Stator compound having an NBIR terpolymer elastomeric base and stators and downhole motors using the same

Abstract

A stator compound including an acrylonitrile butadiene isoprene rubber (NBIR) terpolymer elastomeric base.

Claims

1. A method of making a stator compound, comprising: during a first mixing stage, mixing a high reinforcing carbon black with an elastomeric base at a temperature below about 300 degrees Fahrenheit without curing agents to produce a mixture, wherein the elastomeric base has one or more rubber components, wherein the only rubber components of the elastomeric base are acrylonitrile butadiene isoprene rubbers (NBIR); and during a second mixing stage, mixing curing agents into the mixture.

2. The method of claim 1, wherein mixing a high reinforcing carbon black with the elastomeric base comprises mixing a high reinforcing carbon black having a surface area of about 80 to about 250 (Iodine # mg/g) and a structure of about 70 to about 178 (DOP Absorptioncc/100 g) with the elastomeric base.

3. The method of claim 1, further comprising mixing a semi-reinforcing carbon black with the elastomeric base during the first mixing stage.

4. The method of claim 3, wherein mixing a semi-reinforcing carbon black with the elastomeric base comprises mixing a semi-reinforcing carbon black having a surface area of about 20 to about 50 (Iodine # mg/g) and a structure of about 60 to about 125 (DOP Absorptioncc/100 g) with the elastomeric base.

5. The method of claim 1, further comprising mixing at least one plasticizer selected from the group consisting of polymeric and ester plasticizers with the elastomeric base during the first mixing stage.

6. The method of claim 1, wherein mixing curing agents into the mixture comprises mixing sulfur into the mixture during the second mixing stage.

7. The method of claim 1, further comprising mixing an antioxidant with the elastomeric base during the first mixing stage.

8. The method of claim 1, further comprising mixing at least one of a phenolic resin without a curing agent, zinc oxide, stearic acid, and hexamethylene tetraamine with the elastomeric base during the first mixing stage.

9. A stator for use in a downhole motor or pump and having a stator liner, the stator liner formed of a stator compound having an elastomeric base, the elastomeric base having one or more rubber components, wherein the only rubber components of the elastomeric base are acrylonitrile butadiene isoprene rubbers (NBIR).

10. The stator of claim 9, wherein the rubber components are selected from the group consisting of hydrogenated acrylonitrile butadiene isoprene rubber (HNBIR), acrylonitrile butadiene isoprene rubber that has not been hydrogenated, and carboxylated acrylonitrile butadiene isoprene rubber (XNBIR).

11. The stator of claim 9, wherein the stator liner is formed of a stator compound further including a least one of a high reinforcing carbon black and a semi-reinforcing carbon black.

12. The stator of claim 9, wherein the stator liner is formed of a stator compound further including a high reinforcing carbon black having a surface area of about 80 to about 250 (Iodine # mg/g) and a structure of about 70 to about 178 (DOP Absorptioncc/100 g).

13. The stator of claim 9, wherein the stator liner is formed of a stator compound further including a semi-reinforcing carbon black has a surface area of about 20 to about 50 (Iodine # mg/g) and a structure of about 60 to about 125 (DOP Absorptioncc/100 g).

14. The stator of claim 9, wherein the stator liner is formed of a stator compound further including at least one plasticizer selected from the group consisting of polymeric and ester plasticizers.

15. The stator of claim 9, wherein the stator liner is formed of a stator compound further including an antioxidant.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) 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:

(2) FIG. 1A is a perspective view of a downhole motor assembly suitable for describing a typical application of the principles of the present invention;

(3) FIG. 1B is a top cross-sectional view of the rotor and stator assembly of FIG. 1A; and

(4) FIG. 2 is cutaway view showing a portion of the stator of FIGS. 1A and 1B including a molded stator elastomeric liner fabricated using an NBIR terpolymer according to the principles of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

(5) The principles of the present invention and their advantages are best understood by referring to the illustrated embodiment depicted in FIGS. 1-2 of the drawings, in which like numbers designate like parts.

(6) FIG. 1A is a diagram of an exemplary downhole motor assembly 100, which attaches to the end of a drilling string during oil and gas drilling operations. Exemplary downhole motor assembly 100 includes a top sub 101, stator and rotor assembly 102, transmission 103, offset or adjustable housing 104, bearing assembly 105, and drill bit 106. FIG. 1B is an end cut-away view of stator and rotor assembly 102 and shows the helical rotor 109 offset within the helical liner 108 of stator tube 107.

(7) FIG. 2 is a side cutaway view of stator and rotor assembly 102 of FIG. 1, which shows stator tube 107 and associated molded stator elastomer lining 106 in further detail. The fabrication of molded stator elastomer lining 108 is one exemplary use of a NBIR terpolymer embodying the principles of the present invention.

(8) Moreover, stator compounds of according to the principles of the present invention are also suitable for the fabrication of NBIR terpolymer stator liners used in downhole pumps. (Generally, downhole motors and pumps are structurally similar, and both implement power conversion, with downhole motors typically used to provide torque and rotation to the drill bit and downhole pumps typically used to provide pressure and flow rate for moving fluids. The typical downhole pump stator will have as few as two lobes and the typical downhole motor stator will have between three and ten lobes.)

(9) Several elastomers types and cure systems were investigated by the inventors. The focus was to fabricate a stator lining with good dynamic mechanical properties, low swell in diesel-based muds and good hot mechanical properties at 200-350 F. It was found that the use of NBIR terpolymer in stator compounds improved dynamic mechanical properties such as sealing, hysteresis (Tan Delta) modulus, tensile strength, tear and flex-fatigue resistance. An isoprene unit was selected to be the same as in natural rubber, which is known to have these good dynamic properties. The isoprene content is nominally in the range of 5-50%, and preferably in the range of 10-30%. The acrylonitrile group (ACN) provides the resistance to drilling fluids such as oil and diesel-based muds.

(10) According to one preferred process, the selected NBIR Terpolymer is mixed in a production rubber mixer using a two step mixing procedure to ensure dispersion of high reinforcing carbon black and other additives. In addition, this procedure also produces optimum flow (viscosity) properties and mechanical strength. A sulfur, sulfur phenolic or peroxide/co-agent cure system is preferably used to cure the compound. This cure system was developed to produce optimum scorch and curing properties. A blend of plasticizers is used to achieve good flow and diesel extraction properties.

(11) Table 1 illustrates the preferred ingredients for the first step in producing NBIR stator compounds according to the principles of the present invention. Ranges for the preferred ingredients are listed in parts per one hundred parts of rubber (PHR). In particular, the high reinforcing carbon black has a surface area of 80-250 (Iodine # mg/g) and structure of 70-178 (DOP Absorptioncc/100 g) and the semi-reinforcing carbon black has a surface area of 20-50 (Iodine # mg/g) and structure of 60-125 (DOP Absorptioncc/100 g).

(12) During the first step, the ingredients in Table 1 are mixed in a commercial rubber mixer for approximately 4-10 minutes and a temperature below 300 F. The mixture (i.e., the first pass masterbatch) is then allowed to cool to ambient temperature prior to the second mixing step.

(13) TABLE-US-00001 TABLE 1 INGREDIENTS (1.sup.ST MIX CYCLE) PHR NBIR TERPOLYMER 100.0 ANTIOXIDANT 0.2-2.0 ANTIOZONANT 0.5-3.0 SEMI-REINFORCING CARBON BLACK 40-120 HIGH REINFORCING CARBON BLACK 5.0-40 POLYMERIC PLASTICIZER 5.0-40.0 ESTER PLASTICIZER 5.0-20.0 PHENOLIC RESIN 10.0-50.0 ZINC OXIDE 3.0-5.0 STEARIC ACID 1.0-5.0 HEXAMETHYLENE TETRAAMINE 1.0-8.0 RETARDERS 0.2-4.0

(14) The preferred ingredients for the second mixing step are shown in Table 2. During the second mixing step, the ingredients of Table 2 are mixed for approximately 2-5 minutes at less than 225 F., after which mixture is dumped from the mixer and onto a two-roll mill.

(15) TABLE-US-00002 TABLE 2 INGREDIENTS (2.sup.ND MIX CYCLE) 1.sup.ST PASS MASTERBATCH PHR SULFUR 0.50-5.0 RUBBER ACCELERATORS 0.5-5.0

(16) The resulting NBIR terpolymer compound has been shown to have good resistance in water and diesel-based drilling fluids. This compound also shows good dynamic mechanical properties, flex fatigue life and tear resistance at high temperatures (200-350 F.). The high value at low strain modulus (i.e., less than 25%) reduces flexing of the stator lobe, which results in improved performance.

(17) The characteristics of the preferred embodiment of the present NBIR terpolymer stator compound are provided in Table 3:

(18) TABLE-US-00003 TABLE 3 RHEOLOGICAL, CURE AND MECHANICAL PROPERTIES FOR NBIR STATOR COMPOUND VISCOSITY MOONEY VISC. 20-100 (ASTM D1646) (ML1 + 4) @ 100 C. MU MOONEY SCORCH >60 T5@100 C. minutes RHEOLOGY MDR (Rheometer) 60 @ 160 C. (ASTM 2084) ML (dNm).sup.1 0.5-3.0 MH (dNm) 20-80 TS (2) minutes 1.5-5.0 TC (90) minutes 5.0-25.0 Tan Delta 0.10-0.30 MICRODUMBELL HOT PROPERTIES (ASTM D1708) TENSILE STRENGTH (psi).sup.2 800-2000 Tested @ 121 C. ELONGATION % 125-300 25% MODULUS (psi) 250-600 TEAR DIE C @ 121 C. (ppi) 50-200 (ASTM D624) TROUSER @ 121 C. (ppi).sup.3 5-100 DIN ABRASION (ASTM D5963) cured 30@177 C. 100-250 (mm.sup.3) DeMattia Flex Final Crack Width (mm) 18.5 (ASTM D813) Cycles to Final Width 5,000-20,000 Initial piercing is 2 mm wide per ASTM D813. Width of specimen is 25.4 mm. Capillary Load: 35 kg Shear Rate (s.sup.1) 5-20 Rheometer Kgkilograms (ASTM D5099) Viscosity (Pa .Math. s).sup.4 100-400 Die: 1.0 mm 2.0 mm/Temp: 100 C. DIESEL-BASED MUD RESISTANCE 72 H @ 250 F. % VOLUME CHANGE - +5.0/2.0 SHORE A HARDNESS CHANGE +5/5 25% MODULUS (% CHANGE) +25/10 TENSILE STRENGTH (% CHANGE) +25/10 ELONGATION (% CHANGE) +10/25 .sup.1dNm = decinewtons meter .sup.2Psi = pounds per square inch .sup.3Ppi = pounds per inch .sup.4Pa .Math. s = Pascal .Math. second

(19) Although the invention has been described with reference to specific embodiments, these descriptions are not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed might 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 realized 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.

(20) It is therefore contemplated that the claims will cover any such modifications or embodiments that fall within the true scope of the invention.