BACKGROUNDDownhole tools used in the hydrocarbon recovery industry often experience extreme conditions, such as, high temperatures and high pressures, for example. These high temperatures can be elevated further by heat generated in by the tools themselves. Mud motors, for example, can generate additional heat during operation thereof. Materials used to fabricate the various components that make up the downhole tools are therefore carefully chosen for their ability to operate, often for long periods of time, in these extreme conditions.
Many polymeric materials have maximum operating temperature ranges, that when exceeded, result in early failure of components made therefrom. Advancements in the field that allow tools to operate below these temperature ranges are well received in the art.
BRIEF DESCRIPTIONDisclosed herein is a downhole mud motor. The mud motor includes, a stator, a rotor in operable communication with the stator, a polymer in operable communication with the stator and the rotor, and a plurality of carbon nanotubes embedded in the polymer.
Further disclosed herein is a method of improving durability of a mud motor elastomer. The method includes, dissipating heat through the mud motor elastomer with carbon nanotubes embedded therein, and maintaining temperature of the mud motor elastomer below a threshold temperature.
BRIEF DESCRIPTION OF THE DRAWINGSThe following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
FIG. 1 depicts a side view of a mud motor disclosed herein;
FIG. 2 depicts a cross sectional view of the mud motor ofFIG. 1; and
FIG. 3 depicts a cross sectional view of the mud motor ofFIG. 2 taken along arrows3-3.
DETAILED DESCRIPTIONA 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.
Referring toFIGS. 1-3, an embodiment of adownhole mud motor10 disclosed herein is illustrated. Themud motor10, among other things, includes, astator14, arotor18 and apolymer22, also referred to herein as an elastomer, positioned between thestator14 and therotor18.Mud26, pumped through themud motor10 flows throughcavities30 defined by clearances betweenlobes34 of thestator14 and theelastomer22 andlobes38 of therotor18. Themud26, being pumped through thecavities30, causes therotor18 to rotate relative to thestator14 and theelastomer22. Theelastomer22 is sealingly engaged with both thestator14 and therotor18 to minimize leakage therebetween that could have a detrimental effect on the performance and efficiency of themud motor10. Theelastomer22, of embodiments disclosed herein, has carbon nanotubes42 (CNT) embedded therein to increase heat transfer through theelastomer22 and into thestator14, therotor18 and themud26. The increased heat transfer, provided by thecarbon nanotubes42, permits temperatures of theelastomer22 to more quickly adjust toward temperatures of matter contacting theelastomer22 than would occur if thecarbon nanotubes42 were not present.
The operating temperature of theelastomer22 can affect the durability of theelastomer22. Typically, the relationship is such that the durability of theelastomer22 reduces as the temperature increases. Additionally, temperature thresholds exist, for specific materials, that when exceeded will significantly reduce the life of theelastomer22.
The elevated operating temperatures of themud motor10 are due, in part, to the high temperatures of the downhole environment in which themud motor10 operates. Additional temperature elevation, beyond that of the environment, is due to such things as, frictional engagement of the elastomer with one or more of thestator14, therotor18 and themud26, and to hysteresis energy, in the form of heat, developed in theelastomer22 during operation of themud motor10, for example. This hysteresis energy comes from the difference in energy required to deform theelastomer22 and the energy recovered from theelastomer22 as the deformation is released. The hysteresis energy generates heat in theelastomer22, called heat build-up. It is these additional sources of heat generation within theelastomer22 that the addition of thenanotubes42 to theelastomer22, as disclosed herein, is added to mitigate.
Several parameters effect the additional heat generation, such as, the amount of dimensional deformation that theelastomer22 undergoes during operation, the frictional engagement between theelastomer22 and therotor18 and anoverall length46 of themud motor10, for example. Additional heat generation may be reduced with specific settings of these parameters, and the temperature of theelastomer22 may be maintainable below specific threshold temperatures. Such settings of the parameters, however, may adversely affect the performance and efficiency of themud motor10, for example, by allowing more leakage therethrough, as well as increase operational and material costs associated therewith. Embodiments disclosed herein allow an increase in power density of amud motor10 by, for example, having a smalleroverall mud motor10 that produces the same amount of output energy to abit50, attached thereto, without resulting in increased temperature of theelastomer22. Additionally, themud motor10, using embodiments disclosed herein, may be able to operate at higher pressures, without leakage between theelastomer22 and therotor18, thereby leading to higher overall motor efficiencies, for example.
Thecarbon nanotubes42, disclosed in embodiments herein, are embedded in theelastomer22, such that, thecarbon nanotubes42 interface with asurface54 of theelastomer22. Having thecarbon nanotubes42 interface with thesurface54 allows a decrease frictional engagement to exist between theelastomer22 and matter that comes into contact with thesurface54, such as, therotor18 and themud26, for example. Such a decrease in friction can result in a corresponding decrease in heat generation. Additionally, in embodiments of the invention, the presence of thecarbon nanotubes42, embedded within theelastomer22, decrease the hysteresis energy and heat generation resulting therefrom.
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. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.