Halliburton Energy Services, Inc.

Smith International, Inc.

Neelesh V Deolalikar

Daniel Winslow

Larry DeLynn Chambers

Ravi P Nanayakkara

Larry Delynn Chambers

Brian Lee Doud

Michael Dewayne Finke

Stephen Christopher Janes

Daniel Martin Winslow

Larry Chambers

Richard Thomas Hay

Wei Zhang

Krutibas Panda

Ruchir Shirish Patwa

Jim Darin Tilley

Christopher A Golla

Lizheng Zhang

Pralay K Das

Michael John Strachan

Mukul M Agnihotri

Benjamin Scott Riley

Rui Huang

Benjamin S Riley

Ravi Nanayakkara

Mukul Agnihotri

Methods of manufacturing monolithic components with complex design features and functionally graded properties in any spatial direction may include forming of outer shell with an additive manufacturing process, loading the shell with bulk material and exposing the loaded shell to a hot isostatic pressing (HIP) process. The combination of the additive manufacturing process and the HIP process forms a diffusion bond between the outer shell and the bulk material resulting in a monolithic component with functionally graded properties. The outer shell may include an exterior surface and an inner passage formed with relatively hard surfaces to accommodate fluids in a wellbore.

Additive manufacturing of components with functionally graded properties

An extendable member diagnostic assembly determines performance of one or more components of a rotary steerable system. Based on the determined performance, an operation can be altered, such as a drilling operation. Performance may be based on measurements received from one or more sensors associated with components of the extendable member diagnostic assembly. For example, performance may be based on the time to transition a valve between states where the valve controls actuation of an extendable member, downhole temperature, downhole pressure or any other factors that affect performance of components that are used to perform the drilling operation. A controller receives the measurements from the one or more sensors and updates baseline parameters to determine an accurate performance. Using real time data to determine performance increases efficiency of an operation by eliminating unnecessary replacement of components and indicating that a downhole tool should be retrieved prior to failure.

Using solenoid characteristics for performance diagnostics on rotary steerable systems

A drill string steering system includes a motor and a rotary valve body disposed in a tool body. The motor includes a motor shaft coupled to the motor and extending within a central bore of the tool body. The motor shaft has a downhole engagement portion that includes a first splined surface. The rotary valve body includes a disk-shaped component and a valve shaft coupled to the disk-shaped component and extending uphole of the disk-shaped component. The valve shaft includes a second splined surface engageable with the first splined surface for rotation of the motor shaft to be imparted to the rotary valve body.

Steering system for use with a drill string

A rotary valve can include a seat and a rotary actuator, each with a surface, the rotary actuator rotatably mounted to a housing. The surfaces can form a seal due to their engagement with an engagement force used to maintain the engagement. One biasing device can elevate pressure in a sealed volume in the valve at a constant level above an external pressure. The elevated pressure can produce a pressure differential across the rotary actuator, thereby producing at least a portion of the engagement force. Another biasing device can act between a splined hub and a mated splined shaft, thereby applying at least a portion of the engagement force through the shaft to the rotary actuator. Fluid flowing through a screen can create a pressure drop, thereby causing a pressure differential across the rotary actuator and applying at least a portion of the engagement force to the surfaces.

Rotary valve with valve seat engagement compensation

A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Steering a drill bit with a rotary valve

A rotary steerable tool for directional drilling includes a tool body including an outer surface and a flowbore therethrough, a pad movably coupled to the tool body and alternately movable between an extended position and a retracted position, and a piston engageable with the pad to move the pad. The tool further includes a pressurized fluid supply flow path to provide fluid pressure to the piston for the piston to controllably move the pad to the extended position, and a dump valve in fluid communication with the pressurized fluid supply flow path to selectively vent fluid pressure to allow the pad to move from the extended position toward the retracted position.

Rotary steerable tool with dump valve

The disclosed embodiments include systems and methods to improve downhole drilling. A representative system may include a rotary steering tool having a plurality of hydraulically actuated steering pad assemblies, a fluid outlet, and a variable-orifice valve positioned within a primary flow channel of the rotary steering tool, downhole from the steering pad assemblies, and uphole from a drill bit. The valve comprises a valve port having a variable-area orifice that can be controllably varied to dynamically adjust the magnitude of a pressure drop from a tool bore to a wellbore annulus formed by the inner boundary of the wellbore and an outer boundary of the tool.

Driven rotary steering system having a variable-orifice valve

Steering mechanisms for use in RSS systems may be devoid of an elastomeric piston seal. Pistons of the steering mechanisms have a convex cross-section that permit the piston to pivot along with a steering pad while moving laterally or radially along a piston axis defined by a piston bore. Hydraulic pressure may be maintained as the pad is extended since a limited gap size between the piston and the bore may be maintained throughout the motion of the pistons. The pistons may be retained to the steering pad in a T-slot and may be elongated in a direction orthogonal to the axis of the piston bore. A groove may be provided around the piston for a receiving a back-up seal therein. The back-up seal may include wear resistant balls embedded in a matrix, and balls may be preloaded to serve as flow restrictors even when worn.

Steering actuation mechanism

A directional drilling system includes a rotary steerable tool. The rotary steerable tool includes an extendable member configured to extend outwardly from the rotary steerable tool upon actuation, and a geolocation electronics device configured to track a position of the rotary steerable tool and the extendable member and control actuation of the extendable member. The geolocation electronics device and extendable member are configured to rotate with the rotary steerable tool.

Rotary steerable drilling tool and method

A drill string steering system includes a flow manifold and a rotary valve. An actuation flow channel and a backflow channel are rotatable with respect to piston flow channels of the flow manifold. The actuation flow channel is rotatable relative to the flow manifold to increase or decrease flow toward the piston for controlling actuation of the piston. The backflow channel is rotatable relative to the flow manifold to increase or decrease flow away from the piston to the annulus for controlling retraction of the piston.

According to aspects of the present disclosure, systems and methods for a closed-loop speed/position control mechanism. An example system may include a housing and a planetary gearbox disposed within the housing, wherein a ring gear of the planetary gearbox is coupled to the housing, a sun gear of the planetary gearbox is coupled to a drive shaft, and a planetary carrier of the planetary gearbox is coupled to an output shaft. A controller may receive measurements from sensors proximate to the output shaft and use those measurements to transmit control signals to change the rotation of the drive shaft. In this way, the output shaft may be rotated independently of the housing by controlling the rotation of the drive shaft. In example systems, the output shaft may be a sonde or an offset mandrel coupled to a drill bit. The rive shaft may be coupled to a fluid-controlled controlled drive mechanism and rotation may be controlled by adjusting flow control valve. The closed-loop system may be used to set a target rotation speed of said output shaft or may be used to maintain the output shaft in a constant position or orientation despite housing rotation.

Closed-loop speed/position control mechanism

The disclosed embodiments relate to a rotary steering having a plurality of hydraulically actuated steering pad assemblies and a valve positioned between a primary flow channel of the rotary steering tool and an actuating piston of each of the plurality of steering pad assemblies. The representative valve includes a two-disk valve, with an uphole disk having a single, fixed-area aperture and a downhole disk having a plurality of independently variable-area orifices. Each of the independently variable valve orifices corresponds to one of a plurality of valve ports. In turn, each valve port being is fluidly coupled to, and operable to actuate, a corresponding piston of one of the plurality of steering pad assemblies. The independently variable-area orifices can be manipulated (gradually opened or closed) to vary the pressure drop across the tool, and thereby vary the magnitude of hydraulic force available to actuate the steering pad assemblies.

Driven rotary steering system having variable-aperture valve orifices

A rotary steerable tool for directional drilling includes a tool body including a flowbore for flowing pressurized fluid therethrough and a plurality of extendable members movably coupled to the tool body for selectively engaging a borehole wall, each extendable member including a piston for moving the extendable member to an extended position. The tool further includes a pressurized fluid supply flow path to provide fluid pressure from the flowbore to the pistons, and a plurality of linear actuators, each independently actuatable to control fluid pressure from the pressurized fluid supply flow path to a respective piston.

Rotary steerable tool with independent actuators

A steering head for steering a drill string may include a pad pusher including a steering pad and a piston. The steering pad may have a pivot axis, and be rotatable about the pivot axis between retracted and extended positions. The pad pusher may further include a motion restrictor to restrict rotation about the pivot axis. The steering head may further include a housing having a motion restrictor disposed at a position corresponding to the pad pusher motion restrictor. The pad pusher motion restrictor may be engageable with the housing motion restrictor to restrict motion of the steering pad relative to the housing.

Growing community of inventors

Houston, TX, United States of America

Neelesh V Deolalikar