Even after decades of material science and manufacturing problem-solving, TriStar’s engineering team still finds itself facing new challenges every day. When a leading manufacturer of oil & gas equipment came to us with a concept for a new downhole drilling tool, we drew on our vast experience to help them engineer an innovative, cost-saving product.
The challenge? Design a high-performance Non-Rotating Protector (NRP) that could endure brutal downhole conditions—temperatures up to 300°F, exposure to abrasive drilling muds, unknown fluid chemistries, and sustained axial forces. And it needed to reduce torque, wear, and vibration—while being manufactured in massive quantities.
Early Concepts, Early Lessons
Our first approach involved Rulon® 142 tape, cut to spec and bonded to high-temp urethane pads using a specialized epoxy process. These pads were hand-assembled into segmented collars that protected casing and riser surfaces during drilling. The low-friction, abrasion-resistant properties of Rulon were a promising start, but the manual assembly and bonding steps made the solution too cumbersome for large-scale production.
The Breakthrough: Trilon HTU
Digging deeper into our material toolbox, we landed on Trilon® HTU, a high-performance polymer known for its extreme temperature tolerance, chemical inertness, and low-friction characteristics. Even better, it could be extruded directly into drop-in inserts. After a surface treatment using a hot chemical etchant, the Trilon components bonded beautifully with urethane and held up under intense axial force—up to 30,000 lbs before slippage.
These custom-fitted Trilon pads delivered more than just durability. They helped our customer create a protector that:
- Reduced torque and drag
- Minimized casing, riser, and drill pipe wear
- Cut down on buckling, vibration, and stick-slip
- Withstood heat checking in demanding drilling environments
- Delivered maximum energy to the bit for both cased and open-hole wells
A Game-Changer in the Field
Tens of thousands of NRP pads have since been manufactured using this optimized method. The product has become a cornerstone of the manufacturer’s offerings, one that operators now rely on to boost drilling performance in high-angle and extended-reach wells.
If you have a challenging application—whatever your industry—that would benefit from a collaborative approach, reach out to our engineering team with the details. We’re eager to work with you!
An All-Phase Commitment to Value-Added Engineering
Check out our new deep dive into TriStar’s collaborative engineering process. See how we combine decades of expertise with advanced materials to solve real-world design challenges.