreciated that this 4/5 design is depicted purely for illustrative purposes only, and that the present invention is in no way limited to any particular choice of helical configurations for the power section design.
  • helical cavity component 110 is fabricated from an improved elastomeric material that, despite the teachings and conventional wisdom in the art, is formulated to be both rigid and processable.
  • the elastomer material includes rheological parameter M L in the range from about 1.0 to about 4.0 1b ⁇ in and parameter M H in the range from about 75 to about 110 lb ⁇ in as determined via ASTM D2040 at 380 degrees F with no preheat.
  • M L may be in the range from about 1.0 to about 3.5 lb ⁇ in or even 1.0 to 3.0 1b ⁇ in at 380 degrees F with no preheat.
  • Advantageous embodiments may also include one or more of the mechanical properties in one of the ranges shown in Table I.
  • Table I Elastomeric Property Preferred Range Most Preferred Range 25% Tensile Modulus (psi) > 400 550 - 750 100% Tensile Modulus (psi) > 800 900 - 1200 5% Compression Modulus (psi) > 100 110 - 150 10% Compression Modulus (psi) > 200 225 - 325 15% Compression Modulus (psi) > 300 350 - 475 Hardness (Shore A) > 85 88 - 94
  • elastomer formulations including Nysyn 33-3 nitrile butadiene rubber (having 33 percent acrylonitrile and a Mooney viscosity of 30), at least 15 parts of a phenolic resin plasticizer per 100 parts nitrile rubber, and at least 60 parts carbon black per 100 parts nitrile rubber have been found to have both desirable resilience and processability (e.g., M L in the range from about 1.0 to about 4.0 and M H in the range from about 75 to about 110). Such formulations have also been found to have desirable dynamic properties (e.g., a 250 degree F tan ⁇ value of less than about 0.25).
  • Table II lists exemplary formulations A, B, C, and D in accordance with the present invention as well as a prior art formulation STD. It will be appreciated that this invention is not limited by the precise formulations listed in Table II. The artisan of ordinary skill will readily recognize that the various components in those formulations may be substituted with suitable equivalents.
  • Akrochem P55 phenolic resin is utilized. It will be appreciated that the invention is not limited to any particular phenolic resin. It will also be understood that Akrochem P55 also includes from about 6.5 to about 8.5 percent of a hexa cross-linking agent.
  • Table III lists characteristic properties measured for the formulations listed in Table II. These properties were determined in accordance with the test methodologies listed in Table IV. TABLE III Elastomeric Property STD A B C D Tensile Strength (psi) 2294 2093 2120 1749 2209 Ultimate Elongation (psi) 381 303 252 259 294 25% Tensile Modulus (psi) 210 323 511 695 366 100% Tensile Modulus (psi) 478 701 991 1093 873 5% Compression Modulus (psi) 56 84 108 122 -- 10% Compression Modulus (psi) 111 170 224 276 -- 15% Compression Modulus (psi) 171 261 344 423 -- Tear Strength (1b/in) 203 219 237 234 194 Hardness (Shore A) 75 84 88 91 88 Rheological Parameter M L (lb ⁇ in) 2.3 2.8 3.0 3.3 3.4 Rheological Parameter M H (l
  • the performance of three exemplary drilling motors is contrasted at a flow rate of 600 gallons per minute.
  • the three drilling motors were each sized and shaped in accordance with Dyna-Drill Model No. DD675783.0 having a length of 125 inches, an outer diameter of 6.75 inches, and a 7/8 inch lobe.
  • the drilling motors differed only in the materials used to fabricated the helical cavity component of the respective stators: (i) the conventional elastomer stator being fabricated with elastomer STD in Table II, (ii) the stator in accordance with this invention being fabricated with elastomer C shown in Table II, and (iii) a prior art stator having a Rigid, metallic helical cavity component with an elastomeric liner deployed on an inner surface thereof.
  • FIGURE 3 plots RPM versus pressure drop (psi) from the top to the bottom of the stator.
  • the drilling motor including elastomer C in accordance with this invention advantageously undergoes significantly reduced RPM drop off as compared to that of conventional drilling motor STD.
  • drilling motor C including elastomer C
  • the performance of drilling motor C even compares favorably with prior art drilling motors including a stator with an elastomer lined, rigid metallic helical cavity component (an RPM drop off of 45 rpm versus 30 rpm at 1000 psi).
  • Exemplary embodiments of this invention advantageously obviate the need for the above described tradeoff in elastomer rigidity and processability. Moreover, exemplary embodiments of this invention may even obviate the need for stators having rigid, metallic helical cavity components (except perhaps in the most demanding applications).

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  • Engineering & Computer Science (AREA)
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  • General Engineering & Computer Science (AREA)
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  • Environmental & Geological Engineering (AREA)
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EP07253324A 2006-08-25 2007-08-22 Élastomère fortement renforcé pour une utilisation dans des stators de fond de trou Withdrawn EP1892416A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/510,384 US20080050259A1 (en) 2006-08-25 2006-08-25 Highly reinforced elastomer for use in downhole stators

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EP1892416A1 true EP1892416A1 (fr) 2008-02-27

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CN104744748A (zh) * 2015-03-25 2015-07-01 江汉石油钻头股份有限公司 一种等壁厚螺杆钻具用耐油定子橡胶
EP2817485A4 (fr) * 2012-02-21 2016-05-25 Services Petroliers Schlumberger Stator élastomère renforcé de fibres

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US8734141B2 (en) * 2009-09-23 2014-05-27 Halliburton Energy Services, P.C. Stator/rotor assemblies having enhanced performance
US8777598B2 (en) 2009-11-13 2014-07-15 Schlumberger Technology Corporation Stators for downwhole motors, methods for fabricating the same, and downhole motors incorporating the same
US8523545B2 (en) * 2009-12-21 2013-09-03 Baker Hughes Incorporated Stator to housing lock in a progressing cavity pump
EP2973958A4 (fr) * 2013-03-13 2016-09-21 Services Petroliers Schlumberger Stator élastomérique très renforcé
US9133841B2 (en) 2013-04-11 2015-09-15 Cameron International Corporation Progressing cavity stator with metal plates having apertures with englarged ends
WO2014183024A1 (fr) 2013-05-09 2014-11-13 University Of Houston Synthese de composites polymere nanocharge a base de solution
RU2678265C2 (ru) * 2014-02-18 2019-01-24 РЕМЕ ТЕКНОЛОДЖИС, ЭлЭлСи Усиленный графеном эластомерный статор
CA2945511C (fr) 2015-10-13 2022-08-16 Basintek, LLC Chargement de fibre optimisee de caoutchouc utile dans les stators pdm
US9896885B2 (en) 2015-12-10 2018-02-20 Baker Hughes Incorporated Hydraulic tools including removable coatings, drilling systems, and methods of making and using hydraulic tools
US11371503B2 (en) 2019-12-16 2022-06-28 Saudi Arabian Oil Company Smart drilling motor stator
CA3115512C (fr) 2020-04-21 2023-08-22 Roper Pump Company Stator a interieur modulaire

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Cited By (3)

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Publication number Priority date Publication date Assignee Title
EP2817485A4 (fr) * 2012-02-21 2016-05-25 Services Petroliers Schlumberger Stator élastomère renforcé de fibres
US10844663B2 (en) 2012-02-21 2020-11-24 Smith International, Inc. Fiber reinforced elastomeric stator
CN104744748A (zh) * 2015-03-25 2015-07-01 江汉石油钻头股份有限公司 一种等壁厚螺杆钻具用耐油定子橡胶

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US20080050259A1 (en) 2008-02-28

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