Corrosion97: Paper No

Paper No.
CORROSION97
85
ELASTOMERS IN MUD MOTORS FOR OIL FIELD APPLICATIONS
Hendrik John
Baker Hughes INTEQ GmbH
Christensenstrasse 1
Celle, 29221, Germany
ABSTRACT
Mud motore the most frequently used downhole drilling motors in modern drilling systems are described in
their application and function.
The elastomeric liner in a mud motor acta as a huge continuous seal. Important properties of elastomers
such as chemical resistance, fatigue resistance, mechanical strength, abrasion resistance, bonding to steel and
processability are discussed. Advantages and disadvantages of NBR, HNBR, FKM, TFEP, and EPDM elastomers
for mud motor application are briefly described. The importance of drilling fluids and their physical and chemical
impact on motor elastomers are described. Drilling fluids are categorized in: oil based-, synthetic-, and water
based. Results of compatibility tests in the different drilling muds of the presented categories demonstrate the
complexity of elastomer development. Elastomers with an equally good performance in all drilling muds are not
available. Future developments and improvements are directed towards higher chemical resistance at higher
service temperature. This will be possible only with improved elastomer -to-metal bondhg, increased mechanical
and better dynamic properties,
Keywords: mud motor, oilfield, elastomer, chemical resistance, mechanical properties, NBR, HNBR, FKM,
TFEP, EPDM, drilling fluids, oil based mud, synthetic based mud, water based mud, elastomer-to-metal bonding
INTRODUCTION
Mud motors are the most important direct drive units for directional drilling, but are also usad for
performance drilling in the oil field. They are connected directly to the drill bit.
Copyright
01997by NACE International. Requests for permission to pubhsh this manuscript in any form, in part or in whole must be made in writing to NACE
International, Conferences Division, P.O. Box 218340, Houston, Texas 77218-8340. The material presented and the views expressed in this
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Krishnan Kalyanasundaram - Invoice INV-416942-ZR23KF, downloaded on 2/23/2011 11:58:17 AM - Single-user license only, copying and networking prohibited.
As a functional component of a mud motor the elastomer lining is the crucial component which decidee
over the succese of a motor run. In Figure 1 the poeition of a mud motor in a drill string can be seen.
The reasons for elastomers being a key factor for the success of mud motors are manifold:
. power of motors has doubled in the last 5 yeare
. new synthetic organic carrier fluids for drilling muds appeared in the last 5 to 10 years”)
● reliability and life expectancy has increaeed in the last years
. number of applications are increasing rapidly for mud motors
● new applications are steadily emerging:
- deeper wells (higher temperatures)
- geothermal applications (high temperatures)
- extended reach
Thus the requirements on elastomers have increased very rapidly from different directions: mechanically,
chemically, and thermally. A continuous effort in elaetomer development is therefore necessary to keep up with all
new demands on mud motors.
In the following sections a brief discussion of important aspects for the development of elastomers for
downhole mud motors is made with a special focus on the interaction of the various drilling fluids with the
elastomers,
Function Of Elastomers In Mud Motors
The mud motor can be regarded as a power unit which converts the hydraulic power of the circulated
drilling fluid into mechanical power or rotation of the rotor. The operating principle is the reverse of the MOINEAU
pump principle. In Figure 2 the four basic sub assemblies of a mud motor are shown.
. Bypasa valve assembly

. motor section with atator and rotor
. universal joint assembly
. bearing aesembly with drive shaft
The motor consists of two main components: atator and rotor. In the simplest geometry, the rotor is a steel
shaft having a helical geometry with a round cross-section turning eccentrically in a double helically shaped stator.
Stator and rotor are forming a series of cavities from the top, the inflow side, to the bottom, the outflow side.
Figure 3 shows a section through a mud motor visualizing the open and closed -sealed- cavitiea formed by the
stator and rotor and the flow of the drilling mud. The drilling fluid passes the bypass valve with high preaaure and
enters the open cavities of the motor. The energy transferred from the fluid to the rotor forces the rotor to turn at a
certain speed and causes a pressure drop of e.g. 80 bar (1161) psi
The elastomers in mud motors can be regarded as a continuos seal, sealing off a series of helically wound
chambera along the motor axis.
The functioning of this gigantic sealing area makes the elastomeric lining the inevitable functional com-
ponent of a mud motor.
During the revolution of the rotor, the rubber is deformed cyclically with a deformation frequency of about
5 to 35 Hz (depending on the motor type). The etrain of the elastomer during service can be seen in a cross
section of a motor in Figure 4.
Due to the hysteresis of the elastomer, the strain causes a heat build-up in the elastomer. In addition to
the ambient temperature, given by the circulation temperature of the mud, T., the temperature in the elaetomer,
85/2
T,,,, increases due to the heat build-up, ATHBU, and requirea thus a clearly higher temperature resistance of the
elastomer.
T,l = T“ + ATH,U (1)
The stator elastomer is thus subjected to a complex stress regime: dynamic mechanical loads, tempera-
ture, and chemical impact from the drilling mud are superimposed, This makes the use of elastomers in mud
motors quite unique.
Properties Of Elastomers For Mud Motors
Due to this combination of forces in varying fluids and temperatures, the elastomers for mud motors have
to possess several functional properties which can be named in groups.
● chemical resistance
. fatigue strength
. mechanical strength (tensile and tear)
● abrasion resistance
. bonding to Steel
. processability
These properties have to be leveled out in order to ettein a compromise for a satisfactory working
elastomer, Figure 5. The target for the formulation of a satisfacto~ working elastomer lies in the overlapping area.
Elastomers are being developed for general use or special applications, depending on the mud systems
used, the temperatures anticipated, and the special drilling requirements. In general the focus is on the chemical
resistance and the dynamic properties.
In Table 1a comparison of different elastomers used in the oilfield is shown.
From the perspective of usage elastomers on the basis of Nitrile (NBR) are by far the most widely used.
Another elastomer also used to a notable extent is hydrogenated Nitrile (HNBR), Fluorocarbon elastomers (FKM)
or tetrafluoroethey lene propylena are used in highly aggressive environments. Ethylene propylene diene
elastomer (EPDM) are limited to special applications because they are not oil resistant.
The ~ of elastomers depends on the chemical nature of the fluid and the temperature at
exposure, In addition there is a time effect with a consequence that in an aggressive fluid, at maximum service
temperature, the life time is reduced substantially. Due to the very low oxygen levels in drilling fluids, oxygen plays
no role in the degradation of elastomers in mud motors. Therefore the temperature limits for certain elastomers as
stated in the literature ‘2} cannot be transferred to this application. The lhermal resis- correlates as an
approximation with the chemical resistance. Fluoropolymers have in general an excellent stability in nonpolar fluids
even at high temperatures; the resistance to polar fluids is less good at high temperatures. The stability of
tetrafluoroethylene propylene is better in polar fluids than in nonpolar fluids compared to FKM.
NBR and HNBR have a good or satisfactory resistance to non polar fluids and also polar fluids. EPDM has
a poor resistance to non polar fluids but an excellent resistance to polar fluids. In general it can be said that none
of the elastomers performs well in all types of fluids.
As a favorable factor for the chemical resistance of elastomers in mud motors the relatively short exposure
times can be seen. When compered to exposure timee in the automotive industry there is a factor of 10 in
between.
8513
The ~ are in general ve~ much dependent on the compounding and the vulcanization
system especially. Therefore the ranking can only give a very rough picture of the general potential of these
elastomers. The fluorinated elastomers are generally less fatigue resistant than HNBR/NBR or EPDM.
The _ and also the @asion moDerties are dominated by the Nitrile type elastomers.
is eaaier for Nitrila typa elastomers, EPDM and FKM, than for TFEP elastomers in most
cases. The performance of an elastomer-to-steel bonding on the other hand is also dependent on the type of fluid
and temperature to which the bonding is expoeed.
The ~ocess ablky depends on the actual formulation of an elastomer. However, especially NBR is easy to
process in contract to elastomers on the basis of TFEP which ara difficult. Processability means for mud motore
with a Iangth of up to 18 ff in the first place: an easy flowable elastomer compound. This can only be achieved at
the expense of other properties.
Drilling Fluids And Their Impact On Elastomers Of Mud Motors
The chemical resistance of an elastomer to a drilling mud is most critical for the function of the motor.
Therefore the firet criterion for the eelection of an elastomer for an application is related to compatibility of the
elastomer in the drilling fluids in question at the maximum service temperature anticipated.
Iwea of Dfi A major difficulty in the development of elastomers for mud motors is the variety of
drilling muds in the oil field. And for standard application a motor has to perform well in all kinds of drilling muds
used at locations world wide. Because, no elastomer serves equally well in all fluids, the performance and tha
motor life may differ therefore quite significantly. Drilling fluid technology has changed substantially in the past 5-
10 years(’). The driving force for this change were environmental demands but also new drilling technologies, e.g.
horizontal-, extended reach-, and slimhole drilling.
Drilling muds can be divided into different classes by distinguishing between the carrier fluids utilized.
a) d based ti These are in most cases, brine-in-oil emulsions, formulated by using refined mineral
oils or “normal” diesel (and in rare cases crude oil).
‘( ..
b) s.yMhetic based ~
In these muds synthetic oils such as esters, polya-olefins, linear olefins, paraffins, or di-ethers are used as
the maior fluid comDonent,
c) wkAsmm&
Formulations based on fresh water oftan with high concentrations of salts of potassium, sodium or
calcium,
Besidea the baeic chemistry given by the carrier fluids, many additives are used which can deetroy the
elastomer properties even when added in small quantities, e.g. amine based corrosion inhibitors, torqua reducers
and others.
,..
tion of Dr~ with Flastom The interaction of the drilling fluid with the elaetomer will
change the performance and finally the life time of the motor drastically. This is caused by physical and chemical
effects taking place between the elastomer and the fluid(a.
~Two basic processes are taking place simultaneously
a) absorption and diffusion of the fluid or gae by the elastomer, and

b) an extraction of soluble components(e.g. plasticizer) from the elastomer.
85[4
As a first result of these processes a volume change of the elastomer occurs. For the mud motor this
means the rotor/stator fit -geometry- is altered. In most cases the fluid causes a volume increase - swelling- of the
elastomer (when the absorption is greater than the extraction) with the consequence of a tighter rotor/stator fit. In
some fluids a volume decrease - shrinkage- takes place (when the extraction is greater than the absorption). This
leads to a looser rotor/stator fit. If gaaes are absorbed, e.g. Nitrogen in underbalanced drilling, due to gas uptake
at high pressures, blistera and/or cracks can be the result.
A second result is a change in the mechanical properties. This is because any volume change is linked to
a change in mechanical properties as elasticity, hardness, tensile strength etc. In reality this means a degradation
of the elastomeric properties will finally lead to cracks or fractures in the elastomer.
A further physical effect which is always inherent to the impact of a fluid, and is separated here only for the
sake of clarity, is caused by the temperature. The pure temperature effect generates also a tighter rotor/stator fit
and alters the characteristic mechanical properties of the elastomer significantly. The change of the strength and
the elongation is shown for some elastomers in Figures 7 and 8,
Chemical Fffect$.. The chemical effects are related to chemical reactions of the fluid with the polymer
resulting in a change of the polymer network. These reactions are essentially
a) scission of bonds, and

b) crosslinking
The elastomer responds to the chemical interaction with the fluid by a deterioration of the physical properties, e. g.
reduction of strength, elongation and hardness, In most cases a reduction of hardness takes place with the
consequence of an increased wear rate. Temperature acts as an accelerator. As for chemical reactions in general,
the rate approximately doubles for a 10 ‘C temperature rise.
,..
Mud C~
~11 data are based on a exposure of rubber samples with a diameter of 1.44” and 0.079
thickness in autoclaves for a period of 3 days. The general test- and evaluation procedures were in accordance
with ASTM D471 and DIN 53519. Volume and hardness chsnges were determined, the hardness as International
Rubber Hardness Degree (IRHD).
E@ulis, In the followingsectionresultswillbe presentedfor thecompatibility of differentelastomerswith

fielddrillingfluidsbelongingto thedifferentcategories:oilbased-,syntheticbased-,andwaterbasedmud.In order
to limitthe amountof data presentedforcharacterization of the interactionof the elastomerwiththe drillingmud,
only volume- and hardness change are taken as indicators.
Oil Based Mud, Figure 8 shows the results for the volume change of NBR, HNBR, and FKM elastomers in
a typical Mineral oil based drilling mud (oil/water ratio of 80:20 ),
In this figure the intense reaction of the NBWI and HNBRfl elastomers can be seen. In contrast the FKM/1
exhibits the anticipated low reaction. In Figure 9 the hsrdness change (IRHD) reflects the relstive strong reaction
of HNBR/1, NBR/1 shows at comparable temperatures a slightly lower reaction, and at 200 “C shows FKM/1 also a
significant hardness change although the volume change is still relatively low.
Figure 10 shows the volume change of NBR and HNBR elastomers in field mud systems in comparison to
the standardized high swelling test fluid IRM 903 at 125 “C (257 “F)
Drilling fluids containing diesel are among the most aggressive, only crude oil muds are surpassing diesel
in some cases. The very high hardness change caused by a diesel mud is shown in Frgure 11.
Figures 12 and 13 show the reaction of NBR, HNBR and FKM in a synthetic -ester-
based mud (oil/water ratio 7525) as volume and hardness change over the temperature. Very high volume and
8515
hardness changes can be found for HNBR/1 , also for FKM/1 at 150 “C. NBRJI reacts still strongly, but the level for
the volume change is much lower than for HNBR/1. The strong reaction of FKM/1 is remarkable at these relatively
low temperatures and also the clear temperature dependence of the hardness change, The hardness change over
the temperature is quite strong for most elastomers. The temperature dependence of the volume change is only
pronounced for FKM/1 and in accordance with the hardness change.
In Figures 14 and 15 the volume and hardness change for NBR/11 and HNBWII is plotted for various
synthetic based muds at 125 “C. It can be seen that the ester types are very reactive resulting in high volume- and
hardness changes. For the polya-olefines in test the result was different - one polya-olefin reacting stronger than
the other, The reaction for the isomerized o[efin was IOW whereas the paraffined can be ranked between the highly
reactive esters and the low reactive olefins. The tested HNBR/11 showed in nearly all cases a much lower reaction
than the NBR/11 tested.
In comparison to the oil based muds it can be seen that some synthetic muds are of a comparable
a99reSSiVeneSS. On the other hand there are isomerized olefins and also paraffins which show low or moderate
reactivity.
~. Figures 16 and 17 show the volume and the hardness change for NBR, HNBR, EPDM,
and FKM elastomers in a water based drilling mud.
When comparing the reaction of the different elastomers as volume change, Figure 16, the response is
stronger for NBR/11 than for HNBR/11. In the high temperature range EPDM and a FKM are exhibiting the lowest
volume changes. The differences batween HNBR/1 and HNBR/11 reveal the potential of compounding. In Figure 17
the change in hardness is shown for these elastomers in the water based mud. At the maximum sewice
temperature for NBR the hardness change is significant. HNBFW in contrast shows a considerable hardness
change above 170 ‘C. For the high temperature elastomers EPDM/1 and FKM/11 only little hardness changes are
seen.
In Figure 18 the effect of various water based muds on NBR/11 and HNBR/11 elastomers at 125 ‘C can be
seen, The volume change ranges from no volume change to strong changes near 10 %, essentially in the positive
range. Additives, as e.g. torque reducers - even when added in quite small quantities - can cause a significant
effect, Also for the water based systems the HNBR/11 shows clearly a lower volume change than NBR/11.
In Figure 19 the hardness change is shown for these elastomers exposed under the same conditions.
When comparing Figure 18 with Figure 19 it is to notice that the hardness change is not clearly related to the
volume change. So for example in the seawater with torque reducer the hardness is of the same degree for NBR
and HNBR, but the volume change is less than half for HNBR/11.
For a complete evaluation of the behavior of an elastomer in different fluids it is necessary to determine
the change of the physical properties as elongation, tensile strength, tear strength, heat build-up etc. rathar than
only determine the volume and hardness change after exposure.
All elastomer developmental work as described so far is done on standard lab test samples and does not
reveal any performance data of the material in a mud motor. A successful elastomer development for motors
requires thus tests of the elaetomer and the elastomer-to-steel bonding under drilling conditions before going into
the field. For that purpose small motors are tested under different mechanical loads, fluids, and at various
temparatures.
CONCLUSIONS
Elastomers for mud motors have to function under a stress regime of dynamic mechanical loads, tempera-
ture, and chemical impact from the drilling mud which differa very much for the variety of mud motor applications.
This makes the development of elastomers for this application a challenge.
6516
The special importance of the drilling fluids and their effect on elastomer properties in mud motors was
shown. It could be shown, that some of the new synthetic muds have a better compatibility with mud motor
elastomers than oil baae muds. Because of the variety of drilling fluid chemistry, it is not poaaible to develop
elastomers which perform equally well in all drilling fluids, However, it is possible to develop elastomers which
serve satisfactory under most conditions.
Future developments of elastomers for mud motors are directed to higher chemical resistance, a shift of
the operation temperature limits towards higher temperatures, and better dynamic properlies in general. For the
realization of higher operation temperatures improvements of elastomer-to-metal bonding are mandatoiy. A further
significant increase in the dynamic and strength properties will ba of special interest due to further growth in motor
power. Also special developments for underbalanced- and air drilling applications will be of future importance.
ACKNOWLEDGMENTS
I would like to thank Baker Hughes INTEQ for the opportunity to publish this work. Special thanks I owe to
Ms. Gabriela Wiese for the performance of the compatibility tests and the preparation of the graphs with the
compatibility data for this publication.
REFERENCES
1. R. K. Clark, Journal of Petroleum Technology, 46,9(1994): p. 804

2. K. Nagdi, Rubber as an Engineering Material (Munich, Hansa Publishers, 1993): p. 47
6517
TABLE 1
COMPARISON OF ELASTOMER PROPERTIES OF ELASTOMERS FOR MUD MOTORS
++ excellent
+ good
o satisfactory
poor
OTOR
Figure l- Drill String with Mud Motor
85/9
or
Figure 2- Mud Motor with Subassemblies
85110
Stetor
(Elastomer)
Rotor
Direction
of
Rotation
Fluid FIOW
Universal
Joint
Figure 3- Section ofa Mud Motor with Fluid Flow
85/1 1
Figure 4- Elastic Strain of Elastomere ina Multilobe Mud
Motor
MECHANICAL STRENGTH
Figure 5- Functional Propertiesof Elastomersfor Mud

Motors
85/1 2
22T
20
t
18
16
g 14
I
\
\
4.
2.
0 l+’-
0 25 50 75 100 125 150 175 200
Temperature“C
Figure 6- Tensile strength versus temperature for different elastomers
600 ..—
5004
400
s I
I 00
t
0,
0 25 50 75
Temperature “C
85/1 3
/
50 75 100 125 150 175 200 225 250

Temperature “C
Figure 8- Volume change versus temperature for different elasto-

mers in an oil based mud
~NBR12
-A- FM
-o- HNBRil
——+—+ -—
50 75 100 125 150 175 200 225 250

Temperature “C
Figure 9 Hardness change versus temperature for different elasto-

mers in an oil based mud
8S/14
20,
oNBIUII
■ HNB8fII
1
till
OBM/3 OBM/11 Cm& 011
Fluid
Eliesel MM 903
Figure 10- Volume chamze for NBR and HNBR elastomers in

different oil b~ed fluids at 125°C
—.
2
-2
i4.
~
:!
~-et
m
9.8.
~ -lo
;
-12
-14
❑NBIUI1
● HNBRKI
‘l___
-16 —
OBtvWl OBMIII Crude 0,[ Ok%! IBM 903
Fluid
,.--—
Figure 11- Hardness change for NBR and HNBR elastomers in

different oil based fluids at 125°C
85115
+—NBRA
r
30
I
-E- NBFUII
25 -A-FK!M ● ●
-o- HNBIUI
+ HNBMI
20
.
b
2
g ,5
●
g
v
~ 10
o ~–~
50 60 70 80 90 100 I1O 120 130 140 150
Temperature “C

mers in a synthetic ester based mud
5~“”””-
r~
0
+
] ‘5
a
- .10
i
a
L!]
2
: -15
:
~
: -20 NBRil
-E- NBRJI1
+ FKNW1
-25 -HNBM
+ HNBRAI
-30
50 60 70 80 90 100 110 120 130 140 150
Temperature “C
Figure 13-Hardness change versus temperature fordifferent elasto-

mers in a synthetic ester based mud
85/1 8
I
Fluid
Figure 14- Volume change for NBR and HNBR elastomers in

different synthetic based muds at 125°C
r
o. + E+
-2.
4. I
-6
-8.
-10.
oNBMI
● HNBRill
-12. -.
Figure 15- Hardness change for NBR and HNBR elastomers in

different synthetic based muds at 125°C
85/1 7
-E- NBRiTI
+ EPDMil
+ FKMU
-o- HNBPJI
+ HNBRflI
●
—+-+
50 75 100 125 150 175 200 225 250

Temperature ‘C

mers in water based mud
8 ..-
-E-NBRAI
●
6 + EPDM/1
+FKMilI
4. -0-HNBNI
+ HNBMI
E
:0 ~ d +—
g
: -2
x
54
~
-6
-8 ~:%
.10 I
50 75 100 125 150 175 200 L25 250
Temperature “C
Figure 17- Hardness change versus temperature for different elasto-

mers in water based mud
85118
10 , I
oNBIUII
9
■ HNBRAI
8 1
Figure 18- Volume change for NBR and HNBR elastomers in water
based mud at 125°C
Figure 19- Hardness change for NBR and HNBR elastomers in water
based mud at 125°C
85/1 9

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Paper No.

ELASTOMERS IN MUD MOTORS FOR OIL FIELD APPLICATIONS

Function Of Elastomers In Mud Motors

. Bypasa valve assembly

T,l = T“ + ATH,U (1)

Properties Of Elastomers For Mud Motors

In Table 1a comparison of different elastomers used in the oilfield is shown.

Drilling Fluids And Their Impact On Elastomers Of Mud Motors

~Two basic processes are taking place simultaneously

a) absorption and diffusion of the fluid or gae by the elastomer, and

a) scission of bonds, and

E@ulis, In the followingsectionresultswillbe presentedfor thecompatibility of differentelastomerswith

1. R. K. Clark, Journal of Petroleum Technology, 46,9(1994): p. 804

Figure l- Drill String with Mud Motor

Figure 2- Mud Motor with Subassemblies

Figure 3- Section ofa Mud Motor with Fluid Flow

Figure 5- Functional Propertiesof Elastomersfor Mud

Figure 6- Tensile strength versus temperature for different elastomers

50 75 100 125 150 175 200 225 250

Figure 8- Volume change versus temperature for different elasto-

50 75 100 125 150 175 200 225 250

Figure 9 Hardness change versus temperature for different elasto-

Figure 10- Volume chamze for NBR and HNBR elastomers in

Figure 11- Hardness change for NBR and HNBR elastomers in

Figure 12- Volume change versus temperature for different elasto-

Figure 13-Hardness change versus temperature fordifferent elasto-

Figure 14- Volume change for NBR and HNBR elastomers in

Figure 15- Hardness change for NBR and HNBR elastomers in

50 75 100 125 150 175 200 225 250

Figure 16- Volume change versus temperature for different elasto-

Figure 17- Hardness change versus temperature for different elasto-

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