U.S. patent application number 11/510384 was filed with the patent office on 2008-02-28 for highly reinforced elastomer for use in downhole stators.
This patent application is currently assigned to Dyna-Drill Technologies, Inc.. Invention is credited to Michael Hooper.
Application Number | 20080050259 11/510384 |
Document ID | / |
Family ID | 38659610 |
Filed Date | 2008-02-28 |
United States Patent
Application |
20080050259 |
Kind Code |
A1 |
Hooper; Michael |
February 28, 2008 |
Highly reinforced elastomer for use in downhole stators
Abstract
A Moineau stator for a downhole drilling motor and a method for
fabricating the stator are disclosed. The stator includes an
internal helical cavity component fabricated from an improved
elastomeric material formulated to provide both high resilience and
good processability. For example, in one exemplary embodiment the
elastomer material includes rheological parameters M.sub.L in a
range from about 1.0 to about 4.0 lbin and M.sub.H in a range from
about 75 to about 110 lbin according to ASTM D2084 at 380 degrees
F. 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.
Inventors: |
Hooper; Michael; (Spring,
TX) |
Correspondence
Address: |
W-H ENERGY SERVICES, INC.
2000 W. Sam Houston Pkwy. S, SUITE 500
HOUSTON
TX
77042
US
|
Assignee: |
Dyna-Drill Technologies,
Inc.
Houston
TX
|
Family ID: |
38659610 |
Appl. No.: |
11/510384 |
Filed: |
August 25, 2006 |
Current U.S.
Class: |
418/45 ;
418/48 |
Current CPC
Class: |
E21B 4/02 20130101; F05C
2225/02 20130101; F04C 2/1075 20130101 |
Class at
Publication: |
418/45 ;
418/48 |
International
Class: |
F01C 5/00 20060101
F01C005/00; F01C 1/10 20060101 F01C001/10 |
Claims
1. A stator for use in a downhole drilling motor, the stator
comprising: an outer tube; a helical cavity component deployed
substantially coaxially in the outer tube, the helical cavity
component providing an internal helical cavity and including a
plurality of internal lobes; and the helical cavity component
including an elastomeric material, the elastomeric material
including: 33-3 nitrile butadiene rubber having about 30 percent by
weight acrylonitrile and a Mooney viscosity of about 30; at least
60 parts by weight carbon black per 100 parts by weight of the
nitrile rubber; and at least 15 parts by weight phenolic resin
plasticizer per 100 parts by weight of the nitrile rubber, said
phenolic resin plasticizer further including a hexa cross linking
agent.
2. The stator of claim 1, wherein the phenolic resin plasticizer
includes from about 6.5 to about 8.5 percent by weight of the hexa
cross linking agent.
3. The stator of claim 1, wherein the elastomeric material
comprises about 25 parts by weight of the phenolic resin
plasticizer per 100 parts by weight of the nitrile rubber.
4. The stator of claim 1, wherein the elastomeric material
comprises about 25 parts by weight of the phenolic resin
plasticizer and about 80 parts by weight carbon black per 100 parts
by weight of the nitrile rubber.
5. The stator of claim 1, wherein the helical cavity component is
fabricated substantially entirely from the elastomeric
material.
6. The stator of claim 1, wherein the elastomeric material includes
the following tensile properties: a modulus at 25% elongation in a
range from about 550 to about 750 psi; and a modulus at 100%
elongation in a range from about 900 to about 1200 psi.
7. The stator of claim 1, wherein the elastomeric material includes
the following compressive properties: a modulus at 5% compression
in a range from about 110 to about 150 psi; a modulus at 10%
compression in a range from about 225 to about 325 psi; and a
modulus at 15% compression in a range from about 350 to about 475
psi.
8. The stator of claim 1, wherein the elastomeric material
comprises a Shore A hardness in the range from about 88 to about
94.
9. The stator of claim 1, wherein the elastomer material comprises
rheological parameters M.sub.L in a range from about 1.0 to about
4.0 lbin and M.sub.H in a range from about 75 to about 110 lbin,
said M.sub.L and said M.sub.H representative of a minimum and
maximum torque as determined according to ASTM D2084 at 380 degrees
F. with no preheat.
10. The stator of claim 1, wherein the elastomer material comprises
an aftercure tan .delta. at 250 degrees F. of less than about
0.25.
11. A stator for a downhole drilling motor comprising: an outer
tube; a helical cavity component deployed substantially coaxially
in the outer tube, the helical cavity component providing an
internal helical cavity and including a plurality of internal
lobes; and the helical cavity component being 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 including rheological parameters
M.sub.L in a range from about 1.0 to about 4.0 lbin and M.sub.H in
a range from about 75 to about 110 lbin, said M.sub.L and said
M.sub.H representative of a minimum and maximum torque as
determined according to ASTM D2084 at 380 degrees F. with no
preheat.
12. The stator of claim 11, wherein the elastomeric material
comprises at least 15 parts by weight phenolic resin plasticizer
per 100 parts by weight of the nitrile rubber, the phenolic resin
plasticizer including a hexa cross linking agent.
13. The stator of claim 11, wherein the elastomeric material
comprises about 80 parts by weight carbon black per 100 parts by
weight of the nitrile rubber.
14. The stator of claim 11, wherein the nitrile rubber comprises a
33-3 nitrile butadiene rubber having about 30 percent by weight
acrylonitrile and a Mooney viscosity of about 30.
15. The stator of claim 11, wherein the elastomeric material
includes the following tensile properties: a modulus at 25%
elongation in a range from about 550 to about 750 psi; and a
modulus at 100% elongation in a range from about 900 to about 1200
psi.
16. The stator of claim 11, wherein the elastomeric material
includes the following compressive properties: a modulus at 5%
compression in a range from about 110 to about 150 psi; a modulus
at 10% compression in a range from about 225 to about 325 psi; and
a modulus at 15% compression in a range from about 350 to about 475
psi.
17. The stator of claim 11, wherein the elastomeric material
comprises a Shore A hardness in the range from about 88 to about
94.
18. The stator of claim 11, wherein the elastomer material
comprises an aftercure tan .delta. at 250 degrees F. of less than
about 0.25.
19. The stator of claim 11, wherein ML is in a range from about 1.0
to about 3.5 lbin.
20. The stator of claim 11, wherein ML is in a range from about 1.0
to about 3.0 lbin
21. A method of manufacturing a stator for a downhole drilling
motor, the method comprising: (a) providing an elastomeric compound
including a nitrile rubber having from about 30 to about 40 percent
acrylonitrile, the elastomeric compound further including
rheological parameters M.sub.L in a range from about 1.0 to about
4.0 lbin and M.sub.H in a range from about 75 to about 110 lbin,
said M.sub.L and said M.sub.H representative of a minimum and
maximum torque as determined according to ASTM D2084 at 380 degrees
F. with no preheat; and (b) injection molding 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.
22. The method of claim 21, wherein the nitrile rubber comprises a
Nysyn 333 nitrile butadiene rubber having about 33 percent
acrylonitrile and a Mooney viscosity of about 30.
23. The method of claim 21, wherein the elastomeric compound
comprises about 25 parts by weight phenolic resin plasticizer per
100 parts by weight of the nitrile rubber, the phenolic resin
plasticizer including a hexa cross linking agent.
24. The method of claim 21, wherein the elastomeric compound
comprises about 80 parts by weight carbon black per 100 parts by
weight of the nitrile rubber.
25. A subterranean drilling motor comprising: a rotor having a
plurality of rotor lobes on a helical outer surface of the rotor; a
stator including a helical cavity component, the helical cavity
component providing an internal helical cavity and including a
plurality of internal stator lobes; the rotor deployable in the
helical cavity of the stator such that the rotor lobes are in a
rotational interference fit with the stator lobes, rotation of the
rotor in a predetermined direction causing the rotor lobes to (i)
contact the stator lobes on a loaded side thereof as the
interference fit is encountered, and (ii) pass by the stator lobes
on a non-loaded side thereof as the interference fit is completed;
and the internal stator lobes fabricated from an 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) about 80 parts by weight carbon black per 100 parts by
weight of the nitrile rubber, (iii) and about 25 parts by weight
phenolic resin plasticizer per 100 parts by weight of the nitrile
rubber, said phenolic resin plasticizer further including a hexa
cross linking agent.
26. A subterranean drilling motor comprising: a rotor having a
plurality of rotor lobes on a helical outer surface of the rotor; a
stator including a helical cavity component, the helical cavity
component providing an internal helical cavity and including a
plurality of internal stator lobes; the rotor deployable in the
helical cavity of the stator such that the rotor lobes are in a
rotational interference fit with the stator lobes, rotation of the
rotor in a predetermined direction causing the rotor lobes to (i)
contact the stator lobes on a loaded side thereof as the
interference fit is encountered, and (ii) pass by the stator lobes
on a non-loaded side thereof as the interference fit is completed;
and the internal stator lobes fabricated from an elastomeric
material having the following properties: rheological parameter
M.sub.L in a range from about 1.0 to about 4.0 lbin; rheological
parameter M.sub.H in a range from about 75 to about 110 lbin; a
tensile modulus at 25% elongation from about 550 to about 750 psi;
a tensile modulus at 100% elongation from about 900 to about 1200
psi; a Shore A hardness in the range from about 88 to about 94; and
wherein said M.sub.L and said M.sub.H are representative of minimum
and maximum torque as determined according to ASTM D2084 at 380
degrees F. with no preheat.
Description
RELATED APPLICATIONS
[0001] None.
FIELD OF THE INVENTION
[0002] 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.
BACKGROUND OF THE INVENTION
[0003] 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. For example, 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. Furthermore, 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.
Moreover, many rubber compounds are known to deteriorate in the
presence of hydrocarbons.
[0004] The power section of a typical Moineau style motor includes
a helical rotor disposed within the helical cavity of a
corresponding stator. When viewed in circular cross section, a
typical stator shows a plurality of lobes in the helical cavity. In
most conventional Moineau style power sections, the rotor lobes and
the stator lobes are preferably disposed in an interference fit,
with the rotor including one fewer lobe than the stator. Thus, when
fluid, such as a conventional drilling fluid, is passed through the
helical spaces between rotor and stator, the flow of fluid causes
the rotor to rotate relative to the stator (which may be coupled,
for example, to a drill string). 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.
[0005] 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.
[0006] The chemical and dynamic properties of NBR and HNBR
elastomers are controlled, in part, by the acrylonitrile (ACN)
content of the elastomer. 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.
[0007] One drawback with conventional stators including an all
elastomer helical cavity component is that a tradeoff in elastomer
properties has been required. One such tradeoff has been between
the resilience (rigidity) of the elastomer and its processability
(its flowability during injection molding). For example, U.S. Pat.
No. 6,905,319 to Guo states: "processability is generally inversely
related to the stiffness of the rubber. This is particularly true
in injection-mold processes. . . . Typically, a stiffer compound
will demand much more processing power and time, thereby increasing
manufacturing costs" (column 4, lines 4-12). Despite the potential
advantages of using a stiffer elastomer, 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.
[0008] One significant drawback with conventional stators is that
the elastomer helical cavity component deforms under torque loads
(due to the low rigidity of the elastomer). This deformation
creates a gap on the unloaded side of the stator lobe, thereby
allowing drilling fluid to pass from one cavity to the next without
producing any work (i.e., without causing rotation of the rotor).
This is known in the art as "RPM drop-off." When the torque reaches
a critical level, substantially all of the drilling fluid bypasses
the stator lobes and the rotor stalls.
[0009] Stators including a comparatively rigid helical cavity
component (e.g., fabricated from an elastomer lined metal or
composite material) 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. Pat. No.
5,171,138 to Forrest and U.S. Pat. No. 6,309,195 to Bottos et al.,
for example, 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.
[0010] While 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). As such, rigid stators of the prior
art are often only used in demanding applications in which the
significant added expense is acceptable.
[0011] Other reinforcement materials have also been disclosed. For
example, U.S. Pat. No. 6,183,226 to Wood et al. and U.S. Patent
Publication 20050089429, disclose stators in which the helical
cavity component includes an elastomer liner deployed on a fiber
reinforced composite reinforcement material. The fabrication of
composite reinforced stators has also proven difficult. For
example, removal of the tooling (the stator core) from the injected
composite has proven difficult due to the close fitting tolerances
and the thermal mismatches between the materials.
[0012] Comparatively rigid (resilient) elastomer helical cavity
components are also known in the art (e.g., having a Shore A
hardness of about 90). However, as described above, such 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.
SUMMARY OF THE INVENTION
[0013] 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.
For example, in one exemplary embodiment 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. In another exemplary embodiment, the elastomer
material includes rheological parameters M.sub.L in a range from
about 1.0 to about 4.0 lbin and M.sub.H in a range from about 75 to
about 110 lbin. M.sub.L and M.sub.H are representative of a minimum
and maximum torque as determined according to ASTM D2084 at 380
degrees F. with no preheat.
[0014] Exemplary embodiments of the present invention
advantageously provide several technical advantages. For example,
exemplary embodiments of the invention advantageously reduce the
above described tradeoffs associated with elastomer material
selection (in particular in regard to resilience and
processability). As such, 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. Moreover, 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.
[0015] In one aspect, 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.
[0016] In another aspect, 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 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.sub.L in a range from about 1.0 to about 4.0 lbin and M.sub.H in
a range from about 75 to about 110 lbin, wherein M.sub.L and
M.sub.H are representative of a minimum and maximum torque as
determined according to ASTM D2084 at 380 degrees F. with no
preheat.
[0017] In still another aspect, 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.sub.L in a range from
about 1.0 to about 4.0 lbin and M.sub.H in a range from about 75 to
about 110 lbin, wherein M.sub.L and M.sub.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.
[0018] The foregoing has outlined rather broadly the features and
technical advantages of the present invention in order that the
detailed description of the invention that follows may be better
understood. Additional features and advantages of the invention
will be described hereinafter, which form the subject of the claims
of the invention. It should be appreciated by those skilled in the
art that the conception and the specific embodiments disclosed may
be readily utilized as a basis for modifying or designing other
structures for carrying out the same purposes of the present
invention. It should also be realize by those skilled in the art
that such equivalent constructions do not depart from the spirit
and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a more complete understanding of the present invention,
and the advantages thereof, reference is now made to the following
descriptions taken in conjunction with the accompanying drawings,
in which:
[0020] FIG. 1 depicts a conventional drill bit coupled to a Moineau
style drilling motor utilizing an exemplary stator embodiment of
the present invention.
[0021] FIG. 2 is a circular cross sectional view of the Moineau
style stator as shown on FIG. 1.
[0022] FIG. 3 plots RPM versus pressure drop for an exemplary
embodiment of a downhole drilling motor in accordance with the
invention. The exemplary drilling motor of this invention is
compared with conventional drilling motors; one including an
elastomeric helical cavity component and another including a rigid
metal reinforced helical cavity component.
DETAILED DESCRIPTION
[0023] As described above, conventional Moineau drilling motors
have used an elastomeric helical cavity component bonded to a steel
housing. However, due to the behavior of the selected elastomer
material in various competing conditions, there have been
inevitable tradeoffs in the choice of a desired elastomer material.
Such tradeoffs typically result in the selected elastomer having at
least one less-than-optimal material property (e.g.,
lower-than-desired resilience, suboptimal processability, and/or
inadequate dynamic properties) and as described above, these
tradeoffs tend to compromise various stator fabrication and/or
performance metrics.
[0024] Lower than desired elastomer resilience results in
inadequate torque transmission. As described above, 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. Several 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).
[0025] While increased elastomer resilience is known to reduce RPM
drop-off (thereby improving torque transmission), it is also known
to degrade elastomer processability. As described above in the
Background section, conventional wisdom in the downhole drilling
industry suggests that resilient elastomer materials are not
suitable for downhole stators due to inherently high viscosity
(poor flowability of the pre-cured elastomer) at conventional
injection molding temperatures. The processability of the elastomer
is particularly important in longer and/or smaller diameter
stators. Longer stators (e.g., greater than 20 feet) are often used
in an attempt to minimize RPM drop off. Smaller diameter stators
(e.g., less than four inch diameter) are commonly used in side
tracking or other coiled tubing applications. It is known to those
of skill in the art that increasing stator length and decreasing
lobe diameter significantly increase the required pressure and time
(and therefore expense) required to fabricate a stator via
injection molding.
[0026] One measure of processability commonly used in the art is a
property referred to as 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. However, such measurements can be difficult and
time consuming. Rheological properties can also be used to
determine both the processability and the resilience (rigidity) of
an elastomer. For example, the minimum torque, M.sub.L, as
determined via ASTM D2040, tends to be a good indicator of
elastomer processability, while the maximum torque, M.sub.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.sub.L is in the
range from about 1.0 to about 4.0 lbin when measured at 380 degrees
F. with no preheat. High elastomer resilience (for reducing RPM
drop-off) is typically indicated when M.sub.H is in the range from
about 75 to about 110 lbin as also measured at 380 degrees F. with
no preheat. Conventional stators typically have an M.sub.H of about
55 lbin or less.
[0027] Often increasing the resilience of an elastomer also
degrades the dynamic properties of the elastomer. Such degradation
of the dynamic properties is known to cause localized heating of
the elastomer lobes due to the viscoelastic behavior of the
elastomer (and its poor thermal conductivity). This in turn can
result in thermal degradation of the elastomer and ultimately in
failure of the stator (due to a phenomenon referred to in the art
as "chunking" in which the stator lobes become embrittled and
subsequently crack and tear apart). The dynamic properties are
typically determined in the art by measuring a quantity referred to
as tan .delta., which is the ratio of the loss (or viscoelastic)
modulus to the storage (or elastic) modulus. Increasing tan .delta.
typically indicates increasing viscoelastic behavior and therefore
degraded dynamic properties. While there is no universally agreed
upon industry standard measurement technique for determining tan
.delta., the Applicant has found that a 250 degree F. tan .delta.
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 .delta. 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.
[0028] With reference now to FIGS. 1 and 2, one exemplary
embodiment of a Moineau style power section 100 according to this
invention is shown in use in a downhole drilling motor 60. 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.
[0029] With reference now to FIG. 2, power section 100 is shown in
circular cross section, as shown by the section lines on FIG. 1.
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. In the exemplary embodiment shown, 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.
[0030] With continued reference to FIGS. 1 and 2, 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. In one exemplary
embodiment the elastomer material includes rheological parameter
M.sub.L in the range from about 1.0 to about 4.0 lbin and parameter
M.sub.H in the range from about 75 to about 110 lbin as determined
via ASTM D2040 at 380 degrees F. with no preheat. In other
exemplary embodiments M.sub.L may be in the range from about 1.0 to
about 3.5 lbin or even 1.0 to 3.0 lbin 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-US-00001 TABLE I Preferred Most Preferred Elastomeric
Property Range 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
[0031] In one exemplary embodiment, 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.sub.L in the range from about 1.0 to about 4.0 and M.sub.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 .delta. value of less than about 0.25).
[0032] 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. In the exemplary embodiments shown, 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-US-00002 TABLE II Formulation STD A B C D NYSYN 33-3 100.00
100.00 100.00 100.00 100.00 ASD 75 - 75% Sulfur 4.80 4.80 4.80 4.80
4.80 in NBR 911C - 85% ZnO in NBR 5.00 5.00 5.00 5.00 5.00 Stearic
Acid 1.00 1.00 1.00 1.00 1.00 Agerite Resin D 3.00 3.00 3.00 3.00
3.00 DUSANTOX 6 PPD 2.00 2.00 2.00 2.00 2.00 N774 Ultra Carbon
Black 60.00 60.00 60.00 80.00 100.00 Cumar - R13 15.00 -- -- --
15.00 Akrochem P55 Phenolic 10.00 15.00 25.00 25.00 10.00 Resin
Diisodecyl Phthalate 10.00 15.00 10.00 10.00 10.00 Paraplex G25
5.00 7.50 5.00 5.00 5.00 50% PVI in SBR 1.00 1.00 1.00 1.00 1.00
PB(OBTS)75 2.00 2.00 2.00 2.00 2.00 PB(TMTM)75 0.15 0.15 0.15 0.15
0.15 TOTAL 218.95 216.45 218.95 238.95 258.95
[0033] 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-US-00003 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 210 323 511 695 366 (psi)
100% Tensile Modulus 478 701 991 1093 873 (psi) 5% Compression 56
84 108 122 -- Modulus (psi) 10% Compression 111 170 224 276 --
Modulus (psi) 15% Compression 171 261 344 423 -- Modulus (psi) Tear
Strength (lb/in) 203 219 237 234 194 Hardness (Shore A) 75 84 88 91
88 Rheological Parameter 2.3 2.8 3.0 3.3 3.4 M.sub.L (lb in)
Rheological Parameter 63 73 88 80 68 M.sub.H (lb in) Tan.delta. at
250.degree. F. 0.15 0.18 0.20 0.23 0.24
TABLE-US-00004 TABLE IV Elastomeric Property Test Method Tensile
Strength (psi) ASTM D412, Die C Ultimate Elongation (psi) ASTM
D412, Die C 25% Tensile Modulus (psi) ASTM D412, Die C 100% Tensile
Modulus (psi) ASTM D412, Die C 5% Compression Modulus (psi) ASTM
D575 10% Compression Modulus (psi) ASTM D575 15% Compression
Modulus (psi) ASTM D575 Tear Strength (lb/in) ASTM D624 Die C
Hardness (Shore A) ASTM D2240 Rheological Parameter M.sub.L ASTM
2084, 380.degree. F. no preheat Rheological Parameter M.sub.H ASTM
2084, 380.degree. F. no preheat Tan.delta. at 250.degree. F. RPA
Aftercure, 10 Hz, 7% strain
[0034] With reference now to FIG. 3, 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.
[0035] FIG. 3 plots RPM versus pressure drop (psi) from the top to
the bottom of the stator. As shown, 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. For example, at a pressure drop of
1000 psi drilling motor C (including elastomer C) exhibits an RPM
drop of only about 45 rpm versus an RPM drop off of about 105 rpm
for the conventional stator (including elastomer STD). 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).
[0036] 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).
[0037] Although the present invention and its advantages have been
described in detail, it should be understood that various changes,
substitutions and alternations can be made herein without departing
from the spirit and scope of the invention as defined by the
appended claims.
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