Composite material progressing cavity stators

Abstract

A progressing cavity stator is provided. The progressing cavity stator includes a fiber reinforced composite component providing an internal helical cavity having at least one helical groove and an elastomeric liner disposed on an internal surface of the fiber reinforced composite component. In various exemplary embodiments, the fiber reinforced composite component includes a plurality of fibers disposed in a matrix material, the plurality of fibers being disposed such that distinct portions thereof follow correspondingly distinct directions. Exemplary embodiments of this invention may advantageously exhibit a prolonged service life in downhole applications as compared to conventional progressing cavity stators. A replaceable progressing cavity insert for a stator is also provided. Methods for fabricating progressing cavity stators and progressing cavity inserts are also provided.

Description

FIELD OF THE INVENTION [0001] The present invention relates generally to progressing cavity hydraulic drilling motors, typically for downhole use. This invention more specifically relates to fiber reinforced composite stators and methods for fabricating fiber reinforced composite stators. BACKGROUND OF THE INVENTION [0002] Progressing cavity hydraulic motors and / or pumps are well known in downhole drilling and artificial lift applications, such as for oil and / or gas exploration. Such progressing cavity motors make use of hydraulic power from drilling fluid to provide power, for example, to a drill bit assembly. The power section of a typical progressing cavity motor includes a helical rotor disposed within the cavity of a corresponding stator and converts the hydraulic power of high pressure drilling fluid to mechanical power (e.g., torque). Flow of the high pressure drilling fluid down through the rotor stator assembly rotates the rotor relative to the stator (which is usually conn...

AI Technical Summary

Benefits of technology

[0006] Exemplary embodiments of the present invention advantageously provide several technical advantages. Various embodiments of the progressing cavity stator of this invention may exhibit a prolonged service life as compared to conventional progressing cavity stators. Tools embodying this invention may thus display improved reliability and thereby provide for potentially significant cost savings. Various embodiments of the fabrication procedure may also provide for the fabrication of a replaceable composite stator insert. Such a composite stator insert advantageously promotes field service flexibility. For example, damaged inserts may be replaced in the field at considerable savings of time and expense. Alternatively, an existing insert may be changed to one having, for example, a different number of lobes to optimize power section performance to current needs (e.g., with respect to speed and power).

Problems solved by technology

For example, damaged inserts may be replaced in the field at considerable savings of time and expense.

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