EP4189203A1 - Metal felt and brush structures as sealing elements in metal-metal mud motors - Google Patents
Metal felt and brush structures as sealing elements in metal-metal mud motorsInfo
- Publication number
- EP4189203A1 EP4189203A1 EP21851518.7A EP21851518A EP4189203A1 EP 4189203 A1 EP4189203 A1 EP 4189203A1 EP 21851518 A EP21851518 A EP 21851518A EP 4189203 A1 EP4189203 A1 EP 4189203A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- pattern
- mud motor
- lining
- fiber
- stator
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000002184 metal Substances 0.000 title description 7
- 229910052751 metal Inorganic materials 0.000 title description 7
- 238000007789 sealing Methods 0.000 title description 3
- 239000000835 fiber Substances 0.000 claims abstract description 69
- 239000011248 coating agent Substances 0.000 claims abstract description 6
- 238000000576 coating method Methods 0.000 claims abstract description 6
- 238000000034 method Methods 0.000 claims description 39
- 239000000463 material Substances 0.000 claims description 22
- 230000008569 process Effects 0.000 claims description 21
- 229920001971 elastomer Polymers 0.000 claims description 13
- 239000000806 elastomer Substances 0.000 claims description 11
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 10
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 10
- 229920002530 polyetherether ketone Polymers 0.000 claims description 10
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 10
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 10
- -1 polytetrafluoroethylene Polymers 0.000 claims description 8
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 5
- 229910000881 Cu alloy Inorganic materials 0.000 claims description 5
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 5
- 239000000853 adhesive Substances 0.000 claims description 5
- 230000001070 adhesive effect Effects 0.000 claims description 5
- 238000005219 brazing Methods 0.000 claims description 5
- 239000004917 carbon fiber Substances 0.000 claims description 5
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 239000010949 copper Substances 0.000 claims description 5
- 239000003365 glass fiber Substances 0.000 claims description 5
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 5
- 229910052759 nickel Inorganic materials 0.000 claims description 5
- 229920000642 polymer Polymers 0.000 claims description 5
- 238000005245 sintering Methods 0.000 claims description 5
- 238000005476 soldering Methods 0.000 claims description 5
- 239000010935 stainless steel Substances 0.000 claims description 5
- 229910001220 stainless steel Inorganic materials 0.000 claims description 5
- 238000003466 welding Methods 0.000 claims description 5
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 238000005553 drilling Methods 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000005229 chemical vapour deposition Methods 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 239000003607 modifier Substances 0.000 description 2
- 238000005240 physical vapour deposition Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 241001074085 Scophthalmus aquosus Species 0.000 description 1
- 238000010793 Steam injection (oil industry) Methods 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 239000012267 brine Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 239000003995 emulsifying agent Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000000700 radioactive tracer Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000000638 stimulation Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- 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
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2/00—Rotary-piston machines or pumps
- F04C2/08—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing
- F04C2/10—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member
- F04C2/107—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth
- F04C2/1071—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth the inner and outer member having a different number of threads and one of the two being made of elastic materials, e.g. Moineau type
- F04C2/1073—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth the inner and outer member having a different number of threads and one of the two being made of elastic materials, e.g. Moineau type where one member is stationary while the other member rotates and orbits
- F04C2/1075—Construction of the stationary member
-
- 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
- F04C2230/60—Assembly methods
-
- 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
- F04C2230/90—Improving properties of machine parts
- F04C2230/91—Coating
-
- 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
- F04C2240/00—Components
- F04C2240/10—Stators
-
- 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
- F04C2240/00—Components
- F04C2240/20—Rotors
-
- 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
- F04C2240/00—Components
- F04C2240/80—Other components
- F04C2240/802—Liners
Definitions
- a mud motor is used in a drill string downhole, e.g. to power various tools of the drill string, such as a drill bit, using a flow of mud through the drill string.
- the mud motor includes a stator and a rotor that rotates within the stator, rubbing against the stator as it rotates.
- an elastomeric motor lining is placed on a surface of either the rotor or the stator in order to reduce friction and improve motor efficiency.
- these elastomeric layers decompose at high temperatures, thereby degrading performing.
- the elastomeric layer can be left off, instead allowing the stator and rotor to meet at a metal-metal interface.
- the metal-metal interface however leaves the efficiency and operation of the mud motor susceptible to dimensional tolerances. Therefore, there is a need to provide a lining to a mud motor that operates effectively and over a long time period at high temperatures.
- a mud motor in one aspect, includes a stator, a rotor and a lining between the stator and the rotor, the lining including fibers forming a fiber pattern .
- a drill string in another aspect, includes a mud motor having a stator and a rotor.
- a lining between the stator and the rotor includes fibers forming a fiber pattern.
- FIG. 1 shows a lower section of a drill string
- FIG. 2 shows a cross section of the mud motor in an embodiment
- FIGS. 3 A-3D show various fiber structures or fiber patterns suitable for forming a lining of the mud motor in various embodiments.
- Drill string 100 is configured to drill a borehole into the earth’s subsurface.
- the lower section includes a top sub 102 and a mud motor 104 connected to the top sub 102.
- the mud motor 104 connects at its lower end to a flexible shaft 106 and that passes through a lower sub 108 located below the mud motor 104.
- the lower sub 108 may include an adjustable kick off 110 and a stabilizer 112 which can be used to orient the drill string 100.
- a drill bit 118 at the lower end of the lower sub 108 is used to cut a formation.
- a drilling fluid or mud flows through the drill string 100 from a surface location to exit the drill string at the drill bit 118.
- the mud rotates a rotor of the mud motor with respect to a stator of the mud motor, therefore causing a rotation of the flexible shaft 106.
- Rotation of the flexible shaft 106 causes a rotation of the drill bit 118 which is mechanically coupled to the flexible shaft 106.
- FIG. 2 shows a cross section 200 of the mud motor 104 in an embodiment.
- the cross-section shows a housing 202, a stator 204 within the housing 202 and a rotor 206.
- FIG. 2 shows housing 202 and stator 204 separated.
- housing 202 and stator 204 may be one integral part.
- the stator 204 includes a lobed inner surface 208 and the rotor 206 includes a lobed outer surface 210.
- the number of lobes on the rotor 206 is less than the number of lobes on the stator, thereby causing an eccentric rotation of the rotor.
- the lobed inner surface 208 or the lobed outer surface 210 or both can be coated with a lining.
- the lining material preferably is elastic for high efficiency, ease of assembly, and reasonable tolerances.
- an elastomer e.g. rubber
- elastomer has the disadvantage that it does not withstand high temperatures, such as temperatures higher than 150°C, e.g. higher than 175 °C or even 200 °C.
- fiber structures are used as a material for the lining. The fiber structures are made of fibers forming a fiber pattern as discussed below with respect to FIGS. 3 A-3D.
- FIGS. 3A-3D show various fiber structures or fiber patterns suitable for forming a lining of the mud motor in various embodiments.
- the disclosed fiber patterns form structures which are used as a sealing element for its associated surface.
- the fiber patterns are discussed as being applied to the lobed inner surface 208 of the stator 204.
- the associated surface can also be the lobed outer surface 210 of the rotor 206.
- FIG. 3 A shows a fiber pattern in which the fibers of the lining form a felt pattern over the lobed inner surface 208.
- a felt pattern includes a plurality of fibers 302 that have been matted and pressed together.
- FIG. 3B shows an illustrative embodiment of fibers 302 forming a web pattern on the lobed inner surface 208.
- the web pattern is an ordered pattern of fibers 302, generally forming a two-dimensional pattern.
- the fibers 302 form a windowpane structure in which fibers intersect each other at approximately right angles.
- a web patterns can include any other desired fiber pattern, including hexagonal web patterns, parallelogram web patterns, etc.
- FIG. 3C shows fibers 302 forming a mesh pattern.
- fibers 302 are aligned parallel to each along a selected direction parallel and crossing over to the lobed inner surface 208 of the stator.
- FIG. 3D shows fibers 302 aligned to form a brush pattern at the lobed inner surface 208.
- the fibers 302 are aligned perpendicular, or substantially perpendicular, to the lobed inner surface 208.
- the fibers 302 can be made of any suitable metal to form the fiber patterns.
- Exemplary material for the fibers include metals such as nickel, nickel alloy, stainless steel, low ally steel, copper or copper alloy.
- the material of the fibers can be a carbon fiber, a glass fiber or a polymeric fiber.
- the lining can be adhered to the surface of either the stator or the rotor using any suitable adhering method, including a sintering process, a soldering process, a welding process, a brazing process, or applying an adhesive between the lining and its associated surface.
- a sintering process including a sintering process, a soldering process, a welding process, a brazing process, or applying an adhesive between the lining and its associated surface.
- PVD physical vapor deposition
- CVD chemical vapor deposition
- the fibers can be coated by a suitable coating material to provide improved chemical, thermal and corrosion resistance or better tribological or mechanical properties.
- the fiber patterns can include gaps 304 between the fibers 302.
- the gaps 304 can be left open or vacant.
- the gaps 304 can be filled or partially filled with a secondary material.
- the secondary material can be a polymer, such as an elastomer, polytetrafluoroethylene (PTFE) polyether ether ketone (PEEK), or other composite material etc., or any combination thereof.
- the gaps 304 are at least partially filled with a material but are free of elastomer or rubber.
- a lining made of fiber patterns and free of elastomer is beneficial as the absence of the elastomer enables the lining to withstand higher temperatures, such as temperatures higher than 150 C, e.g. 175 C, or even 200 C.
- a mud motor comprising a lining made of fiber patterns, such as a lining made of fiber patterns and free of elastomer, is operable at high temperature downhole conditions (for examples, at temperatures higher than 150° C, 175° C, or even 200 C) for a significant amount of time, such as a time larger than 40, 120, or even 360 circulation hours (i.e. the amount of hours the drilling fluid is circulated through the motor).
- Such a mud motor allows drilling runs in a downhole environment with an environmental temperature higher than 150 C, 175 C, or even 200 C, wherein the drilling runs last 40, 120, or even 360 circulation hours without the need to pull the mud motor out of the borehole for the reason of insufficient motor efficiency (e.g. insufficient motor torque, insufficient motor power, or insufficient rotational velocity of the rotor relative to the stator of the motor).
- insufficient motor efficiency e.g. insufficient motor torque, insufficient motor power, or insufficient rotational velocity of the rotor relative to the stator of the motor.
- Embodiment 1 A mud motor.
- the mud motor includes a stator, a rotor and a lining between the stator and the rotor, the lining including fibers forming a fiber pattern.
- Embodiment 2 The mud motor of any prior embodiment, wherein the lining is a coating of at least one of a lobed inner surface of the stator and a lobed outer surface of the rotor.
- Embodiment 3 The mud motor of any prior embodiment, wherein the lining is adhered by at least one of: (i) an adhesive; (ii) a sintering process; (iii) a soldering process; (iv) a welding process; and (v) a brazing process.
- Embodiment 4 The mud motor of any prior embodiment, wherein the fiber pattern further comprises one of: (i) a felt pattern; (ii) a web pattern; (iii) a mesh pattern; and (iv) a brush pattern.
- Embodiment 5 The mud motor of any prior embodiment, wherein a material of the fibers includes at least one of: (i) nickel; (ii) nickel alloy; (iii) stainless steel; (iv) low alloy steel; (v) copper; (vi) copper alloy; (vii) carbon fiber; (viii) glass fiber; and (ix) polymeric fiber.
- Embodiment 6 The mud motor of any prior embodiment, wherein the fiber pattern includes a gap between the fibers.
- Embodiment 7 The mud motor of any prior embodiment, further comprising a secondary material in the gap, the secondary material being at least one of: (i) polytetrafluoroethylene (PTFE); (ii) polyether ether ketone (PEEK); (iii) a polymer; and (iv) an elastomer.
- PTFE polytetrafluoroethylene
- PEEK polyether ether ketone
- a polymer elastomer
- Embodiment 8 The mud motor of any prior embodiment, wherein the gap is unfilled.
- Embodiment 9 The mud motor of any prior embodiment, wherein the mud motor is configured to operate at temperatures higher than 150 C for more than 40 circulation hours.
- Embodiment 10 A method of manufacturing a mud motor.
- a mud motor is formed including a stator and a rotor.
- a lining is disposed between the stator and the rotor, the lining including fibers forming a fiber pattern.
- Embodiment 11 The method of any prior embodiment, wherein the lining is a coating of at least one of a lobed inner surface of the stator and a lobed outer surface of the rotor.
- Embodiment 12 The method of any prior embodiment, wherein the lining is adhered by at least one of: (i) an adhesive; (ii) a sintering process; (iii) a soldering process; (iv) a welding process; and (v) a brazing process.
- Embodiment 13 The method of any prior embodiment, wherein the fiber pattern further comprises one of: (i) a felt pattern; (ii) a web pattern; (iii) a mesh pattern; and (iv) a brush pattern.
- Embodiment 14 The method of any prior embodiment, wherein a material of the fibers include at least one of: (i) nickel; (ii) nickel alloy; (iii) stainless steel; (iv) low alloy steel; (v) copper; (vi) copper alloy; (vii) carbon fiber; (viii) glass fiber; and (ix) polymeric fiber.
- Embodiment 15 The method of any prior embodiment, wherein the fiber pattern includes a gap between the fibers.
- Embodiment 16 The method of any prior embodiment, wherein the gaps are filled with a secondary material, wherein the secondary material is at least one of: (i) PTFE (polytetrafluoroethylene); (ii) PEEK (polyether ether ketone); (iii) a polymer; and (iv) an elastomer.
- PTFE polytetrafluoroethylene
- PEEK polyether ether ketone
- a polymer polymer
- an elastomer an elastomer.
- Embodiment 17 The method of any prior embodiment, wherein the one or more gaps are unfilled.
- Embodiment 18 The method of any prior embodiment, wherein the mud motor is configured to operate at temperatures higher than 150 C for more than 40 circulation hours.
- the use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).
- the teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and / or equipment in the wellbore, such as production tubing.
- the treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof.
- Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc.
- Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.
Abstract
A mud motor and a drill string having the mud motor. The mud motor includes a stator and a rotor. A lining between the stator and the rotor includes fibers forming a fiber pattern. The lining is a coating of at least one of a lobed inner surface of the stator and a lobed outer surface of the rotor.
Description
METAL FELT AND BRUSH STRUCTURES AS SEALING ELEMENTS IN METAL-
METAL MUD MOTORS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of United States Application No 63/059,856, filed July 31, 2020, which is incorporated by reference herein in its entirety.
BACKGROUND
[0002] In the resource recovery industry, a mud motor is used in a drill string downhole, e.g. to power various tools of the drill string, such as a drill bit, using a flow of mud through the drill string. The mud motor includes a stator and a rotor that rotates within the stator, rubbing against the stator as it rotates. Often an elastomeric motor lining is placed on a surface of either the rotor or the stator in order to reduce friction and improve motor efficiency. However, these elastomeric layers decompose at high temperatures, thereby degrading performing. Alternatively, the elastomeric layer can be left off, instead allowing the stator and rotor to meet at a metal-metal interface. The metal-metal interface however leaves the efficiency and operation of the mud motor susceptible to dimensional tolerances. Therefore, there is a need to provide a lining to a mud motor that operates effectively and over a long time period at high temperatures.
SUMMARY
[0003] In one aspect, a mud motor is disclosed. The mud motor includes a stator, a rotor and a lining between the stator and the rotor, the lining including fibers forming a fiber pattern .
[0004] In another aspect, a drill string is disclosed. The drill string includes a mud motor having a stator and a rotor. A lining between the stator and the rotor includes fibers forming a fiber pattern.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting in any way.
With reference to the accompanying drawings, like elements are numbered alike:
[0006] FIG. 1 shows a lower section of a drill string;
[0007] FIG. 2 shows a cross section of the mud motor in an embodiment; and
[0008] FIGS. 3 A-3D show various fiber structures or fiber patterns suitable for forming a lining of the mud motor in various embodiments.
DETAILED DESCRIPTION
[0009] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0010] Referring to FIG. 1, a lower section of a drill string 100 is shown. Drill string 100 is configured to drill a borehole into the earth’s subsurface. The lower section includes a top sub 102 and a mud motor 104 connected to the top sub 102. The mud motor 104 connects at its lower end to a flexible shaft 106 and that passes through a lower sub 108 located below the mud motor 104. The lower sub 108 may include an adjustable kick off 110 and a stabilizer 112 which can be used to orient the drill string 100. A drill bit 118 at the lower end of the lower sub 108 is used to cut a formation. In operation, a drilling fluid or mud, flows through the drill string 100 from a surface location to exit the drill string at the drill bit 118. As the mud passes through the mud motor 104, the mud rotates a rotor of the mud motor with respect to a stator of the mud motor, therefore causing a rotation of the flexible shaft 106. Rotation of the flexible shaft 106 causes a rotation of the drill bit 118 which is mechanically coupled to the flexible shaft 106.
[0011] FIG. 2 shows a cross section 200 of the mud motor 104 in an embodiment.
The cross-section shows a housing 202, a stator 204 within the housing 202 and a rotor 206. FIG. 2 shows housing 202 and stator 204 separated. Alternatively, housing 202 and stator 204 may be one integral part. The stator 204 includes a lobed inner surface 208 and the rotor 206 includes a lobed outer surface 210. The number of lobes on the rotor 206 is less than the number of lobes on the stator, thereby causing an eccentric rotation of the rotor. The lobed inner surface 208 or the lobed outer surface 210 or both can be coated with a lining. The lining material preferably is elastic for high efficiency, ease of assembly, and reasonable tolerances. In one embodiment, an elastomer (e.g. rubber) is used as a material for the lining. However, elastomer has the disadvantage that it does not withstand high temperatures, such as temperatures higher than 150°C, e.g. higher than 175 °C or even 200 °C. In another embodiment, fiber structures are used as a material for the lining. The fiber structures are made of fibers forming a fiber pattern as discussed below with respect to FIGS. 3 A-3D.
[0012] FIGS. 3A-3D show various fiber structures or fiber patterns suitable for forming a lining of the mud motor in various embodiments. The disclosed fiber patterns form
structures which are used as a sealing element for its associated surface. For ease of explanation, the fiber patterns are discussed as being applied to the lobed inner surface 208 of the stator 204. However, it is to be understood that the associated surface can also be the lobed outer surface 210 of the rotor 206. FIG. 3 A shows a fiber pattern in which the fibers of the lining form a felt pattern over the lobed inner surface 208. A felt pattern includes a plurality of fibers 302 that have been matted and pressed together. The matting or pressing process produces fibers 302 of the felt structure that are randomly oriented or otherwise unaligned with each other. FIG. 3B shows an illustrative embodiment of fibers 302 forming a web pattern on the lobed inner surface 208. The web pattern is an ordered pattern of fibers 302, generally forming a two-dimensional pattern. As shown in FIG. 3B, the fibers 302 form a windowpane structure in which fibers intersect each other at approximately right angles. However, a web patterns can include any other desired fiber pattern, including hexagonal web patterns, parallelogram web patterns, etc. FIG. 3C shows fibers 302 forming a mesh pattern. In the mesh pattern, fibers 302 are aligned parallel to each along a selected direction parallel and crossing over to the lobed inner surface 208 of the stator. FIG. 3D shows fibers 302 aligned to form a brush pattern at the lobed inner surface 208. In a brush pattern, the fibers 302 are aligned perpendicular, or substantially perpendicular, to the lobed inner surface 208.
[0013] The fibers 302 can be made of any suitable metal to form the fiber patterns. Exemplary material for the fibers include metals such as nickel, nickel alloy, stainless steel, low ally steel, copper or copper alloy. In other embodiments, the material of the fibers can be a carbon fiber, a glass fiber or a polymeric fiber.
[0014] The lining can be adhered to the surface of either the stator or the rotor using any suitable adhering method, including a sintering process, a soldering process, a welding process, a brazing process, or applying an adhesive between the lining and its associated surface. In one embodiment, physical vapor deposition (PVD) or chemical vapor deposition (CVD) can be used to chemically grow or deposit the fibers onto the outer surface. The fibers can be coated by a suitable coating material to provide improved chemical, thermal and corrosion resistance or better tribological or mechanical properties.
[0015] As seen in FIGS. 3A-3D, the fiber patterns can include gaps 304 between the fibers 302. In various embodiments, the gaps 304 can be left open or vacant. In other embodiments, the gaps 304 can be filled or partially filled with a secondary material. The secondary material can be a polymer, such as an elastomer, polytetrafluoroethylene (PTFE) polyether ether ketone (PEEK), or other composite material etc., or any combination thereof.
In one embodiment, the gaps 304 are at least partially filled with a material but are free of elastomer or rubber. A lining made of fiber patterns and free of elastomer is beneficial as the absence of the elastomer enables the lining to withstand higher temperatures, such as temperatures higher than 150 C, e.g. 175 C, or even 200 C. For example, a mud motor comprising a lining made of fiber patterns, such as a lining made of fiber patterns and free of elastomer, is operable at high temperature downhole conditions (for examples, at temperatures higher than 150° C, 175° C, or even 200 C) for a significant amount of time, such as a time larger than 40, 120, or even 360 circulation hours (i.e. the amount of hours the drilling fluid is circulated through the motor). Such a mud motor allows drilling runs in a downhole environment with an environmental temperature higher than 150 C, 175 C, or even 200 C, wherein the drilling runs last 40, 120, or even 360 circulation hours without the need to pull the mud motor out of the borehole for the reason of insufficient motor efficiency (e.g. insufficient motor torque, insufficient motor power, or insufficient rotational velocity of the rotor relative to the stator of the motor).
[0016] Set forth below are some embodiments of the foregoing disclosure:
[0017] Embodiment 1 : A mud motor. The mud motor includes a stator, a rotor and a lining between the stator and the rotor, the lining including fibers forming a fiber pattern.
[0018] Embodiment 2: The mud motor of any prior embodiment, wherein the lining is a coating of at least one of a lobed inner surface of the stator and a lobed outer surface of the rotor.
[0019] Embodiment 3: The mud motor of any prior embodiment, wherein the lining is adhered by at least one of: (i) an adhesive; (ii) a sintering process; (iii) a soldering process; (iv) a welding process; and (v) a brazing process.
[0020] Embodiment 4: The mud motor of any prior embodiment, wherein the fiber pattern further comprises one of: (i) a felt pattern; (ii) a web pattern; (iii) a mesh pattern; and (iv) a brush pattern.
[0021] Embodiment 5: The mud motor of any prior embodiment, wherein a material of the fibers includes at least one of: (i) nickel; (ii) nickel alloy; (iii) stainless steel; (iv) low alloy steel; (v) copper; (vi) copper alloy; (vii) carbon fiber; (viii) glass fiber; and (ix) polymeric fiber.
[0022] Embodiment 6: The mud motor of any prior embodiment, wherein the fiber pattern includes a gap between the fibers.
[0023] Embodiment 7. The mud motor of any prior embodiment, further comprising a secondary material in the gap, the secondary material being at least one of: (i)
polytetrafluoroethylene (PTFE); (ii) polyether ether ketone (PEEK); (iii) a polymer; and (iv) an elastomer.
[0024] Embodiment 8: The mud motor of any prior embodiment, wherein the gap is unfilled.
[0025] Embodiment 9: The mud motor of any prior embodiment, wherein the mud motor is configured to operate at temperatures higher than 150 C for more than 40 circulation hours.
[0026] Embodiment 10: A method of manufacturing a mud motor. A mud motor is formed including a stator and a rotor. A lining is disposed between the stator and the rotor, the lining including fibers forming a fiber pattern.
[0027] Embodiment 11 : The method of any prior embodiment, wherein the lining is a coating of at least one of a lobed inner surface of the stator and a lobed outer surface of the rotor.
[0028] Embodiment 12: The method of any prior embodiment, wherein the lining is adhered by at least one of: (i) an adhesive; (ii) a sintering process; (iii) a soldering process; (iv) a welding process; and (v) a brazing process.
[0029] Embodiment 13: The method of any prior embodiment, wherein the fiber pattern further comprises one of: (i) a felt pattern; (ii) a web pattern; (iii) a mesh pattern; and (iv) a brush pattern.
[0030] Embodiment 14: The method of any prior embodiment, wherein a material of the fibers include at least one of: (i) nickel; (ii) nickel alloy; (iii) stainless steel; (iv) low alloy steel; (v) copper; (vi) copper alloy; (vii) carbon fiber; (viii) glass fiber; and (ix) polymeric fiber.
[0031] Embodiment 15: The method of any prior embodiment, wherein the fiber pattern includes a gap between the fibers.
[0032] Embodiment 16: The method of any prior embodiment, wherein the gaps are filled with a secondary material, wherein the secondary material is at least one of: (i) PTFE (polytetrafluoroethylene); (ii) PEEK (polyether ether ketone); (iii) a polymer; and (iv) an elastomer.
[0033] Embodiment 17: The method of any prior embodiment, wherein the one or more gaps are unfilled.
[0034] Embodiment 18: The method of any prior embodiment, wherein the mud motor is configured to operate at temperatures higher than 150 C for more than 40 circulation hours.
[0035] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the particular quantity).
[0036] The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and / or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc.
[0037] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited.
Claims
1. A mud motor (104), comprising: a stator (204); a rotor (206); and a lining between the stator (204) and the rotor (206), the lining including fibers (302) forming a fiber pattern.
2. The mud motor (104) of claim 1, wherein the lining is a coating of at least one of a lobed inner surface (208) of the stator (204) and a lobed outer surface (210) of the rotor (206).
3. The mud motor (104) of claim 2, wherein the lining is adhered by at least one of:
(i) an adhesive; (ii) a sintering process; (iii) a soldering process; (iv) a welding process; and (v) a brazing process.
4. The mud motor (104) of claim 1, wherein the fiber pattern further comprises one of: (i) a felt pattern; (ii) a web pattern; (iii) a mesh pattern; and (iv) a brush pattern.
5. The mud motor (104) of claim 1, wherein a material of the fibers includes at least one of: (i) nickel; (ii) nickel alloy; (iii) stainless steel; (iv) low alloy steel; (v) copper; (vi) copper alloy; (vii) carbon fiber; (viii) glass fiber; and (ix) polymeric fiber.
6. The mud motor (104) of claim 1, wherein the fiber pattern includes a gap (304) between the fibers (302).
7. The mud motor (104) of claim 6, further comprising a secondary material in the gap (304), the secondary material being at least one of: (i) polytetrafluoroethylene (PTFE);
(ii) polyether ether ketone (PEEK); (iii) a polymer; and (iv) an elastomer.
8. The mud motor (104) of claim 6, wherein the gap (304) is unfilled.
9. A method for manufacturing a mud motor (104), the method comprising: forming a mud motor (104) comprising a stator (204) and a rotor (206); and disposing a lining between the stator (204) and the rotor (206), the lining including fibers (302) forming a fiber pattern.
10. The method of claim 8, wherein the lining disposed between the stator (204) and the rotor (206) by coating at least one of a lobed inner surface (208) of the stator (204) and a lobed outer surface (210) of the rotor (206) with the lining.
11. The method of claim 10, further comprising adhering the lining by at least one of: (i) an adhesive; (ii) a sintering process; (iii) a soldering process; (iv) a welding process; and (v) a brazing process.
12. The method of claim 9, wherein the fiber pattern further comprises one of: (i) a felt pattern; (ii) a web pattern; (iii) a mesh pattern; and (iv) a brush pattern.
13. The method of claim 9, wherein a material of the fibers (302) include at least one of: (i) nickel; (ii) nickel alloy; (iii) stainless steel; (iv) low alloy steel; (v) copper; (vi) copper alloy; (vii) carbon fiber; (viii) glass fiber; and (ix) polymeric fiber.
14. The method of claim 9, wherein the fiber pattern includes one or more gaps (304) between the fibers.
15. The method of claim 14, wherein the gaps are filled with a secondary material, wherein the secondary material is at least one of: (i) PTFE (polytetrafluoroethylene); (ii) PEEK (polyether ether ketone); (iii) a polymer; and (iv) an elastomer.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US202063059856P | 2020-07-31 | 2020-07-31 | |
PCT/US2021/043494 WO2022026572A1 (en) | 2020-07-31 | 2021-07-28 | Metal felt and brush structures as sealing elements in metal-metal mud motors |
Publications (1)
Publication Number | Publication Date |
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EP4189203A1 true EP4189203A1 (en) | 2023-06-07 |
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Family Applications (1)
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EP21851518.7A Pending EP4189203A1 (en) | 2020-07-31 | 2021-07-28 | Metal felt and brush structures as sealing elements in metal-metal mud motors |
Country Status (4)
Country | Link |
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US (1) | US20220034314A1 (en) |
EP (1) | EP4189203A1 (en) |
CN (1) | CN116137877A (en) |
WO (1) | WO2022026572A1 (en) |
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JP3604438B2 (en) * | 1995-01-13 | 2004-12-22 | 株式会社東芝 | Silicon carbide based fiber composite material and method for producing the same |
US7563504B2 (en) * | 1998-03-27 | 2009-07-21 | Siemens Energy, Inc. | Utilization of discontinuous fibers for improving properties of high temperature insulation of ceramic matrix composites |
US6604922B1 (en) * | 2002-03-14 | 2003-08-12 | Schlumberger Technology Corporation | Optimized fiber reinforced liner material for positive displacement drilling motors |
US20050089429A1 (en) * | 2003-10-27 | 2005-04-28 | Dyna-Drill Technologies, Inc. | Composite material progressing cavity stators |
US20090152009A1 (en) * | 2007-12-18 | 2009-06-18 | Halliburton Energy Services, Inc., A Delaware Corporation | Nano particle reinforced polymer element for stator and rotor assembly |
US9340854B2 (en) * | 2011-07-13 | 2016-05-17 | Baker Hughes Incorporated | Downhole motor with diamond-like carbon coating on stator and/or rotor and method of making said downhole motor |
US20130052067A1 (en) * | 2011-08-26 | 2013-02-28 | Baker Hughes Incorporated | Downhole Motors and Pumps with Improved Stators and Methods of Making and Using Same |
CN205422525U (en) * | 2016-04-03 | 2016-08-03 | 吉林大学 | Screw rod drilling tool motor |
-
2021
- 2021-07-28 EP EP21851518.7A patent/EP4189203A1/en active Pending
- 2021-07-28 CN CN202180060440.4A patent/CN116137877A/en active Pending
- 2021-07-28 WO PCT/US2021/043494 patent/WO2022026572A1/en active Application Filing
- 2021-07-28 US US17/386,886 patent/US20220034314A1/en active Pending
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US20220034314A1 (en) | 2022-02-03 |
CN116137877A (en) | 2023-05-19 |
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