EP4731866A1 - Devices, systems, and methods for steering a wellbore - Google Patents

Abstract

A steering unit may include a housing. A steering unit may include a plurality of actuator supports arranged circumferentially around the housing. A steering unit may include an actuator pad extending through the housing. A steering unit may include a cutting element connected to the housing between two of the plurality of actuator supports.

Description

DEVICES, SYSTEMS, AND METHODS FOR STEERING A WELLBORE

BACKGROUND OF THE DISCLOSURE

[0001] Rotary drilling is defined as a system in which a bottom hole assembly, including the drill bit, is connected to a drill string which is rotatably driven from the drilling platform at the surface. When drilling holes in subsurface formations, it is sometimes desirable to be able to vary and control the direction of drilling, for example, to direct the borehole towards a desired target, or to control the direction horizontally within the payzone once the target has been reached. It may also be desirable to correct for deviations from the desired direction when drilling a straight hole, or to control the direction of the hole to avoid obstacles. Further, steering or directional drilling techniques may also provide the ability to reach reservoirs where vertical access is difficult or not possible (e.g., where an oilfield is located under a city, a body of water, or a difficult to drill formation) and the ability to group multiple wellheads on a single platform (e.g., for offshore drilling).

SUMMARY

[0002] In some aspects, the techniques described herein relate to a steering system. The steering system includes a housing and a plurality of actuator supports arranged circumferentially around the housing. An actuator pad extends through the housing. A cutting element is connected to the housing between two of the plurality of actuator supports. In some embodiments, the steering system is connected to a bit.

[0003] In some aspects, the techniques described herein relate to a method for manufacturing a drilling system. The method includes securing a plurality of actuator supports to a housing of a steering unit. A plurality of actuator pads are inserted through the plurality of actuator supports and the housing. A cutting element is secured to the housing between two of the plurality of actuator supports.

[0004] This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Additional features and aspects of embodiments of the disclosure will be

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SUBSTITUTE SHEET ( RULE 26) set forth herein, and in part will be obvious from the description, or may be learned by the practice of such embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0006] FIG. 1 is a representation of a drilling system for drilling an earth formation to form a wellbore; according to at least one embodiment of the present disclosure;

[0007] FIG. 2 is a schematic representation of a steering system located in a wellbore, according to at least one embodiment of the present disclosure;

[0008] FIG. 3-1 is a schematic representation of a steering system, according to at least one embodiment of the present disclosure;

[0009] FIG. 3-2 is a schematic cross-sectional view of the steering system of FIG. 3-1 located in a wellbore;

[0010] FIG. 4 is a schematic representation of a steering system, according to at least one embodiment of the present disclosure;

[0011] FIG. 5 is a schematic representation of a steering system, according to at least one embodiment of the present disclosure;

[0012] FIG. 6 is a schematic representation of a steering system, according to at least one embodiment of the present disclosure;

[0013] FIG. 7 is a schematic representation of a steering system, according to at least one embodiment of the present disclosure;

[0014] FIG. 8 is a schematic representation of a steering system, according to at least one embodiment of the present disclosure;

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SUBSTITUTE SHEET ( RULE 26) [0015] FIG. 9 is a schematic representation of a steering system, according to at least one embodiment of the present disclosure; and

[0016] FIG. 10 is a flowchart of a method for manufacturing a steering system, according to at least one embodiment of the present disclosure.

DETAILED DESCRIPTION

[0017] This disclosure generally relates to devices, systems, and methods for steering systems in a downhole drilling environment. A steering system may include a bit and a steering unit. The steering unit may include one or more actuator pads that extend to contact the wellbore wall. The actuator pads may cause the bit to be redirected. In accordance with at least one embodiment of the present disclosure, the steering system may include one or more cutting elements located between two actuator pads. While drilling a dogleg, the cutting elements may engage the inner diameter of the dogleg. This may help to widen the wellbore at the dogleg. Widening the inner diameter of the wellbore at the dogleg may allow the steering unit to be deflected further, thereby increasing the maximum DLS. For example, widening the inner radius of the DLS of the wellbore at the dogleg may prevent the closed actuator on the opposite side from the extended actuator from touching the borehole, this may allow the opposite open pad to extend further, thereby allowing the actuator to deflect the steering unit further and increasing the DLS and/or the steering control of the drilling system.

[0018] In accordance with at least one embodiment of the present disclosure, the cutting elements on the steering unit may be located circumferentially between the actuator supports of the steering unit. For example, the actuator supports may be spaced circumferentially around a housing of the steering unit. The cutting elements may be located circumferentially between the actuator supports. This may allow the cutting elements to engage and degrade the inner diameter of the wellbore wall while the actuator pads engage the outer diameter of the wellbore wall, thereby increasing the DLS and/or the steering control of the drilling system.

[0019] In some embodiments, the steering unit may include multiple cutting elements between actuator supports of the steering unit. The cutting elements may be arranged in a pattern to efficiently engage and degrade the wellbore wall. For example, two or more of the cutting elements may at least partially overlap circumferentially, longitudinally, or both longitudinally and circumferentially. This may help to increase the efficiency of the cutting elements that engage the

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SUBSTITUTE SHEET ( RULE 26) inner diameter of the wellbore wall, thereby increasing the DLS and/or the steering control of the drilling system.

[0020] To facilitate understanding of the reader, FIG. 1 shows one example of a drilling system 100 for drilling an earth formation 101 to form a wellbore 102. The drilling system 100 includes a drill rig 103 used to turn a drilling tool assembly 104 which extends downward into the wellbore 102. The drilling tool assembly 104 may include a drill string 105, a bottomhole assembly (BHA) 106, and a bit 110, attached to the downhole end of drill string 105.

[0021] The drill string 105 may include several joints of drill pipe 108 connected end-to-end through tool joints 109. The drill string 105 transmits drilling fluid through a central bore and transmits rotational power from the drill rig 103 to the BHA 106. In some embodiments, the drill string 105 further includes additional components such as subs, pup joints, etc. The drill pipe 108 provides a hydraulic passage through which drilling fluid is pumped from the surface. The drilling fluid discharges through nozzles, jets, or other orifices in the bit 110 for the purposes of cooling the bit 110 and cutting structures thereon, for lifting cuttings out of the wellbore 102 as it is being drilled, for controlling influx of fluids in the well, for maintaining the wellbore integrity, and for other purposes.

[0022] The BHA 106 may include the bit 110 or other components. An example BHA 106 may include additional or other components (e.g., coupled between to the drill string 105 and the bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement- while-drilling (MWD) tools, logging-while-drilling (LWD) tools, downhole motors, underreamers, section mills, hydraulic disconnects, jars, vibration or damping tools, other components, or combinations of the foregoing. The BHA 106 may further include a directional tool 111 such as a bent housing motor or a rotary steerable system (RSS). The directional tool 111 may include directional drilling tools that change a direction of the bit 110, and thereby the trajectory of the wellbore. In some cases, at least a portion of the directional tool 111 may maintain a geostationary position relative to an absolute reference frame, such as gravity, magnetic north, or true north. Using measurements obtained with the geostationary position, the directional tool 111 may locate the bit 110, change the course of the bit 110, and direct the directional drilling tool 111 on a projected trajectory. For instance, although the BHA 106 is shown as drilling a vertical portion 102-1 of the wellbore 102, the BHA 106 (including the directional tool 111) may instead drill directional or deviated well portions, such as directional portion 102-2.

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SUBSTITUTE SHEET ( RULE 26) [0023] Examples of directional tools 111 and/or steering systems may include “push-the-bif ’ systems, “point-the-bif ’ systems, hybrid systems, any other system, and combinations thereof. In a push-the-bit system, actuator pads may extend from the directional tool 111 to contact the wellbore wall. The actuator pads may apply a force against the wellbore wall, which may push the bit away from the actuator pad. Other examples of push-the-bit systems may include RSS systems, non-rotating (with respect to the hole) eccentric stabilizers (e.g., displacement-based systems). Steering is achieved by creating non co-linearity between the drill bit and at least two other touch points.

[0024] In point-the-bit systems, the axis of rotation of the bit 110 is deviated from the local axis of the BHA 106 in the general direction of the desired path (target attitude). The borehole is propagated in accordance with the customary three-point geometry defined, for example, by upper and lower stabilizers and the hole reaming cutters. The angle of deviation of the drill bit axis coupled with a finite distance between the lower and middle touch points results in the noncollinear condition for a curve to be generated. This may be accomplished, for example, by a fixed bend at a point in the BHA 106 close to the lower stabilizer or flexure in the drill bit drive shaft distributed between the upper and lower stabilizers.

[0025] In accordance with at least one embodiment of the present disclosure, a steering system may include a directional tool 111 including one or more cutting elements located between steering actuator supports. The cutting elements between the steering actuator supports may help to increase the DLS of the directional portion 102-2. For example, while drilling the directional portion 102-2, the actuator pads may extend away from the directional tool 111 to contact an outer radial surface 112 of the directional portion 102-2 of the wellbore. Contact of the actuator pads of the directional tool 111 with the outer radial surface 112 may push the directional tool 111 toward an inner radial surface 113 of the directional portion 102-2. This may help to create the dogleg of the directional portion 102-2.

[0026] The actuator pads have a maximum extension. The extension of the actuator pads may be the eccentricity of the directional tool 111. In some situations, the actuator pads may not be able to extend to their maximum extension. For example, the actuator pads may engage the outer radial surface 112 of the directional portion 102-2. The actuator pads may push the directional tool 111 toward the inner radial surface 113. In some situations, the directional tool 111 may engage the inner radial surface 113 before the actuator pads have extended to the maximum extension. This

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SUBSTITUTE SHEET ( RULE 26) may reduce the DLS of the 102-2. In some situations, the actuator pads may begin to degrade or erode the outer radial surface 112 of the directional portion 102-2.

[0027] In accordance with at least one embodiment of the present disclosure, when the actuator pads push the directional tool 111 away from the outer radial surface 112, the cutting elements between the actuator supports of the directional tool 111 may engage the inner radial surface 113 of the directional portion 102-2. The cutting elements may degrade a portion of the formation at the inner radial surface 113. This may increase the diameter of the wellbore at the directional portion 102-2. In some embodiments, this may help to increase the distance that actuator pads may push the directional tool 111. In some embodiments, the cutting elements may cut the inner radial surface 113 enough to allow the actuator pads to extend to their full extension. In some embodiments, the cutting elements may be configured to more preferentially cut the wellbore wall than the actuator pads (e.g., be more efficient at cutting the wellbore wall), thereby reducing the amount of the wellbore that the actuator pads degrade. This may help to increase the DLS of the directional portion 102-2.

[0028] In general, the drilling system 100 may include additional or other drilling components and accessories, such as special valves (e.g., kelly cocks, blowout preventers, and safety valves). Additional components included in the drilling system 100 may be considered a part of the drilling tool assembly 104, the drill string 105, or a part of the BHA 106 depending on their locations in the drilling system 100.

[0029] In some embodiments, the BHA 106 includes a downhole motor to power for downhole systems and/or provide rotational energy for downhole components (e.g., rotate the bit 110, drive the directional tool 111, etc.). The downhole motor may be any type of downhole motor, including a positive displacement pump (such as a progressive cavity motor) or a turbine. In some embodiments, a downhole motor is powered by the drilling fluid flowing through the drill pipe 108. In other words, the drilling fluid pumped downhole from the surface may provide the energy to rotate a rotor in the downhole motor. The downhole motor may operate with an optimal pressure differential or pressure differential range. The optimal pressure differential may be the pressure differential at which the downhole motor may not stall, bum out, overspin, or otherwise be damaged. In some cases, the downhole motor may rotate the bit 110 such that the drill string 105 may not be rotated at the surface, or may rotate at a different rate (e.g., slower) than the rotation of the bit 110.

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SUBSTITUTE SHEET ( RULE 26) [0030] The bit 110 in the BHA 106 may be any type of bit suitable for degrading downhole materials such as earth formation 101. Example types of drill bits used for drilling earth formations are fixed-cutter or drag bits, roller cone bits, and combinations thereof. In other embodiments, the bit 110 may be a mill used for removing metal, composite, elastomer, other downhole materials, or combinations thereof. For instance, the bit 110 may be used with a whipstock to mill into casing 107 lining the wellbore 102. The bit 110 may also be a junk mill used to mill away tools, plugs, cement, other materials within the wellbore 102, or combinations thereof. Swarf or other cuttings formed by use of a mill may be lifted to surface or may be allowed to fall downhole. In still other embodiments, the bit 110 may include a reamer. For instance, an underreamer may be used in connection with a drill bit and the drill bit may bore into the formation while the underreamer enlarges the size of the bore.

[0031] FIG. 2 is a schematic representation of a steering system 215 located in a wellbore, according to at least one embodiment of the present disclosure. The steering system 215 includes a bit 210 and a steering unit 214. The bit 210 and the steering unit 214 may be located in a wellbore 202. The steering unit 214 shown includes a push-the-bit steering system, however, it should be understood that the principles of this disclosure may be applied to any steering system, including point-the-bit systems, hybrid systems, any other system, and combinations thereof.

[0032] The steering unit 214 includes a set of stabilizer pads 216 and a set of steering pads 218. The steering pads 218 may be extended through the housing of the steering unit 214 and through one or more actuator supports. The steering pads 218 may extend out of the housing and the actuator supports to contact the wellbore wall 220. For example, when extended, the steering pads 218 may apply a force to an outer radial surface 212 of the wellbore wall 220. The stabilizer pads 216 may contact the wellbore wall 220 as the steering pads 218 push outer radial surface 212. The eccentricity in the force may cause the bit 210 to be pointed in a different direction. In this manner, as the bit 210 engages the wellbore wall 220 to advance the wellbore 202, the wellbore 202 may be deviated in a “dogleg,” or a curve away from a straight-line trajectory.

[0033] The steering system 215 shown includes a stiff three-point steering assembly. The steering pads 218 engage the wellbore wall 220 at a lower contact point 222. The steering pads 218 are located further downhole (e.g., closer to the bit, further from the collar of the wellbore 202), than the stabilizer pads 216. The stabilizer pads 216 engage the wellbore wall 220 at an upper contact point 224. The bit 210 engages the wellbore wall 220 at a bit contact point 226, which may

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SUBSTITUTE SHEET ( RULE 26) be the uphole-most portion of the bit 210 that contacts the wellbore wall 220. The bit contact point 226 may be at the portion of the bit 210 that is pushed into the wellbore wall 220 based on the steering pads 218 pushing against the wellbore wall 220.

[0034] In the stiff three-point steering assembly shown, the dogleg severity (DLS) capability or curvature response may be expressed as: where ecc is the eccentricity (e.g., the stroke length of the steering pads 218, the distance the steering pads 218 push the bit 210), L 1 is the distance from the uphole-most active cutting structure on the bit and the steering pad, and L2 is the distance from the steering pad to the upper contact point. In the illustrated embodiment, the LI distance 237 may be the distance from the bit contact point 226 and the lower contact point 222 and the L2 distance 235 may be the distance from the upper contact point 224 and the lower contact point 222.

[0035] As may be seen in Eq. 1, the DLS is inversely proportional to the LI distance 237 and the L2 distance 235. Thus, a reduction in the LI distance 237 or the L2 distance 235 results in an increase in DLS. In practice, the LI distance 237 is shorter than the L2 distance 235. Thus, a change of a few inches or cm in the LI distance 237 may result in a larger increase in the DLS than a comparative change in the L2 distance 235.

[0036] In some embodiments, the uphole-most gauge cutting element 228 is the uphole-most cutting element on the bit 210. As the uphole-most gauge cutting element is on the bit, the uphole- most gauge cutting element 228 may contact the wellbore wall 220 at the bit contact point 226. The uphole-most gauge cutting element may be the last (or uphole-most) active cutting element on the bit 210, or the last cutting element that is configured to engage the wellbore wall 220 to actively degrade the formation.

[0037] In accordance with at least one embodiment of the present disclosure, the steering system 215 may include a steering cutting element 230. The steering cutting element 230 may be located on a housing 232 of the steering unit 214 between two actuator supports. The steering cutting element 230 may be configured to engage an inner radial surface 213 of the wellbore wall 220. The steering cutting element 230 may be positioned and oriented to degrade at least a portion of the inner radial surface 213 of the wellbore wall 220. For example, as the steering pads 218 engages the outer radial surface 212 of the wellbore wall 220, the actuation force from the steering pads 218 may push the steering cutting element 230 into the inner radial surface 213 of the 8

SUBSTITUTE SHEET ( RULE 26) wellbore wall 220. The steering cutting element 230 may remove material from the inner radial surface 213, thereby increasing the diameter of the wellbore. For example, this may cause the diameter at the dogleg to be increased locally at the dogleg. In some embodiments, this may cause the diameter to be increased eccentrically. This may allow the steering pads 218 to extend further, thereby increasing the eccentricity (e.g., ecc from Eq. 1). This may help to increase the DLS of the steering system 215.

[0038] In at least one embodiment, the LI distance 237 can be reduced by moving the bit contact point 226 closer to the steering pads 218. The steering cutting element 230 may be considered the uphole-most gauge cutting element of the steering system 215. As may be seen, this may reduce the LI distance 237. But in at least one embodiment, a different relationship may be identified and/or utilized to determine the DLS of the steering system 215.

[0039] The steering cutting element 230 may have the same diameter (e.g., a steering gauge diameter) as a bit gauge diameter of the bit 210. In some embodiments, the steering cutting element 230 has a different steering gauge diameter than the bit gauge diameter of the bit 210. For example, the steering cutting element 230 may have a larger steering gauge diameter than the bit gauge diameter of the bit 210. In some examples, the steering cutting element 230 may have a smaller steering gauge diameter than the bit gauge diameter of the bit 210. Adjusting the steering gauge diameter of the steering cutting element 230 may help to adjust whether and/or how much of the wellbore wall 220 is removed by the steering cutting element 230, which may adjust the total DLS of the steering system 215.

[0040] In some embodiments, the steering cutting element 230 is a cutting element. For example, the steering cutting element 230 may be a cutting element having any shape, such as planar, axe, wedge, conical, any other shape, and combinations thereof. In some embodiments, the steering cutting element 230 has a shape and/or orientation that is configured to cut the formation. In this manner, when the steering cutting element 230 engages the wellbore wall 220, the steering cutting element 230 may widen the diameter of the wellbore 202 at the inner surface of the dogleg (e.g., the inner radial surface 213).

[0041] FIG. 3-1 is a schematic representation of a steering system 315, according to at least one embodiment of the present disclosure. The steering system 315 includes a bit 310. The bit 310 may include a body 346 with one or more blades 348 extending therefrom. A plurality of bit cutting

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SUBSTITUTE SHEET ( RULE 26) elements 350 may be secured to the blades 348. The bit cutting elements 350 may be arranged and configured to cut the formation to advance the wellbore.

[0042] The steering system 315 shown includes a steering unit 314 having a housing 332. The housing 332 may include one or more actuators or steering pads (collectively 318). The steering pads 318 may be supported by and/or extend to (e.g., have their extension halted by) an actuator support (e g., a kicker, collectively 344), which may help to prevent the steering pads 318 from overextending. For example, the steering pads 318 may be inserted through the housing 332 and the actuator supports 344 to extend past an outer surface of the housing 332. Inserting the steering pads 318 through the housing 332 and the actuator supports 344 may allow the steering pads 318 to extend through the housing 332 and the actuator supports 344 to contact the wellbore wall. In some embodiments, the steering pads 318 and/or the actuator supports 344 may be removable and/or replaceable. For example, the steering pads 318 may be removable from the actuator supports 344. This may allow the steering pads 318 to be replaced when worn and/or when a different shape, size, or geometry of steering pads 318 is desired. In some embodiments, removing the actuator supports 344 may allow the actuator supports 344 to be replaced when worn and/or when a different shape, size, or geometry of actuator supports 344 and/or connected steering pad 318 is desired.

[0043] The steering unit 314 further includes a steering cutting element 330. The steering cutting element 330 may be located between two of the steering pads 318 and/or two of the actuator supports 344. For example, the steering cutting element 330 may be located between a first steering pad 318-1 and a second steering pad 318-2. The steering cutting element 330 may be located between a first actuator support 344-1 and a second actuator support 344-2.

[0044] During operation of the steering unit 314, the steering pads 318 may extend away from the housing 332. For example, each steering pad 318 may be connected to their associated actuator support 344 with a hinge 334. When the steering pad 318 extends, the steering pad 318 may rotate about the hinge 334. While embodiments of the present disclosure may illustrate and describe the steering pads 318 as rotating about a hinge 334, it should be understood that any other extension mechanism may be utilized to extend the steering pads 318.

[0045] The steering unit 314 includes a third steering pad 318 located opposite the steering cutting element 330. As the third steering pad 318 extends out of the housing 332, the third steering pad 318 may push the housing 332 into the wellbore, thereby causing the steering cutting element

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SUBSTITUTE SHEET ( RULE 26) 330 to engage the wellbore wall. As discussed herein, the steering cutting element 330 may remove a portion of the wellbore wall, thereby allowing the third steering pad 318 to extend further. This may increase the DLS of the steering system 315.

[0046] FIG. 3-2 is a schematic cross-sectional view of the steering system 315 of FIG. 3-1 located in a wellbore 302. As may be seen, the steering system 315 includes the first steering pad 318-1 connected to the housing 332 with a first hinge 334-1, the second steering pad 318-2 connected to the housing 332 with a second hinge 334-2, and a third steering pad 318-3 connected to the housing 332 with a third hinge 334-3. The steering pads 318 may be extendable away from the housing 332 by rotating about the hinges 334.

[0047] The steering system 315 further includes a first steering cutting element 330-1 located on the outer surface of the housing 332 opposite the first steering pad 318-1, a second steering cutting element 330-2 located on the outer surface of the housing 332 opposite the second steering pad 318-2, and a third steering cutting element 330-3 located on the outer surface of the housing 332. In this manner, when a steering pad 318 extends away from the housing 332, the opposing steering cutting element 330 may engage the wellbore wall 320 of the wellbore 302.

[0048] In the embodiment shown, the third steering pad 318-3 is extended to contact an outer radial surface 312 of the wellbore wall 320. This may push the housing 332 toward an inner radial surface 313 of the wellbore wall 320. This may push the third steering cutting element 330-3 into the inner radial surface 313 of the wellbore wall 320. The third steering cutting element 330-3 may engage the inner radial surface 313 of the wellbore wall 320, thereby removing at least a portion of the material from the third steering cutting element 330-3. Removing some of the material from the inner radial surface 313 of the wellbore wall 320 may help to increase the amount that the third steering pad 318-3 may extend away from the housing 332. This may increase the eccentricity of the steering system 315, thereby increasing the DLS of the steering system 315.

[0049] The steering cutting elements 330 extend to a steering gauge diameter. The steering gauge diameter may be the diameter formed by the extension of the steering cutting elements 330 from the outer surface of the housing 332. In some embodiments, the steering gauge diameter may be greater than, or greater than or equal to, the diameter formed by the actuator supports 344. This may help to further cut the inner radial surface 313 of the wellbore wall 320, thereby allowing the steering pads 318 to extend further. In some embodiments, the steering gauge diameter may be greater than, or greater than or equal to, the bit gauge diameter of the bit 310. This may help to

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SUBSTITUTE SHEET ( RULE 26) further cut the inner radial surface 313 of the wellbore wall 320, thereby allowing the steering pads 318 to extend further.

[0050] In some embodiments, the steering gauge diameter may be less than the bit gauge diameter of the bit. This may help to cut the inner radial surface 313 of the wellbore wall 320 without widening the wellbore during drilling, such as while drilling straight or while drilling at less than the full DLS. In some embodiments, the steering gauge diameter may be less than the diameter formed by the actuator supports 344. This may help to cut the inner radial surface 313 of the wellbore wall 320 without widening the wellbore during drilling, such as while drilling straight or while drilling at less than the full DLS.

[0051] FIG. 4 is a schematic representation of a steering system 415, according to at least one embodiment of the present disclosure. The steering system 415 includes a bit 410 configured to engage the formation to advance the wellbore. The steering system 415 shown includes a steering unit 414 having a housing 432. The housing 432 may include one or more actuators or steering pads 418. The steering pads 418 may be supported by and/or extend (e.g., have their extension halted by) to an actuator support 444 (e.g., a kicker), which may help to prevent the steering pads 418 from overextending. The steering unit 414 further includes a plurality of steering cutting elements 430. The steering cutting elements 430 may be located between two of the steering pads 418 and/or two of the actuator supports 444.

[0052] In some embodiments, the cutting elements 430 may be oriented in a pattern. In the embodiment shown, the cutting elements 430 may be oriented such that adjacent cutting elements 430 circumferentially overlap. For example, the cutting elements 430 shown may be arranged on the outer surface of the housing 432 between two circumferentially adjacent steering pads 418 such that a line circumscribed around a circumference of the housing 432 may intersect two or more of the cutting elements 430. Arranging the cutting elements 430 to circumferentially overlap around the outer surface of the housing 432 may help the cutting elements 430 more effectively and/or efficiently engage the wellbore wall. For example, arranging the cutting elements 430 to circumferentially overlap may allow the overlapping cutting elements 430 to be backup cutting elements. This may help to increase the DLS and increase the operating life of the cutting elements 430 of the steering system 415.

[0053] FIG. 5 is a schematic representation of a steering system 515, according to at least one embodiment of the present disclosure. The steering system 515 includes a bit 510 configured to

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SUBSTITUTE SHEET ( RULE 26) engage the formation to advance the wellbore. The steering system 515 shown includes a steering unit 514 having a housing 532. The housing 532 may include one or more actuators or steering pads 518. The steering pads 518 may be supported by and/or extend (e.g., have their extension halted by) to an actuator support 544 (e.g., a kicker), which may help to prevent the steering pads 518 from overextending. The steering unit 514 further includes a plurality of steering cutting elements 530. The steering cutting elements 530 may be located between two of the steering pads 518 and/or two of the actuator supports 544.

[0054] In some embodiments, the cutting elements 530 may be oriented in a pattern. In the embodiment shown, the cutting elements 530 may be oriented such that adjacent cutting elements 530 longitudinally overlap. For example, the cutting elements 530 shown may be arranged on the outer surface of the housing 532 between two longitudinally adjacent steering pads 518 such that a line drawn on the outer surface of the housing 532 along the longitudinal axis may intersect two or more of the cutting elements 530. Arranging the cutting elements 530 to longitudinally overlap along the outer surface of the housing 532 may help the cutting elements 530 more effectively and/or efficiently engage the wellbore wall. For example, arranging the cutting elements 530 to longitudinally overlap may allow the overlapping cutting elements 530 to cut a larger longitudinal portion of the wellbore wall. This may reduce the cutting load on each individual cutting element 530. This may help to increase the DLS and increase the operating life of the cutting elements 530 of the steering system 515.

[0055] FIG. 6 is a schematic representation of a steering system 615, according to at least one embodiment of the present disclosure. The steering system 615 includes a bit 610 configured to engage the formation to advance the wellbore. The steering system 615 shown includes a steering unit 614 having a housing 632. The housing 632 may include one or more actuators or steering pads 618. The steering pads 618 may be supported by and/or extend (e.g., have their extension halted by) to an actuator support 644 (e.g., a kicker), which may help to prevent the steering pads 618 from overextending. The steering unit 614 further includes a plurality of steering cutting elements 630. The steering cutting elements 630 may be located between two of the steering pads 618 and/or two of the actuator supports 644.

[0056] In some embodiments, the cutting elements 630 may be oriented in a pattern. In the embodiment shown, the cutting elements 630 may be oriented such that adjacent cutting elements 630 longitudinally and circumferentially overlap. For example, the cutting elements 630 shown

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SUBSTITUTE SHEET ( RULE 26) may be arranged on the outer surface of the housing 632 between two adjacent steering pads 618 such that a line drawn on the outer surface of the housing 632 along the longitudinal axis may intersect two or more of the cutting elements 630. Further, a line circumscribed around a circumference of the housing 632 may intersect two or more of the cutting elements 630. Arranging the cutting elements 630 to longitudinally and circumferentially overlap along the outer surface of the housing 632 may help the cutting elements 630 more effectively and/or efficiently engage the wellbore wall. For example, arranging the cutting elements 630 to longitudinally and circumferentially overlap may allow the overlapping cutting elements 630 to cut a larger longitudinal portion of the wellbore wall and provide backup cutting for adjacent cutting elements. This may reduce the cutting load on each individual cutting element 630. This may help to increase the DLS and increase the operating life of the cutting elements 630 of the steering system 615.

[0057] FIG. 7 is a schematic representation of a steering system 715, according to at least one embodiment of the present disclosure. The steering system 715 includes a bit 710 configured to engage the formation to advance the wellbore. The steering system 715 shown includes a steering unit 714 having a housing 732. The housing 732 may include one or more actuators or steering pads 718. The steering pads 718 may be supported by and/or extend (e.g., have their extension halted by) to an actuator support 744 (e.g., a kicker), which may help to prevent the steering pads 718 from overextending. The steering unit 714 further includes a plurality of steering cutting elements 730. The steering cutting elements 730 may be located between two of the steering pads 718 and/or two of the actuator supports 744.

[0058] In some embodiments, the cutting elements 730 may be oriented in a pattern. In the embodiment shown, the cutting elements 730 may be oriented such that adjacent cutting elements 730 longitudinally and circumferentially overlap. In some embodiments, the cutting elements 730 may extend along a support length of the steering pads 718 and the actuator support 744. For example, the cutting elements 730 may extend along the support length from uphole end of the steering pads 718 and/or the actuator support 744 to a downhole end of the steering pads 718 and/or the actuator support 744. In some embodiments the cutting elements 730 may extend along an entirety of the support length. Extending the cutting elements 730 along the longitudinal length of the steering pads 718 and/or the actuator support 744 may cause the cutting elements 730 to cut the wellbore along the longitudinal length of the steering pads 718 and/or the actuator support 744. This may help to remove material from the inner radial surface of the wellbore wall along the

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SUBSTITUTE SHEET ( RULE 26) length of the steering pads 718 and/or the actuator support 744. This may help the steering pads 718 to extend further, thereby increasing the DLS of the steering system 715. This may further help to reduce the cutting load on any individual cutting element 730, thereby increasing the operating life of the steering system 715.

[0059] In some embodiments, the cutting elements 730 may be arranged independently of the cutting elements on the bit 710. For example, the bit 710 may be connected to the housing 732 of the steering unit 714 with a threaded connection, and the cutting elements on the blade of the bit 710 may not be rotationally aligned or otherwise oriented with the cutting elements 730.

[0060] In some embodiments, the cutting elements 730 may be arranged in a pattern based on or aligned with the cutting elements on the bit 710. For example, the bit 710 may be connected to the housing 732 of the steering unit 714 with a bolted connection. The cutting elements 730 may be circumferentially and longitudinally arranged based on the arrangement of the cutting elements on the bit 710. This may help the cutting elements 730 to more efficiently engage the wellbore, thereby improving how they remove material from the wellbore wall.

[0061] FIG. 8 is a schematic representation of a steering system 815, according to at least one embodiment of the present disclosure. The steering system 815 includes a bit 810 configured to engage the formation to advance the wellbore. The steering system 815 shown includes a steering unit 814 having a housing 832. The housing 832 may include one or more actuators or steering pads 818. The steering pads 818 may be supported by and/or extend (e.g., have their extension halted by) to an actuator support 844 (e.g., a kicker), which may help to prevent the steering pads 818 from overextending. The steering unit 814 further includes a plurality of steering cutting elements 830. The steering cutting elements 830 may be located between two of the steering pads 818 and/or two of the actuator supports 844.

[0062] In some embodiments, the cutting elements 830 may be oriented in a pattern. For example, the cutting elements 830 may be oriented such that adjacent cutting elements 830 may circumferentially overlap, longitudinally overlap, or circumferentially and longitudinally overlap. In some embodiments, the cutting elements 830 may be arranged in multiple rows between the steering pads 818. The multiple rows of cutting elements 830 may be arranged in a pattern to help improve the cutting efficiency and/or the cutting pattern of the steering unit 814.

[0063] FIG. 9 is a schematic representation of a steering system 915, according to at least one embodiment of the present disclosure. The steering system 915 includes a bit 910 configured to

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SUBSTITUTE SHEET ( RULE 26) engage the formation to advance the wellbore. The steering system 915 shown includes a steering unit 914 having a housing 932. The housing 932 may include one or more actuators or steering pads 918. The steering pads 918 may be supported by and/or extend (e.g., have their extension halted by) to an actuator support 944 (e.g., a kicker), which may help to prevent the steering pads 918 from overextending. The steering unit 914 further includes a plurality of steering cutting elements 930. The steering cutting elements 930 may be located between two of the steering pads 918 and/or two of the actuator supports 944. The steering pads 918 may be connected to their associated actuator supports 944 with a hinge 934. When the steering pad 918 extends, the steering pad 918 may rotate about the associated hinge 934.

[0064] In some embodiments, the cutting elements 930 may be arranged on the hinge 934. For example, the cutting elements 930 may be secured to an outer surface of the hinge 934. The cutting elements 930 may engage the wellbore wall at the hinge 934. This may help the cutting elements 930 to remove material from the wellbore wall. In some embodiments, the hinge 934 may be replaceable when the steering pads 918 and/or the actuator support 944 are replaced. This may make the cutting elements 930 easy and/or convenient to install and/or replace.

[0065] FIG. 10 is a flowchart of a method 1060 for manufacturing a steering system, according to at least one embodiment of the present disclosure. During assembly, an operator may secure a plurality of actuator supports to a housing of a steering unit at 1062. As discussed herein, in some embodiments, the actuator supports may be removably secured to the housing, such as with a bolted connection, an interlocking connection, or other removable connection.

[0066] In some embodiments, the operator may insert a plurality of actuator pads through the plurality of actuator supports and the housing at 1064. The actuator pads may be inserted through the actuator supports and the housing and secured to the actuator supports. In some embodiments, multiple actuator pads may be inserted through and secured to a single actuator support. In some embodiments, a single actuator pad may be inserted through and secured to a single actuator support.

[0067] In some embodiments, the operator may secure one or more cutting elements to the housing between two of the plurality of actuator supports at 1066. The operator may secure the cutting elements to the housing using any securing mechanism, such as brazing, welding, a mechanical fastener, any other securing mechanism, and combinations thereof. As discussed

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SUBSTITUTE SHEET ( RULE 26) herein, the cutting elements may be secured to the housing along a circumference of the housing, along a length of the housing, in a pattern, in rows, any other pattern, and combinations thereof.

[0068] The embodiments of the steering system have been primarily described with reference to wellbore drilling operations; the steering systems described herein may be used in applications other than the drilling of a wellbore. In other embodiments, steering systems according to the present disclosure may be used outside a wellbore or other downhole environment used for the exploration or production of natural resources. For instance, steering systems of the present disclosure may be used in a borehole used for placement of utility lines. Accordingly, the terms “wellbore,” “borehole” and the like should not be interpreted to limit tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

[0069] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the presently disclosed techniques. Additionally, in an effort to provide a concise description of these embodiments, not all features of an actual embodiment may be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous embodimentspecific decisions will be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one embodiment to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0070] Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. For example, any element described in relation to an embodiment herein may be combinable with any element of any other embodiment described herein. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable

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SUBSTITUTE SHEET ( RULE 26) manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.

[0071] A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims is to be embraced by the claims.

[0072] The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that is within standard manufacturing or process tolerances, or which still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

[0073] The present disclosure may be embodied in other specific forms without departing from its spirit or characteristics. The described embodiments are to be considered as illustrative and not restrictive. The scope of the disclosure is, therefore, indicated by the appended claims rather than by the foregoing description. Changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.

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SUBSTITUTE SHEET ( RULE 26)

Claims

CLAIMS What is claimed is:

1. A steering system, comprising: a housing; a plurality of actuator supports arranged circumferentially around the housing; an actuator pad extending through the housing; and a cutting element connected to the housing between two of the plurality of actuator supports.

2. The steering system of claim 1, wherein the cutting element includes a plurality of cutting elements.

3. The steering system of claim 2, wherein the plurality of actuator supports extend a support length longitudinally along the housing, the plurality of cutting elements located along the support length of the plurality of actuator supports.

4. The steering system of claim 3, wherein the plurality of cutting elements are located along an entirety of the support length of the plurality of actuator supports.

5. The steering system of claim 2, wherein two of the plurality of cutting elements at least partially circumferentially overlap.

6. The steering system of claim 2, wherein two of the plurality of cutting elements at least partially longitudinally overlap.

7. The steering system of claim 1, wherein the cutting element has a gauge diameter that is greater than a diameter of the plurality of actuator supports.

8. The steering system of claim 1, wherein the cutting element has a gauge diameter that is less than a diameter of the plurality of actuator supports.

9. A drilling system, comprising: a bit having a bit gauge diameter; a housing connected to the bit; a plurality of actuator supports connected to the housing; a plurality of actuator pads extending through the plurality of actuator supports; and a cutting element located between two of the plurality of actuator supports.

10. The drilling system of claim 9, wherein the cutting element has a steering gauge diameter that is greater than or equal to the bit gauge diameter.

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SUBSTITUTE SHEET ( RULE 26)

11. The drilling system of claim 9, wherein the cutting element has a steering gauge diameter that is less than the bit gauge diameter.

12. The drilling system of claim 9, wherein the cutting element has a steering gauge diameter that is between a diameter of the plurality of actuator pads and the bit gauge diameter.

13. The drilling system of claim 9, wherein the cutting element includes a plurality of cutting elements, the plurality of cutting elements extending along a length of the housing.

14. The drilling system of claim 13, wherein the plurality of cutting elements extend along a length and a circumference of the housing.

15. The drilling system of claim 9, wherein the cutting element includes a plurality of cutting elements, the plurality of cutting elements extending along a circumference of the housing.

16. A method for manufacturing a drilling system, comprising: securing a plurality of actuator supports to a housing of a steering unit; inserting a plurality of actuator pads through the plurality of actuator supports and the housing; and securing a cutting element to the housing between two of the plurality of actuator supports.

17. The method of claim 16, further comprising securing a bit to the housing of the steering unit.

18. The method of claim 16, wherein securing the cutting element to the housing includes securing a plurality of cutting elements to the housing along a circumference of the housing.

19. The method of claim 16, wherein securing the cutting element to the housing includes securing a plurality of cutting elements to the housing along a length of the housing.

20. The method of claim 19, wherein securing the plurality of cutting elements to the housing includes securing the plurality of cutting elements to the housing along a length and circumference of the housing.

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SUBSTITUTE SHEET ( RULE 26)