US20110129375A1 - Work extraction from downhole progressive cavity devices - Google Patents
Work extraction from downhole progressive cavity devices Download PDFInfo
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- US20110129375A1 US20110129375A1 US12/742,465 US74246508A US2011129375A1 US 20110129375 A1 US20110129375 A1 US 20110129375A1 US 74246508 A US74246508 A US 74246508A US 2011129375 A1 US2011129375 A1 US 2011129375A1
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- Prior art keywords
- drive
- rotor shaft
- rotor
- shaft
- rotation
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- 230000000750 progressive effect Effects 0.000 title claims abstract description 18
- 238000000605 extraction Methods 0.000 title description 2
- 238000000034 method Methods 0.000 claims abstract description 8
- 230000033001 locomotion Effects 0.000 claims abstract description 6
- 239000012530 fluid Substances 0.000 claims description 22
- 238000005553 drilling Methods 0.000 claims description 12
- 230000005611 electricity Effects 0.000 claims description 3
- 238000005086 pumping Methods 0.000 claims description 3
- 238000010008 shearing Methods 0.000 claims description 2
- 238000005520 cutting process Methods 0.000 description 3
- 230000009977 dual effect Effects 0.000 description 3
- 239000004576 sand Substances 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 2
- 239000000806 elastomer Substances 0.000 description 2
- 238000010079 rubber tapping Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000013536 elastomeric material Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP 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
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/12—Methods or apparatus for controlling the flow of the obtained fluid to or in wells
- E21B43/121—Lifting well fluids
- E21B43/128—Adaptation of pump systems with down-hole electric drives
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01C—ROTARY-PISTON OR OSCILLATING-PISTON MACHINES OR ENGINES
- F01C1/00—Rotary-piston machines or engines
- F01C1/08—Rotary-piston machines or engines of intermeshing engagement type, i.e. with engagement of co- operating members similar to that of toothed gearing
- F01C1/10—Rotary-piston machines or engines 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
- F01C1/107—Rotary-piston machines or engines 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01C—ROTARY-PISTON OR OSCILLATING-PISTON MACHINES OR ENGINES
- F01C21/00—Component parts, details or accessories not provided for in groups F01C1/00 - F01C20/00
- F01C21/008—Driving elements, brakes, couplings, transmissions specially adapted for rotary or oscillating-piston machines or engines
-
- 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
- F04C13/00—Adaptations of machines or pumps for special use, e.g. for extremely high pressures
- F04C13/008—Pumps for submersible use, i.e. down-hole pumping
-
- 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
Definitions
- This invention relates to techniques for extracting work from progressive cavity devices such as pumps (PCPs) and motors (PDMs).
- PCPs pumps
- PDMs motors
- the invention relates to such techniques for use with downhole devices such as are used in wells in the oil and gas industry.
- PCPs and PDMs comprise a hollow cylindrical stator with an elongate rotor positioned therein.
- the stator has helical lobes formed on its inner surface, typically formed from some elastomeric material.
- the rotor has helical lobes formed on its outer surface. As is explained below, the number of lobes and their helical pitch are different for the rotor and stator of any pump or motor.
- the term ‘progressive cavity device’ is used here to mean any such device, whether configured as a pump or as a motor. Progressive cavity devices are used in oilfield applications in two major segments: artificial lift and drilling. They have shown a high life if designed and dimensioned properly, and have demonstrated acceptable tolerance to finer solids (such as LCM during drilling and sand during production).
- the rotor and stator axes of a progressive cavity device are eccentric to each other, leading to a rotation of the rotor inside the stator with a simultaneous nutation of the rotor centreline to the stator centreline.
- an electric motor drives the rotor through a eccentric universal joint to allow for the eccentricity of the rotor to the centre.
- the flow of drilling fluid through the device forces the rotor to rotate inside the stator, leading to a rotation of the drillbit through a double universal joint system or a flexible drive shaft.
- the configuration of the rotor/stator lobes is one-off (e.g. 1:2, 3:4, 7:8) and this ratio can be used to calculate the nutation speed of the rotor around the centreline of the stator given the rotation speed of the rotor on itself.
- the nutation rotation direction is opposite to that of the rotor rotation.
- a first aspect of the invention provides a progressive cavity device comprising a hollow stator having a rotor shaft positioned therein, wherein the rotor shaft is provided with rotating motion drive connections at both ends thereof.
- the drive connections can be for driving the rotor shaft or for extracting drive from rotation of the rotor shaft.
- at least one of the drive connections operates at a speed that is different to the rotation speed of the shaft.
- the drive connections can couple to the rotation of the shaft.
- Such drive connections preferably comprise a shaft connecting two universal joints, or a flexible shaft.
- the drive connections can couple to the nutation of the shaft.
- Such drive connections can include a non-nutating connection that imposes a nutation speed on the shaft.
- Such a drive connection can comprise a disc mounted for rotation on a further shaft, the rotor shaft being connected eccentrically to the disc.
- Nutating connections can include, for example, a planetary gear system, the rotor shaft being connected to a planet gear.
- the device can be configured to act as a motor or as a pump.
- the rotor When configured as a motor, the rotor is driven by pumping fluid through the stator, and a rotating drive connection is taken from both ends of the stator to power other devices.
- the drive at one end is used to rotate a drill bit.
- the drive at the other end can be used to power a crushing device or an electricity generating device.
- the rotor When configured as a pump, the rotor is driven by a drive connection from a motor at one end and a rotating drive connection is taken from the other end of the rotor to power other devices.
- a rotating drive connection Examples of preferred devices to be powered via the rotating drive connection include fluid air mixers, crushing devices, reaming or drilling devices and fluid mixing/shearing devices.
- This invention provides methods of tapping to and extracting rotation at both ends of a progressive cavity device rotor.
- This rotation can be extracted at various rates and used to perform simultaneous operations with the use of only one pump or motor. Even when one end of the pump is what drives the rotor to create a fluid circulation, the other end can be used to perform additional work, without the need for another hydraulic or electric motor being added.
- Potential applications exist in various oilfield segments.
- FIGS. 1 and 2 show axial and radial sections of rotor/stator combinations for progressive cavity devices
- FIG. 3 shows one embodiment of a non-nutating drive connection
- FIG. 4 shows another embodiment of a non-nutating drive connection
- FIGS. 5 and 6 show embodiments of progressive cavity devices with drive connections at both ends of the rotor.
- This invention provides techniques for tapping to and extracting rotation of both ends of a progressive cavity device rotor. For example, this rotation can be used for a cuttings crusher at the entrance of the device, or for a gas/fluid agitator at the end of a downhole pump. This invention describes how different output speeds can be utilized in various oilfield applications.
- the power section of a downhole motor converts hydraulic energy from the drilling fluid into mechanical energy to turn the bit.
- the positive displacement motors operate by using the surface pumps to force the drilling fluid between a helical shaft, and a sealing sheath.
- the helical shaft is rotated by the fluid and is called the “rotor”, while the sheath is fixed and called the “stator.”
- the stator is connected to the rest of the drill-string (or a Coiled Tubing) via the top sub.
- the inertia of the drill string counters the torque created by the operation of the motor.
- the stator will only rotate when the drill string is rotated when driven from the surface.
- a relatively known and constant amount of rotation is required to pass a fixed volume of fluid through the system, so the motor rotation, or revolutions per minute (rpm), is proportional to the flow rate.
- rpm revolutions per minute
- FIGS. 1 and 2 show axial and radial sections of rotor/stator combinations.
- the rotor 10 has a single lobe and the stator 12 has two lobes 14 (ratio 1:2).
- the rotor 16 has five lobes 18 and the stator 20 has six lobes 22 (ratio 5:6).
- the power section of such a downhole motor is designated by the ratio of its rotor/stator lobes. For example, a 4:5 power section has four lobes in the rotor and five in the stator.
- Motors such as the PowerPak range of motors from Schlumberger are available in 1:2, 2:3, 3:4, 4:5, 5:6, and 7:8 lobe configurations.
- the ratio of the rotor/stator helical pitch is the same as the ratio of the rotor/stator lobes.
- the stator pitch of a current commercial 5:6 lobe motor is 52.70 in, and the pitch of its rotor is (5 ⁇ 6) ⁇ 52.70 in, or 43.92 in.
- the rotor and stator form a continuous seal at their contact points, producing cavities independent from each other.
- fluid water, mud, or air
- the rotor causes the rotor to move around inside the stator.
- the movement is the combination of rotation and nutation.
- the rotor nutates once for each of the rotor lobes. Therefore, nutation creates mechanical stresses on the motor at a much higher rate than the rotation itself, and becomes a limiting factor in many cases.
- a motor with 7:8 rotor/stator lobe configuration rotating at 100 rpm has a nutation speed of 700 cycles/minute.
- an electric motor is usually situated below the PCP pump and is driven via electrical cables running from the surface.
- an electric motor is placed above the PC pump and drives it to create a fluid circulation to carry the cuttings.
- This same pump can also be used in to create a vacuum in low bottomhole pressure reservoirs for sand and debris cleanout operations.
- the drive input or output connects to the rotor shaft axis such that one rotation of the shaft equates to one rotation at the drive connection.
- the connection can be via a non-nutating drive as shown in FIG. 3 that rotates (or dictates) the rotor *nutation* speed.
- the end of the rotor shaft 40 projects from the stator which comprises a metal housing 42 having an elastomeric insert defining the lobe structure 44 (the example shown here is a 1:2 system for simplicity, other ratios are equally applicable).
- the non-nutating drive comprises a nutation disc 46 fixed to the end of a shaft 48 which is itself mounted in bearings 50 for rotation.
- the end of the rotor shaft 40 connects to the nutation disc 46 by means of a rotation bearing 52 which is offset from the disc centre.
- the rotor shaft 40 is driven to rotate about its axis in direction ⁇ R whereas the nutation at the end of the rotor 40 is coupled via the disc 46 such that the shaft 48 rotates in the opposite, nutation direction ⁇ N .
- the shaft 48 is the one that could be driven by a motor, the non-nutating connection being used to provide a drive input to the rotor, typically when acting in a pump configuration.
- a faster spinning (and therefore more efficient) electrical motor can be used to rotate a pump at a lower rpm.
- the rotation of the bit can be at the faster nutation rate, and allows use of faster-turning bits without the necessity for a high rotor rotation rate.
- Typical rotation rates for drilling bits are in 100-300 rpm.
- the nutation is used as the drive via the non-nutating connection, then for a 300 rpm rotation of the bit, only a 150 rpm rotor rotation would be required.
- the decreased torque penalty can be offset by providing additional (longer) motor stages for example.
- the nutation of the rotor can be used to drive (or be driven by) the planet carrier of a planetary gearbox at the rotor nutation speed.
- the rotation of the planet carrier with respect to the sun gear (or output/input shaft) via the planets and the relationship of the planet and sun teeth, can dictate the output shaft rotation as a fixed proportion of the nutation speed.
- the nutation disc of FIG. 3 is replaced by a planetary gear arrangement which comprises a non-rotating housing 60 having the ring gear 62 fixed thereto.
- the sun gear 64 is fixed to the shaft 48 .
- the end of the rotor shaft 40 connects to a planet gear 66 mounted on a planet carrier 68 (further idler planet gears (not shown) may also be mounted on the carrier 68 ).
- the shaft 48 rotates in the same direction as the rotor shaft 40 rotates (due to the reversing effect of the gears), but at a rate f ⁇ N that is a function of the nutation dependent on the gear ratios in the planetary gear system.
- the shaft rotation is coaxial with the drive axis of the motor/pump.
- connections are provided at both ends of the rotor of a progressive cavity pump, therefore allowing work to be extracted above and below the pump (without the need to run electrical wires and drive additional electrical motors, or the need to add two hydraulic motors).
- a similar benefit is the use of the upper rotation of the rotor when the lower part is attached to a driving electrical motor via a gearbox.
- FIGS. 5 and 6 show embodiments using such techniques for connecting to both ends of the rotor of a progressive cavity device.
- one end of the rotor 40 is connected to a load/motor 70 by means of a connection shaft 72 having universal joints 74 at the shaft and load/motor ends.
- the other end of the rotor shaft 40 is connected to a second load/motor 76 by means of a flexible shaft 78 .
- the loads/motors 70 , 76 are driven/drive at the same rate and direction ⁇ R as the rotor 40 .
- the load/motor 70 is connected to the rotor 40 by means of a non-nutating connection 80 of the type described above in relation to FIG. 3 .
- the load/motor 76 is connected to the rotor 40 by means of a dual universal joint connection 82 of the type described above in relation to FIG. 5 .
- the load/motor 70 operates at the nutation rate, i.e. in the opposite direction to the rotor shaft rotation and at a rate ⁇ N , whereas the load/motor 76 operates at the same rate and direction ⁇ R as the rotor 40 .
Abstract
A progressive cavity device and method of use are provided, the progressive cavity device comprising a hollow stator having a rotor shaft positioned therein. The rotor shaft is provided with rotating motion drive connections at both ends thereof.
Description
- The present application is based on and claims priority to GB Application No. 0722445.4, filed 15 Nov. 2007; and International Patent Application No. PCT/EP2008/009607, filed 6 Nov. 2008. The entire contents of each are herein incorporated by reference.
- This invention relates to techniques for extracting work from progressive cavity devices such as pumps (PCPs) and motors (PDMs). In particular the invention relates to such techniques for use with downhole devices such as are used in wells in the oil and gas industry.
- PCPs and PDMs comprise a hollow cylindrical stator with an elongate rotor positioned therein. The stator has helical lobes formed on its inner surface, typically formed from some elastomeric material. The rotor has helical lobes formed on its outer surface. As is explained below, the number of lobes and their helical pitch are different for the rotor and stator of any pump or motor. The term ‘progressive cavity device’ is used here to mean any such device, whether configured as a pump or as a motor. Progressive cavity devices are used in oilfield applications in two major segments: artificial lift and drilling. They have shown a high life if designed and dimensioned properly, and have demonstrated acceptable tolerance to finer solids (such as LCM during drilling and sand during production).
- In both cases, the rotor and stator axes of a progressive cavity device are eccentric to each other, leading to a rotation of the rotor inside the stator with a simultaneous nutation of the rotor centreline to the stator centreline. In the case of artificial lift, an electric motor drives the rotor through a eccentric universal joint to allow for the eccentricity of the rotor to the centre. In the case of drilling motors, the flow of drilling fluid through the device forces the rotor to rotate inside the stator, leading to a rotation of the drillbit through a double universal joint system or a flexible drive shaft. The configuration of the rotor/stator lobes is one-off (e.g. 1:2, 3:4, 7:8) and this ratio can be used to calculate the nutation speed of the rotor around the centreline of the stator given the rotation speed of the rotor on itself. The nutation rotation direction is opposite to that of the rotor rotation.
- A first aspect of the invention provides a progressive cavity device comprising a hollow stator having a rotor shaft positioned therein, wherein the rotor shaft is provided with rotating motion drive connections at both ends thereof.
- The drive connections can be for driving the rotor shaft or for extracting drive from rotation of the rotor shaft. Preferably, at least one of the drive connections operates at a speed that is different to the rotation speed of the shaft.
- The drive connections can couple to the rotation of the shaft. Such drive connections preferably comprise a shaft connecting two universal joints, or a flexible shaft. Alternatively, the drive connections can couple to the nutation of the shaft. Such drive connections can include a non-nutating connection that imposes a nutation speed on the shaft. Such a drive connection can comprise a disc mounted for rotation on a further shaft, the rotor shaft being connected eccentrically to the disc. Nutating connections can include, for example, a planetary gear system, the rotor shaft being connected to a planet gear.
- The device can be configured to act as a motor or as a pump. When configured as a motor, the rotor is driven by pumping fluid through the stator, and a rotating drive connection is taken from both ends of the stator to power other devices. In a preferred embodiment, the drive at one end is used to rotate a drill bit. The drive at the other end can be used to power a crushing device or an electricity generating device.
- When configured as a pump, the rotor is driven by a drive connection from a motor at one end and a rotating drive connection is taken from the other end of the rotor to power other devices. Examples of preferred devices to be powered via the rotating drive connection include fluid air mixers, crushing devices, reaming or drilling devices and fluid mixing/shearing devices.
- This invention provides methods of tapping to and extracting rotation at both ends of a progressive cavity device rotor. This rotation can be extracted at various rates and used to perform simultaneous operations with the use of only one pump or motor. Even when one end of the pump is what drives the rotor to create a fluid circulation, the other end can be used to perform additional work, without the need for another hydraulic or electric motor being added. Potential applications exist in various oilfield segments.
-
FIGS. 1 and 2 show axial and radial sections of rotor/stator combinations for progressive cavity devices; -
FIG. 3 shows one embodiment of a non-nutating drive connection; -
FIG. 4 shows another embodiment of a non-nutating drive connection; and -
FIGS. 5 and 6 show embodiments of progressive cavity devices with drive connections at both ends of the rotor. - This invention provides techniques for tapping to and extracting rotation of both ends of a progressive cavity device rotor. For example, this rotation can be used for a cuttings crusher at the entrance of the device, or for a gas/fluid agitator at the end of a downhole pump. This invention describes how different output speeds can be utilized in various oilfield applications.
- The power section of a downhole motor converts hydraulic energy from the drilling fluid into mechanical energy to turn the bit. Using the reverse Moineau pump principle, the positive displacement motors operate by using the surface pumps to force the drilling fluid between a helical shaft, and a sealing sheath. The helical shaft is rotated by the fluid and is called the “rotor”, while the sheath is fixed and called the “stator.” The stator is connected to the rest of the drill-string (or a Coiled Tubing) via the top sub. Thus the inertia of the drill string counters the torque created by the operation of the motor. The stator will only rotate when the drill string is rotated when driven from the surface.
- A relatively known and constant amount of rotation is required to pass a fixed volume of fluid through the system, so the motor rotation, or revolutions per minute (rpm), is proportional to the flow rate. A small part of the flow ‘bypasses’ doing rotary work as it leaks through the rotor and stator contact line from a high-pressure cavity to an adjacent low-pressure cavity.
- Both rotor and stator have matching helical profiles, but the rotor has one less spiral (or lobe) than the stator.
FIGS. 1 and 2 show axial and radial sections of rotor/stator combinations. InFIG. 1 , therotor 10 has a single lobe and thestator 12 has two lobes 14 (ratio 1:2). InFIG. 2 , therotor 16 has fivelobes 18 and thestator 20 has six lobes 22 (ratio 5:6). The power section of such a downhole motor is designated by the ratio of its rotor/stator lobes. For example, a 4:5 power section has four lobes in the rotor and five in the stator. Motors such as the PowerPak range of motors from Schlumberger are available in 1:2, 2:3, 3:4, 4:5, 5:6, and 7:8 lobe configurations. The ratio of the rotor/stator helical pitch is the same as the ratio of the rotor/stator lobes. For example, the stator pitch of a current commercial 5:6 lobe motor is 52.70 in, and the pitch of its rotor is (⅚)×52.70 in, or 43.92 in. - In an assembled power section, the rotor and stator form a continuous seal at their contact points, producing cavities independent from each other. As fluid (water, mud, or air) is forced through these progressive cavities, it causes the rotor to move around inside the stator. The movement is the combination of rotation and nutation. When completing a revolution, the rotor nutates once for each of the rotor lobes. Therefore, nutation creates mechanical stresses on the motor at a much higher rate than the rotation itself, and becomes a limiting factor in many cases. As an example, a motor with 7:8 rotor/stator lobe configuration rotating at 100 rpm has a nutation speed of 700 cycles/minute.
- In the case of an artificial lift pump, an electric motor is usually situated below the PCP pump and is driven via electrical cables running from the surface.
- Finally, in the case of a circulation pump in a wireline powered and conveyed drilling machine, an electric motor is placed above the PC pump and drives it to create a fluid circulation to carry the cuttings. This same pump can also be used in to create a vacuum in low bottomhole pressure reservoirs for sand and debris cleanout operations.
- There are a number of ways in which the concept of this invention can be implemented. In a conventional drive connection, the drive input or output connects to the rotor shaft axis such that one rotation of the shaft equates to one rotation at the drive connection. In one embodiment of the invention, instead of connecting to the rotor centre to extract or create the rotation, the connection can be via a non-nutating drive as shown in
FIG. 3 that rotates (or dictates) the rotor *nutation* speed. In this embodiment, the end of therotor shaft 40 projects from the stator which comprises ametal housing 42 having an elastomeric insert defining the lobe structure 44 (the example shown here is a 1:2 system for simplicity, other ratios are equally applicable). The non-nutating drive comprises anutation disc 46 fixed to the end of ashaft 48 which is itself mounted inbearings 50 for rotation. The end of therotor shaft 40 connects to thenutation disc 46 by means of a rotation bearing 52 which is offset from the disc centre. In use, where the rotor is being driven by fluid flow or a motor attached to the other end of the rotor (not shown), therotor shaft 40 is driven to rotate about its axis in direction ωR whereas the nutation at the end of therotor 40 is coupled via thedisc 46 such that theshaft 48 rotates in the opposite, nutation direction ωN. Alternatively, theshaft 48 is the one that could be driven by a motor, the non-nutating connection being used to provide a drive input to the rotor, typically when acting in a pump configuration. - Using the embodiment of
FIG. 3 , a faster spinning (and therefore more efficient) electrical motor can be used to rotate a pump at a lower rpm. In the case of a downhole motor, the rotation of the bit can be at the faster nutation rate, and allows use of faster-turning bits without the necessity for a high rotor rotation rate. Typical rotation rates for drilling bits are in 100-300 rpm. Thus, when connecting directly to the rotor shaft rotation for drive, a 200-600 rpm nutation of the rotor in the stator (of a 1:2 motor) must be accommodated, increasing the fatigue stresses on the stator elastomer. If the nutation is used as the drive via the non-nutating connection, then for a 300 rpm rotation of the bit, only a 150 rpm rotor rotation would be required. The decreased torque penalty can be offset by providing additional (longer) motor stages for example. - In another embodiment, as shown in
FIG. 4 , the nutation of the rotor can be used to drive (or be driven by) the planet carrier of a planetary gearbox at the rotor nutation speed. The rotation of the planet carrier with respect to the sun gear (or output/input shaft) via the planets and the relationship of the planet and sun teeth, can dictate the output shaft rotation as a fixed proportion of the nutation speed. In the embodiment ofFIG. 4 , the nutation disc ofFIG. 3 is replaced by a planetary gear arrangement which comprises a non-rotating housing 60 having thering gear 62 fixed thereto. Thesun gear 64 is fixed to theshaft 48. The end of therotor shaft 40 connects to aplanet gear 66 mounted on a planet carrier 68 (further idler planet gears (not shown) may also be mounted on the carrier 68). In this case, theshaft 48 rotates in the same direction as therotor shaft 40 rotates (due to the reversing effect of the gears), but at a rate fωN that is a function of the nutation dependent on the gear ratios in the planetary gear system. - In the embodiments of both
FIG. 3 andFIG. 4 , the shaft rotation is coaxial with the drive axis of the motor/pump. - In another embodiment of the invention, connections are provided at both ends of the rotor of a progressive cavity pump, therefore allowing work to be extracted above and below the pump (without the need to run electrical wires and drive additional electrical motors, or the need to add two hydraulic motors). A similar benefit is the use of the upper rotation of the rotor when the lower part is attached to a driving electrical motor via a gearbox.
- Apart from or in addition to the extraction methods of the nutation speed from the rotor described above, methods of torque and rotation transmission that are currently used in other technologies can also be used; such as through a dual universal joint configuration, or through a flexible shaft that can flex to accommodate the full offset of the rotor nutation. The flexible shaft is subjected to higher fatigue loads, but has neither moving nor rubbing parts as the universal joints do.
-
FIGS. 5 and 6 show embodiments using such techniques for connecting to both ends of the rotor of a progressive cavity device. InFIG. 5 , one end of therotor 40 is connected to a load/motor 70 by means of aconnection shaft 72 havinguniversal joints 74 at the shaft and load/motor ends. The other end of therotor shaft 40 is connected to a second load/motor 76 by means of aflexible shaft 78. In both cases, the loads/motors rotor 40. InFIG. 6 , the load/motor 70 is connected to therotor 40 by means of anon-nutating connection 80 of the type described above in relation toFIG. 3 . The load/motor 76 is connected to therotor 40 by means of a dual universaljoint connection 82 of the type described above in relation toFIG. 5 . In this case, the load/motor 70 operates at the nutation rate, i.e. in the opposite direction to the rotor shaft rotation and at a rate ωN, whereas the load/motor 76 operates at the same rate and direction ωR as therotor 40. - There are a number of ways in which the embodiments of the invention can be implemented to involve fluid flow turning the rotor and in turn a drill bit below, but with the added benefit of a rotation above the motor that can be used for grinding or for reaming for example. For a pump, an electrical motor below can create the rotor rotation, and the rotation above the pump can be used to drive a fluid/air mixer to ease dual phase reservoir fluid lift.
- The ability to drive the rotor from either end and to extract rotating motion from the other (at rotation or nutation speeds) allows for a multitude of applications. Such applications include:
-
- for drilling applications: using a hydraulic motor to drive a drill bit at a lower end, and using upper end rotation/nutation to drive a crusher to protect the stator elastomer by reducing solids size; or using upper end [higher] nutation speed to power an alternator and create electricity to power sensors and actuators (such as for a flow bypass), without having to use power from the power system of an associated MWD tool;
- for artificial lift applications: using an electric motor below to drive the artificial lift pump, with a fluid/air mixer above to facilitate lift; or using an electric motor above to drive the pump, and a crusher below to break, or detain and grind larger rocks before they enter the pump;
- for wireline drilling and lateral construction applications: using an electric motor to drive a fluid circulation pump, and a cuttings crusher below to assure that only small particles enter the pump section; or using an electric motor to drive a circulation pump, and using upper rotor rotation or nutation to drive a backreamer;
- for a wired Coiled Tubing well cleaning application; using an electric motor to drive a vacuum/suction pump, and using lower rotor rotation or nutation to mobilize sand or thick muds (to break the thixotropy).
- These are just preferred examples of embodiments of the invention and other changes within the scope of the invention will be apparent.
Claims (18)
1. A progressive cavity device comprising a hollow stator having a rotor shaft positioned therein, wherein the rotor shaft is provided with rotating motion drive connections at both ends thereof.
2. The device as claimed in claim 1 , wherein the drive connections are adapted to drive the rotor shaft.
3. The device as claimed in claim 1 , wherein the drive connections are adapted to extract drive from rotation of the rotor shaft.
4. The device as claimed in claim 1 , wherein at least one of the drive connections operates at a speed that is different to the rotation speed of the rotor shaft.
5. The device as claimed in claim 1 , wherein the drive connections couple to the rotation of the shaft.
6. The device as claimed in claim 5 , wherein the drive connections comprise a shaft connecting two universal joints.
7. The device as claimed in claim 5 , wherein the drive connections comprise a flexible shaft.
8. The device as claimed in claim 1 , wherein the drive connections couple to the nutation of the rotor shaft.
9. The device as claimed in claim 8 , wherein the drive connections comprise a non-nutating connection that imposes a nutation speed on the rotor shaft.
10. The device as claimed in claim 9 , wherein the drive connections comprise a disc mounted for rotation on a further shaft, the rotor shaft being connected eccentrically to the disc.
11. The device as claimed in claim 8 , wherein the drive connections comprise a planetary gear system, the rotor shaft being connected to a planet gear.
12. The device as claimed in claim 1 , configured to act as a motor or as a pump.
13. The device as claimed in claim 12 , wherein when configured as a motor, the rotor shaft is driven by pumping fluid through the hollow stator, and a rotating drive connection is taken from both ends of the hollow stator to power other devices.
14. The device as claimed in claim 13 , wherein the drive at one end is used to rotate a drill bit.
15. The device as claimed in claim 14 , wherein the drive at the other end is used to power a crushing device or an electricity generating device.
16. The device as claimed in claim 12 , wherein when configured as a pump, the rotor shaft is driven by a drive connection from a motor at one end and a rotating drive connection is taken from the other end of the rotor shaft to power other devices.
17. The device as claimed in claim 16 , wherein the other devices to be powered via the rotating drive connection comprise fluid air mixers, crushing devices, reaming or drilling devices and fluid mixing/shearing devices.
18. A method for powering a crushing device in a wellbore, comprising the steps of:
positioning a progressive cavity device in the wellbore, the progressive cavity device comprising a hollow stator having a rotor shaft positioned therein, wherein the rotor shaft is provided with rotating motion drive connections at both ends thereof;
driving the rotor shaft by pumping fluid through the hollow stator; and
powering a crushing device by means of a rotating drive connection taken from both ends of the hollow stator.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0722445.4A GB2454700B (en) | 2007-11-15 | 2007-11-15 | Work extraction from downhole progressive cavity devices |
GB0722445.4 | 2007-11-15 | ||
PCT/EP2008/009607 WO2009062717A2 (en) | 2007-11-15 | 2008-11-06 | Work extraction from downhole progressive cavity devices |
Publications (1)
Publication Number | Publication Date |
---|---|
US20110129375A1 true US20110129375A1 (en) | 2011-06-02 |
Family
ID=38896369
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/742,465 Abandoned US20110129375A1 (en) | 2007-11-15 | 2008-11-06 | Work extraction from downhole progressive cavity devices |
Country Status (3)
Country | Link |
---|---|
US (1) | US20110129375A1 (en) |
GB (1) | GB2454700B (en) |
WO (1) | WO2009062717A2 (en) |
Cited By (13)
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US20120201659A1 (en) * | 2011-02-08 | 2012-08-09 | Halliburton Energy Services Inc. | Multiple motor/pump array |
WO2013158096A1 (en) * | 2012-04-19 | 2013-10-24 | Halliburton Energy Services Inc. | Drilling assembly with high-speed motor gear system |
US20140005637A1 (en) * | 2012-06-30 | 2014-01-02 | Elite Body Sculpture | Laser Nil Liposuction System and Method |
WO2014182312A1 (en) | 2013-05-10 | 2014-11-13 | Halliburton Energy Services, Inc. | Positionable downhole gear box |
US9045942B2 (en) | 2012-06-20 | 2015-06-02 | Drilformance Technologies, Llc | Downhole motor assembly |
CN104797774A (en) * | 2012-11-20 | 2015-07-22 | 哈里伯顿能源服务公司 | Dynamic agitation control apparatus, systems, and methods |
US20160215564A1 (en) * | 2013-09-10 | 2016-07-28 | Welltec A/S | Drilling tool |
US20160326857A1 (en) * | 2014-02-20 | 2016-11-10 | Halliburton Energy Services, Inc. | Closed-loop speed/position control mechanism |
US20170023068A1 (en) * | 2015-07-24 | 2017-01-26 | Ulterra Drilling Technologies, L.P. | Universal joint |
WO2017186497A1 (en) * | 2016-04-28 | 2017-11-02 | BSH Hausgeräte GmbH | Eccentric screw pump |
US10619678B2 (en) | 2015-05-22 | 2020-04-14 | Ulterra Drilling Technologies, L.P. | Universal joint |
EP3529449B1 (en) * | 2016-10-24 | 2021-12-08 | Rival Downhole Tools LC | Drilling motor with bypass and method |
US11261666B2 (en) | 2013-11-05 | 2022-03-01 | Baker Hughes Holdings Llc | Hydraulic tools, drilling systems including hydraulic tools, and methods of using hydraulic tools |
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US8113289B2 (en) * | 2010-01-19 | 2012-02-14 | Robbins & Myers Energy Systems L.P. | Flow regulator for downhole progressing cavity motor |
US9797197B1 (en) * | 2014-10-06 | 2017-10-24 | William Alvan Eddy | Motor rotary steerable system |
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EP3529449B1 (en) * | 2016-10-24 | 2021-12-08 | Rival Downhole Tools LC | Drilling motor with bypass and method |
Also Published As
Publication number | Publication date |
---|---|
GB2454700B (en) | 2013-05-15 |
WO2009062717A3 (en) | 2009-09-24 |
GB0722445D0 (en) | 2007-12-27 |
GB2454700A (en) | 2009-05-20 |
WO2009062717A2 (en) | 2009-05-22 |
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