Oil & Gas Industry

Mud Rotors

Problem :

A mud motor rotor is a progressive cavity positive displacement pump (PCPD) placed in the drill string to provide additional power to the bit while drilling. The PCPD pump uses drilling fluid (commonly referred to as drilling mud or slurry) to create eccentric motion in the power section of the motor which is transferred as concentric power to the drill bit. The mud motor uses different rotor and stator configurations to provide optimum performance for the desired drilling operation. Since the mud is forced through the rotor at high pressure and flow rate, the abrasive, erosive and corrosive particles in the mud wear out the rotor surface thereby increasing clearance and reducing operational efficiency. Most mud rotors had historically been chrome plated or nickel plated, but the life expectancy of these coatings is very limited. Micro-cracks inherent to chrome plating weaken the mechanical properties of the plating. Drilling mud is contaminated with chlorides permeate through these micro cracks and corrode the underlying steel.

Solution :
PIC DC09 Coating

Our PIC DC09 coated mud rotors can withstand extreme abrasive and corrosive environments and offer exceptional operational life and performance. The coating is applied with robotic controlled HP-HVOF process in repeated passes that produces a dense and homogeneous coating. We offer complete repair and refurbished tungsten carbide coated rotors and conversion of hard chrome plated rotors to Tungsten Carbide Coated rotors. We have indigenously developed a complete set of procedures with our internal research and technical expertise combined with highly skilled man force. Our PIC DC09 coated mud motor rotors offer up to 5 – 7x operational life as compared to traditionally hard chrome plated rotors.

The coated rotors are impregnated with indigenously developed ceramic sealant and cured to fill the inherent porosity. The rotor surface is then ground and polished to achieve mirror surface finish. The contour profiles and diameters are maintained as per customer specifications and verified by matching with template. We have specialized measuring and monitoring instruments dedicated for inspection of rotors. We have in-house capabilities to completely repair and refurbish rotors up to a maximum length of 8 meters.

Coating Properties PIC DC09
Micro Hardness 1100 - 1400 HV0.3
Porosity < 0.8%
Bond Strength > 10000 Psi
Abrasion Resistance Excellent
Corrosion Resistance Very Good
Max Temperature < 450°C
Finish Coating Thickness 180 to 200 µm
Surface Finish < 0.4 Ra µm

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