RUBBER BEARINGS FOR DOWN-HOLE PUMPS

Synopsis of project activity: 1998--Awarded cost share grant from DOE. 1st Qtr 1999--Developed fail safe lubricating system. 2nd Qtr 1999--Performed first large scale test with nitrile based bearings. It failed due to material swelling. Failure was blamed on improper tolerance. 3rd Qtr 1999--Material tests were performed with autoclaves and exposure tests to Casa Diablo fluids. Testing of Viton materials began. Alternate bearing designs were developed to limit risk of improper tolerances. 4th Qtr 1999--Site testing indicated a chemical attack on the bearing material caused the test failure and not improper bearing tolerance. 1st Qtr 2000--The assistance of Brookhaven National Laboratory was obtained in evaluating the chemical attack. The National Laboratory also began more elaborate laboratory testing on bearing materials. 2nd Qtr 2000--Testing indicated Viton was an inappropriate material due to degradation in Casa Diablo fluid. Testing of EPDM began. 3rd Qtr 2001--EPDM bearings were installed for another large scale test. Bearings failed again due to swelling. Further testing indicated that larger then expected oil concentrations existed in lubricating water geothermal fluid causing bearing failure. 2002-2003--Searched for and tested several materials that would survive in hot salt and oil solutions. Kalrez{reg_sign}, Viton{reg_sign}ETP 500 and Viton{reg_sign}GF were identified as possible candidates. 2003-2005--Kalrez{reg_sign}has shown superior resistance to downhole conditions at Casa Diablo from among the various materials tested. Viton ETP-500 indicated a life expectancy of 13 years and because it is significantly less expensive then Kalrez{reg_sign}, it was selected as the bearing material for future testing. Unfortunately during the laboratory testing period Dupont Chemical chose to stop manufacturing this specific formulation and replaced it with Viton ETP 600S. The material is available with six different fillers; three based on zinc oxide and three based on silicon oxide. Samples of all six materials have been obtained and are being tested at the National Laboratory in Brookhaven, New York. This new material's properties as a bearing material and its ability to adhere to a bearings shell must be reviewed, but cost information deemed the material to be too expensive to be economical