Progressive Cavity Rotor Stator for Downhole Reaming
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Solution Overview
Problem
Downhole tools with progressive cavity sections face challenges in achieving efficient reaming and rotation due to defects in well holes, which can prevent casing from being fully inserted, requiring reaming tools that are costly and complex to operate.
Innovation Solution
A downhole tool with a progressive cavity section featuring a stator and rotor formed by electrochemical machining (ECM) or three-dimensional printing, where the stator is formed as a single integral block or connected by dowels, and a hollow rotor sleeve, enabling efficient reaming and rotation through fluid flow, with a reamer part mounted to rotate relative to the stator or rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional reaming tools are used to achieve smooth well holes for casing insertion, then reaming function is accomplished, but the tools are costly and complex to operate
Solution Approach 1:
The patent replaces conventional mechanical reaming systems with a progressive cavity section that uses fluid pressure to drive a rotor-stator mechanism. The rotor, with its helical lobes, rotates within the stator to create progressive cavities that move fluid and debris, achieving reaming through fluid dynamics rather than traditional mechanical cutting or abrasion.
Solution Approach 2:
The invention changes the operational parameters by using non-newtonian fluid properties and controlled fluid pressure to drive the reaming process. The fluid pressure and flow rate are adjusted to optimize rotor rotation and reaming effectiveness, replacing constant mechanical force with variable fluid dynamic parameters.
2Adaptability or versatility
If progressive cavity sections are used for reaming, then reaming function is achieved, but manufacturing precision and material formation are challenging
Solution Approach 1:
The patent applies different material properties and surface characteristics to specific regions of the stator and rotor. The stator is designed with a specific internal geometry and surface finish in the region where it contacts the rotor, while the rotor has optimized lobe profiles and surface treatments in contact areas. This local optimization ensures precise interaction and effective progressive cavity formation without requiring perfect precision throughout the entire component.
Solution Approach 2:
The stator and rotor are designed as separate, modular components that can be manufactured independently using optimized processes. The stator is formed as a hollow structure with precise internal geometry, while the rotor is manufactured as a separate piece with helical lobes. This segmentation allows each component to be manufactured with focused precision in its critical areas using appropriate manufacturing techniques.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for effective reaming and rotation of the reamer part, ensuring smooth well holes and efficient casing insertion, reducing operational costs and complexity by using innovative material formation methods.
Implementation Method 1
the stator, the rotor, or the stator and the rotor are formed by electrochemical machining (ECM)
Implementation Method 2
pumping fluid through the tubing string to rotate a reamer part, of the reamer tool, relative to an uphole end tubing connector and a downhole end tubing connector of the reamer tool
Data Source
AI summary
Various downhole tools, such as drilling motors, drilling tools, reamer tools, casing reamer shoes, and related methods of installation, assembly and use. Casing reamer shoes and drilling reamers or motors may have internal impellers, progressive cavity pumps, hollow rotors and other parts, universal joints, and other features. A progressive cavity section may have a rotor and a stator. Rotor contacting surfaces of the stator, and stator contacting surfaces of the rotor, may be rigid during use. The stator contacting surfaces and the rotor contacting surfaces may be made of metal. After the casing is run, the casing is cemented and the reamer shoe drilled out.