WO2016178663A1 - Sintering a multi-lobed helical rotor - Google Patents
Sintering a multi-lobed helical rotor Download PDFInfo
- Publication number
- WO2016178663A1 WO2016178663A1 PCT/US2015/029070 US2015029070W WO2016178663A1 WO 2016178663 A1 WO2016178663 A1 WO 2016178663A1 US 2015029070 W US2015029070 W US 2015029070W WO 2016178663 A1 WO2016178663 A1 WO 2016178663A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- helical rotor
- powdered
- lobed helical
- lobed
- compacting
- Prior art date
Links
- 238000005245 sintering Methods 0.000 title claims abstract description 19
- 239000012255 powdered metal Substances 0.000 claims abstract description 57
- 238000000034 method Methods 0.000 claims abstract description 52
- 238000005498 polishing Methods 0.000 claims abstract description 40
- 239000007787 solid Substances 0.000 claims abstract description 33
- 229910052751 metal Inorganic materials 0.000 claims abstract description 29
- 239000002184 metal Substances 0.000 claims abstract description 29
- 238000006073 displacement reaction Methods 0.000 claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 claims abstract description 21
- 238000002156 mixing Methods 0.000 claims abstract description 9
- 239000000203 mixture Substances 0.000 claims abstract description 5
- 239000000654 additive Substances 0.000 claims description 33
- 239000000463 material Substances 0.000 claims description 16
- 230000000996 additive effect Effects 0.000 claims description 13
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 6
- 239000010949 copper Substances 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 claims description 5
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- 230000014759 maintenance of location Effects 0.000 claims description 3
- 150000002739 metals Chemical class 0.000 claims description 3
- 239000010935 stainless steel Substances 0.000 claims description 3
- 229910001220 stainless steel Inorganic materials 0.000 claims description 3
- 238000005056 compaction Methods 0.000 description 22
- 238000005553 drilling Methods 0.000 description 17
- 239000012530 fluid Substances 0.000 description 12
- 239000000843 powder Substances 0.000 description 10
- 238000003801 milling Methods 0.000 description 5
- 238000007517 polishing process Methods 0.000 description 5
- UIIMBOGNXHQVGW-UHFFFAOYSA-M Sodium bicarbonate Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 description 4
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
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- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 235000020234 walnut Nutrition 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910000684 Cobalt-chrome Inorganic materials 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 239000005909 Kieselgur Substances 0.000 description 1
- 101150034459 Parpbp gene Proteins 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- WAIPAZQMEIHHTJ-UHFFFAOYSA-N [Cr].[Co] Chemical compound [Cr].[Co] WAIPAZQMEIHHTJ-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 125000004429 atom Chemical group 0.000 description 1
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- 230000009286 beneficial effect Effects 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- -1 but not limited to Substances 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 239000010952 cobalt-chrome Substances 0.000 description 1
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- 238000005260 corrosion Methods 0.000 description 1
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- 229910003460 diamond Inorganic materials 0.000 description 1
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- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
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- 239000012467 final product Substances 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 125000004435 hydrogen atom Chemical class [H]* 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000006072 paste Substances 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/16—Both compacting and sintering in successive or repeated steps
- B22F3/164—Partial deformation or calibration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- 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
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/06—Arrangements for treating drilling fluids outside the borehole
- E21B21/063—Arrangements for treating drilling fluids outside the borehole by separating components
- E21B21/065—Separating solids from drilling fluids
-
- 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
- E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
- E21B29/02—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground by explosives or by thermal or chemical means
-
- 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
-
- 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
- F04C2/082—Details specially related to intermeshing engagement type machines or pumps
- F04C2/084—Toothed wheels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
- B22F2003/023—Lubricant mixed with the metal powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/247—Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/001—Cutting tools, earth boring or grinding tool other than table ware
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2301/00—Metallic composition of the powder or its coating
- B22F2301/35—Iron
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2304/00—Physical aspects of the powder
- B22F2304/10—Micron size particles, i.e. above 1 micrometer up to 500 micrometer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- 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
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/01—Arrangements for handling drilling fluids or cuttings outside the borehole, e.g. mud boxes
-
- 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
-
- 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
- F04C2/12—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type
- F04C2/126—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of other than internal-axis type with radially from the rotor body extending elements, not necessarily co-operating with corresponding recesses in the other rotor, e.g. lobes, Roots type
-
- 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
- F04C2230/00—Manufacture
- F04C2230/20—Manufacture essentially without removing material
- F04C2230/22—Manufacture essentially without removing material by sintering
Definitions
- the present disclosure rela tes to a method and process for manufacturing parts and tools used in the oiifieid. More particularly, the present disclosure relates to the manufacturing of multi-lobed helical rotors with sintered powdered metals.
- FIG. 1 is an illustration of an example of a multi-lobed helical rotor within a pump
- FIG. 2 is a schematic illustration of an example multi-lobed helical rotor manufacturing process
- FIG. 3 is an illustration of an example of muiti-iobed heiicai rotor die; and [0007] Fig. 4 is an illustration of an example of a drilling system using a positive displacement pump.
- the present disclosure relates generally to a method and process for manufacturing parts and tools used in the o ilfield. More particularly, a method and process for manufacturing a multi-lobed helical rotor.
- the disclosure describes a method and process that manufactures parts and tools used in the oilfield through sintering powdered metai.
- a process may comprise mixing powdered metals, compacting the powdered metals, sintering the powdered metals, and polishing the resultant product.
- an information handling system may include any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, iiitel.lige.nce, or data for business, scientific, control, or other purposes.
- an information handling system may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price.
- the information handling system may include random access memory (RAM), one or more processing resoyrces such as a centra!
- Additional components of the information handling system may include one or more disk drives, one or more network ports for communication with external devices as well as various input and output (1/0) devices, such as a keyboard, a mouse, and a video display.
- the information handling system may also include one or more buses operable to transmit communications between the various hardware components.
- An example of a method for manufacturing a multi-lobed helical rotor may comprise mixing one or more powdered metals, compacting a mixture of the one or more powdered metals to form a solid metal piece, sintering the solid metal piece, and polishing the solid metal piece.
- the method may further comprise choosing one or more powdered metals as the base material for the multi-lobed helical rotor.
- the method may comprise choosing the one or more powdered metals and at least one additive as the base material for the multi-lobed helical rotor.
- the step of mixing may comprise combining the one or more powdered metals with at least one additive and the step of compacting may comprise adding the at least one powdered metal and at least one additive to a die.
- the step of compacting may comprise compacting at least one powdered metal and at least one additive with a hydraulic rani.
- the step of compacting at least one powdered metai and at least one additive with a hydraulic ram may form the multi-lobed helical rotor.
- the step of sintering may comprise placing the multi-lobed helical rotor in a furnace, wherein the furnace may be a multi-belt furnace.
- the step of polishing may be performed by an abrasive -flow machine.
- the step of compacting and the step of sintering may be combined into a single step in which the compacting may be performed at elevated temperatures.
- a system may comprise a positive displacement pump which may further comprise a casing, a multi-lobed helical rotor disposed in the casing, wherein the multi- lobed helical rotor may comprise sintered powdered metals, an inlet, to the casing, and an outlet leading from the casing.
- the sintered powdered metals may be formed from powdered metals having a particle size of about 0.5 microns to about. 100 microns.
- the multi-lobed helical rotor may comprise i 7-4 stainless steel, wherein, die multi-lobed helical rotor may further comprise at least one additive selected from a group which may consist of plastic, carbon, copper, wax, and/or combinations thereof.
- the system may further comprise a second multi-lobed helical rotor disposed in the casing, wherein the second multi-lobed helical rotor may comprise sintered powdered metal
- the system may further comprise feed conduit coupled to the positive displacement pump, and a drill string coupled to the feed conduit, wherein the drill string may be at least partially disposed in a wellbore.
- the system may further comprise a derrick comprising a traveling block for raising and lowering the drill string, wherein the positive displacement pump may be connected to a solids control system.
- the solids control system may be connected to a retention pit.
- Fig. 1 illustrates an example of a positive displacement pump 2.
- Positi ve displacement pump 2 may comprise a multi-lobed helical rotor 4, a casing 6, an inlet 8, and an outlet 1.0. It should be noted that positive displacement, pump 2 may comprise more than a single and/or a plurality of multi-lobed helical, rotors 4. in examples, a positive displacement pump may produce the same flow at any given, speed, no matter what the discharge pressure may be. Positive displacement pumps may be considered constant flow machines. Benefits of using positive displacement pumps, for example a lobe pump, within the chemical industry' may be the sanitary qualities, high efficiency, reliability, corrosion resistance, and good clean-in-place and steam-in-place characteristics.. Additionally, positive displacement pumps may be able to handle solids, slurries, pastes, and a variety of liquids.
- the manufacturing process of a multi-lobed helical rotor 4, and an associated method may embody principles of this disclosure.
- the process and method, of manufacturing a multi-lobed helical rotor 4 maybe one example of an application, of the principles of ibis disclosure in practice.
- a wide variety of manufactured oilfield tools and parts may be possible with the disclosed process and methods. Therefore, the application of this disclosure is not limited to the details of a. manufacturing process for a multi-lobed helical rotor 4 and method as described herein and/or illustrated in the drawings.
- a multi-lobed helical rotor 4 may comprise a plurality of lobes 12.
- Multi-lobed helical rotor 4 and lobes 1.2 may be made of any suitable material to withstand the pressures and chemicals that they may contact. This may make the material makeup of multi-lobed helical rotor 4 an important factor during manufacturing.
- individual lobes 12 may be of any suitable diameter, shape, angle, twist rate, and/or orientation to satisfy pumping requirements.
- Manufacturing a multi-lobed helical rotor 4 and lobes 12 may be complex, require precision, and be time intensive, tit some known methods, milling machines may be used to produce multi-lobed hel ical rotors 4, Milling times may take forty hours before completion and may require an additional, fifteen hours of polishing before a multi-lobed helical, rotor 4 may be ready for service.
- the high demand, for these complex, parts may make the forty to fifty-five hour manufacturing time an inefficient and cosily process.
- Fig. 2 illustrates a manufacturing process that may be used to cut the production time of multi-lobed helical rotor 4.
- the process may use powdered metals and a sintering process to manufacture multi-lobed helical rotor 4.
- the process may comprise mixing 1.4 powdered metals, compaction 16 of the powdered metals, sintering 18 the powdered metals, and polishing 20 the final product.
- Mixing 14 of powdered metals may be used to control the strength, toughness, and/or other characteristics a multi-lobed helical rotor 4 may require when in use.
- Typical materials may be .17-4 stainless steel, iron, tungsten carbide, cobalt chromium, aluminum, copper, carbon, and/or any combination thereof Selection of powder size may control density and consistency of the finished part. For example, powder size may range may be about 0.5 microns to about 100 microns, which may produce the best die .fill with ninety nine percent or greater finished part density. Additional additives add to the powdered metal may also improve and/or add special characteristics to multi-lobed helical rotor 4.
- Characteristics such, as lubricity, conductivity, and others may be beneficial during the lifetime use of multi-lobed helical rotor 4,
- fillers may be plastic, carbon, copper and wax can be used to enhance the manufacturing process (plastics and wax may aid in the compaction process and die fill) while carbon, copper and other elements may be added to modify the physical characteristics of the part (copper may be added for lubricity and enhanced thermal/electrical conductivity).
- Mixing 14 powdered metals and additives may be accomplished using a dry powder blender. These blenders can be the tumble type and/or rotary blenders. In examples, powdered metals and additives may be added in stages during compaction 16, providing different metal characteristics throughout multi-lobed helical rotor 4.
- Compaction 16 may include placing mixed powdered metal within a die 22.
- Die 22, best illustrated in Fig. 3, may be used to form the structure and shape of multi- !obed helical rotor 4. Additionally, die 22 may be used to form intricate twisting, angles, and/or shapes of lobe 6.
- Compaction 16 may be performed by traditional means, cold iso- static pressing, and/or hot iso-static pressing.
- Traditional compaction 16 may include placing a predetermined amount of powder into a die 22, Die 22 may be sealed and pressure may be applied to the powdered metal (and additives) by a hydraulic and/or mechanical rams/actaators. Actuation of hydraulic and/or mechanical rams/actuators may be performed and monitored by an information handling system. In examples, the pressure applied may be as low as 20 kst and as high as 60 ksi. A target or desired compaction pressure may depend on a specific part size, powder content, and/or required density. A hold time (which may be defined as the time that the powdered metal may be compacted under the compaction pressure) may also be dependent on the size and shape of the part Compaction times may range from about ten to about one hundred and twenty minutes.
- Pressure applied to powdered metals (and additives) may cause the molecular structure of a powdered metal to merge with the mokcular structure of adjacent powdered metals and/or additives.
- Sensors may be used within dies 16 which may provide information to the information handling system relating to the compression and formation between powdered metals and additives. The traditional process may not require heat due to the large amount of pressure applied to the powdered metal.
- the powdered metal and/or additives may have formed a solid metal piece. The solid metal piece may then be removed from, die 22 and moved to a sintering process 18.
- compaction 16 may be repeated any number of times, which may allow for the addition of different powdered metal mixtures and/or additives to die 22. This may allow an operator to manipulate the strengths, toughness, properties, and chatacteristics in different areas of muUi-lobed helical rotor 4. Compaction 16 may also be performed by cold iso ⁇ stat.ic pressing.
- Cold iso-static pressing may be performed at room temperature with water and/or oil .
- Powdered material and/or additives may be placed within a die 22.
- Cold iso- static pressing may use a die 22 which may be flexible.
- Die 22 may be flexible from material such as elastomer, urethane, and/or any combination which may be used to create die 22.
- the fluid e.g., oil, water, and/or any other suitable liquid for compression
- Pressures applied may he between 60 ksi and 150 ksi.
- Compaction pressure may usually be determined by a specific part size, powder content, and/or required density.
- a hold time (which may be defined as the time that the powdered metal may be compacted under the compaction pressure) may also be dependent on the size and shape of the part. Compaction times may range from about ten to about one hundred and twenty minutes.
- the amount of fluid used and amount of pressure applied may be monitored by an information handling system. The information handling system may further monitor and alert an operator as to the merging between the powdered metals and/or additives. Additional machining may be required due to the flexibility of die 22. After compaction 16, the powdered metal and/or additives may have formed a solid metal piece. The solid metal piece may then be removed from die 22 and moved to a sintering process 18.
- compaction 16 may be repeated any number of times which may allow for the addition of different powdered mixtures and/or additives to die 22. This may allow an operator to manipulate the strengths, toughness, properties, and characteristics in different areas of mu!fi-lobed helical rotor 4.
- Compaction 16 may additionally be performed by hot iso-static pressing.
- Hot iso-static pressing may be used to produce a more uniform grain structure over multi- lobed helical rotor 4. This form of pressing may be performed at elevated temperatures. Temperatures are typically near 65-70% of the melt temperature of the target metal powder. Ex: 1.7-4 SS has a green bar melt temperature of 2560-2625F so a typical process range may be S 792-1837F, Powdered metal and/or additives may be placed within die 22.
- Die 22 may be made of metals that may be able to resist the high temperatures and pressures exerted upon the powdered metals and. additives. For example, suitable metals may be, but.
- Pressure may be applied to the powdered metal and/or additives using a gas.
- the application of gas and pressure may be monitored, by an information handling system.
- the information handling system may further monitor the temperature and formation between the powdered metals arid/or additives.
- Pressure applied to powdered metals and/or additives may be about 15 ksi at 2000 F°.
- Compaction pressure may usually be determined by a specific part size, powder content, and/or required density.
- a hold time (which may be defined as the time that, the powdered metal may be compacted under the compaction pressure) may also be dependent on the size and. shape of the part. Compaction times may range from about ten to about one hundred and twenty minutes.
- the metal product produced may not: need to be sent to a sintering 18 process and may only require a polishing process 20.
- a sintering process 18 may be described as heating a solid mass of material by heat and/or pressure without melting it. to the point ofliquefaction. Atoms in a material, may diffuse across boundaries of adjacent particles, fusing the particles together and creating one solid object. As described above, the powdered metals and additives may have been pressed together hi a process of compaction 16.
- the solid metal objects formed may be placed, onto a. conveyor system and/or placed into a furnace..
- a furnace and/or the conveyor system may be controlled by an information handling system.
- the furnace may be a batch furnace and/or a continuous furnace.
- Additive gases such as, but not limited to, nitrogen, hydrogen, and/or other inert gases, and/or any combination thereof may control the cleanliness and material properties of the solid metal object placed within the furnace. Temperatures within the furnace, controlled by an information handling system, may heat the sol id metal object to between se venty and ninety percent of the melting temperature. Temperatures may range from 2000 to 2100 F°, which may depend on melting temperatures of the base metal powders. Traditional furnaces may heat the solid metal object at the same temperature throughout the furnace. In examples, a mesh-belt furnace may be used to heat the solid metal object in three different zones. There may be a preheat zone, a hot zone, and/or a cooling zone.
- Each zone may be heated to different temperatures, in examples, after heating the solid metal object, the process may control the temperature at which the solid metal object cools.
- the rate of cooling may he dependent on the type of base material .
- base materials such, as martensile and ausenite may be cooled at a rate which may be determined by the part size and/or configuration (e.g. thin wall versus (hick wall or solid bar, etc.). Heating and cooling the solid metal object may require as little as three hours in the sintering 18 process.
- the solid metal object may be a "near net" multi -Iobed helical rotor 4 and/or any oilfield tool or part.
- a "near net" multi-lobed helical rotor 4 may be described as a multi-lobed helical rotor 4 that may only need minimal amounts of polishing process 20.
- Polishing process 20 may be a final step in a process before multi-lobed helical rotor 4 may be ready for service. Polishing may be performed using electropolishing, mechanical polishing, and/or an abrasive flow machine, Electrapolishing may immerse mu!ti-Iobed helical rotor 4 in a temperature-controlled bath of electrolyte, serving as an anode. The tempera ture of the bath may be control led by an information handling system. Multi-lobed helical rotor 4 may be connected to a positive terminal of a DC power supply and a cathode may be attached to the negative terminal. The cathode may further be placed within the temperature-controlled bath.
- a current may pass from multi-lobed helical rotor 4 to the cathode.
- the metal on the surface of multi- lobed helical, rotor 4 may oxidize and dissolve in the electrolyte. This type of polishing may passivate the material but may also work as final polish due to the smoothing of multi- lobed helical rotor's 4 surface.
- mechanical polishing may be performed using blasters and/or standard mechanical disks and/or belt sanders.
- a blasting method may use powders and/or any combination of mediums comprising, but not limited to, baking soda, walnut shells, and/or glass bead.
- a wand blasting device may ⁇ be used for polishing the inner diameter of multi-lobed helical rotor 4 (more relevant to a stator. ID of rotor can be machined or left in as manufactured state provided tolerances are met). Blasting within a cabinet may be used for polishing the outer diameter of multi- lobed helical rotor 4.
- Grit may be a medium comprising, but not limited to, baking soda, walnut shells, and/or glass bead.
- grit may surface harden multi-lobed helical rotor 4 and "dimple" the surface, providing a roughness for additional bonding strength and/or a final polish.
- Mechanical polishing may be labor intensive and require specialized personnel to perform the polishing.
- An additional polishing process of abrasive flow machining may be used as an alternate to mechanical polishing.
- Abrasive flow machining may be used for polishing both, inner features and. outer features of muit.i ⁇ l.obed helical rotor 4.
- Polishing the inner features of multi-lobed helical rotor 4, an abrasive flow machine may comprise two media chambers (in examples there may be more than two media chambers) and a hydraulic ram within each chamber. Hydraulic rams may be connect at the ends of a tubular (stator). Within the chambers may be a polishing medium. Polishing mediums may be, but are not limited to, silicon carbide, aluminum oxide, and/or boron carbide with sixes ranging from about fourteen grans to about two thousand grains.
- the viscosity of the medium selected may depend on how fine a finish is required (e.g., low viscosity medium for minimal material removal and high viscosity medium for maximum material removal-per cycle). The harder the surface of the finished pari may require a more aggressive polishing medium and process pressure,
- polishing media may be forced through the inner features of multi-!obed helical rotor 4. Contacting the surface of multi-lobed heiical rotor 4, the polishing media may slowly polish and/or remove the surface roughness. This may be repeated until the desired dimensions are produced.
- the dimensions may be routinely monitored by an information handling system as polishing mediums are pushed through the inner features of multi-lobed helical rotor 4. in examples, the polishing may be done within a one-way flow loop and/or a two way flow loop. Using a flow system, the polishing medium may be constantly reused, reducing waste and cost.
- a flow system may keep reused polishing media in contact with the surface of multi-lobed helical rotor 4, reducing the time it may take to polish the surface.
- the abrasive flow machine may then be reset, or an extra abrasive flow machine may be used, to poiish the outer features of multi-lobed helical rotor 4.
- Polishing the outer features of multi-lobed helical rotor 4 with, an abrasive flow machine may be accomplished with polishing media that may comprise, but are not limited to, a belt type, a one-way flow loop, a two way flow loop, and/or any combination thereof.
- Multi-lobed helical rotor 4 may be placed within a tubular comprising polishing media.
- the polishing media may be forced around the outside dimensions of multi-lobed helical rotor 4 through hydraulic and/or tumbling means. As described above, the polishing media may he reused and recycled. This may allow polishing media to stay in direct, contact with multi-lobed helical rotor 4. reducing the polishing time.
- an. abrasive flow machine may reduce the time and waste when polishing multi-lobed helical rotor 4, allowing multi-lobed heiical rotor 4 (or any type of oilfield tool and/or part) to be ready for use in. a shorter amount of time.
- a drilling system 24 is illustrated thai may use a positive displacement pump 2.
- a positive displacement pump 2 may be used to move wellbore fluids through the wellbore and/or throughout drilling system 24.
- Fig. 4 generally depicts a land-based drilling system, those skilled in the art will readily recognize that the principles describe herein are equally applicable to subsea drilling operations that employ floating or sea- based platforms and rigs, without departing form the scope of the disclosure.
- drilling system 24 may include a drilling platform 26 that supports a derrick 28 having a traveling block 30 for raising and lowering a drill string 32.
- Drill string 32 may include, but is not limited to, drill pipe and coil tubing, as generally known to those skilled in the art.
- a kelly 34 may support, drill string 32 as it may be lowered through a rotary table 36,
- a drill bit 38 may be attached to the distal end of drill sting 32 and may be driven either by a downhole motor and/or via rotation of drill string 32 from the well, surface.
- drill bit 38 may include, roller cone bits, FIX ' bits, natural diamond bits, any hole openers, reamers, coring bits, and the like. As drill bit 38 rotates, it may create a wellbore 40 that penetrate various subterranean formations 42.
- Drilling system 24 may further include a. positive displacement pump 2, one or more solids control system 44, and a retention pit 46.
- Positive displacement pump 2 may include any conduits, pipelines, trucks, lobulars, and/or pipes used to fluidically convey drilling fluid 48 downhole, any pumps, compressors, or motors (e.g., topside or downhole) used to drive the drilling fluid 48 into motion, any valves or related joints used to regulate the pressure or flow rate of drilling fluid 48, any sensors (e.g., pressure, temperature, How rate, etc.), gauges, and/or combinations thereof, and the like.
- Positive displacement pump 2 may circulate drilling fluid.48 through a feed conduit 50 and to kelly 34, which may convey drilling fluid 48 downhole through the interior of drill string 32 and through one or more orifices in drill bit 38. Drilling fluid 48 may then be circulated back to the surface via an annulus 52 defined between drill string 36 and the walls of wellbore 40, A t the surface, the recirculated or spent drilling fluid 48 may be exit the annulus 52 and may be conveyed to one or more solids control system 44 via an interconnecting flow line 54.
- the solids control system 44 may include, but is not limited to, one or more of a shaker (e.g., a shale shaker), a centrifuge, a hydrocyclone, a separator (including magnetic and electrical separators), a desi!ler, a desander, a separator, a filter (e.g., diatomaceous earth filters), a beat exchanger, and/or any fluid reclamation equipment.
- the solids control system 44 may further include one or more sensors, gauges, pumps, compressors, and the like used store, monitor, regulate, and/or recondition the drilling fluid 48.
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/565,293 US20180079005A1 (en) | 2015-05-04 | 2015-05-04 | Sintering a Multi-lobed Helical Rotor |
DE112015006512.1T DE112015006512T5 (en) | 2015-05-04 | 2015-05-04 | Sintering a multi-bladed screw rotor |
CA2981001A CA2981001A1 (en) | 2015-05-04 | 2015-05-04 | Sintering a multi-lobed helical rotor |
PCT/US2015/029070 WO2016178663A1 (en) | 2015-05-04 | 2015-05-04 | Sintering a multi-lobed helical rotor |
GB1715453.5A GB2552912A (en) | 2015-05-04 | 2015-05-04 | Sintering a multi-lobed helical rotor |
SG11201707688SA SG11201707688SA (en) | 2015-05-04 | 2015-05-04 | Sintering a multi-lobed helical rotor |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2015/029070 WO2016178663A1 (en) | 2015-05-04 | 2015-05-04 | Sintering a multi-lobed helical rotor |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2016178663A1 true WO2016178663A1 (en) | 2016-11-10 |
Family
ID=57218394
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2015/029070 WO2016178663A1 (en) | 2015-05-04 | 2015-05-04 | Sintering a multi-lobed helical rotor |
Country Status (6)
Country | Link |
---|---|
US (1) | US20180079005A1 (en) |
CA (1) | CA2981001A1 (en) |
DE (1) | DE112015006512T5 (en) |
GB (1) | GB2552912A (en) |
SG (1) | SG11201707688SA (en) |
WO (1) | WO2016178663A1 (en) |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5195882A (en) * | 1990-05-12 | 1993-03-23 | Concentric Pumps Limited | Gerotor pump having spiral lobes |
US5248896A (en) * | 1991-09-05 | 1993-09-28 | Drilex Systems, Inc. | Power generation from a multi-lobed drilling motor |
US5310320A (en) * | 1990-04-27 | 1994-05-10 | Svenska Rotor Maskiner Ab | Rotor for a rotary screw machine having internal member and external shell made of pressed metal powder |
WO2001092673A2 (en) * | 2000-06-01 | 2001-12-06 | Pancanadian Petroleum Limited | Fluid displacement apparatus and method |
US20130149182A1 (en) * | 2010-08-16 | 2013-06-13 | National Oilwell Varco, L.P. | Reinforced Stators and Fabrication Methods |
-
2015
- 2015-05-04 DE DE112015006512.1T patent/DE112015006512T5/en not_active Withdrawn
- 2015-05-04 SG SG11201707688SA patent/SG11201707688SA/en unknown
- 2015-05-04 US US15/565,293 patent/US20180079005A1/en not_active Abandoned
- 2015-05-04 CA CA2981001A patent/CA2981001A1/en not_active Abandoned
- 2015-05-04 WO PCT/US2015/029070 patent/WO2016178663A1/en active Application Filing
- 2015-05-04 GB GB1715453.5A patent/GB2552912A/en not_active Withdrawn
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5310320A (en) * | 1990-04-27 | 1994-05-10 | Svenska Rotor Maskiner Ab | Rotor for a rotary screw machine having internal member and external shell made of pressed metal powder |
US5195882A (en) * | 1990-05-12 | 1993-03-23 | Concentric Pumps Limited | Gerotor pump having spiral lobes |
US5248896A (en) * | 1991-09-05 | 1993-09-28 | Drilex Systems, Inc. | Power generation from a multi-lobed drilling motor |
WO2001092673A2 (en) * | 2000-06-01 | 2001-12-06 | Pancanadian Petroleum Limited | Fluid displacement apparatus and method |
US20130149182A1 (en) * | 2010-08-16 | 2013-06-13 | National Oilwell Varco, L.P. | Reinforced Stators and Fabrication Methods |
Also Published As
Publication number | Publication date |
---|---|
US20180079005A1 (en) | 2018-03-22 |
SG11201707688SA (en) | 2017-10-30 |
CA2981001A1 (en) | 2016-11-10 |
GB201715453D0 (en) | 2017-11-08 |
DE112015006512T5 (en) | 2018-03-29 |
GB2552912A (en) | 2018-02-14 |
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