US20220282573A1 - Rotary steerable system with optimized piston extension - Google Patents
Rotary steerable system with optimized piston extension Download PDFInfo
- Publication number
- US20220282573A1 US20220282573A1 US17/682,383 US202217682383A US2022282573A1 US 20220282573 A1 US20220282573 A1 US 20220282573A1 US 202217682383 A US202217682383 A US 202217682383A US 2022282573 A1 US2022282573 A1 US 2022282573A1
- Authority
- US
- United States
- Prior art keywords
- piston
- rotary steerable
- stator
- steerable system
- steering section
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000012530 fluid Substances 0.000 description 41
- 238000005553 drilling Methods 0.000 description 27
- 230000004913 activation Effects 0.000 description 11
- 125000006850 spacer group Chemical group 0.000 description 7
- 230000007704 transition Effects 0.000 description 6
- 230000000712 assembly Effects 0.000 description 4
- 238000000429 assembly Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 230000006870 function Effects 0.000 description 4
- 238000012423 maintenance Methods 0.000 description 4
- 238000000926 separation method Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- 230000007935 neutral effect Effects 0.000 description 3
- 241000239290 Araneae Species 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000001934 delay Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
- E21B7/06—Deflecting the direction of boreholes
- E21B7/064—Deflecting the direction of boreholes specially adapted drill bits therefor
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B44/00—Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/10—Wear protectors; Centralising devices, e.g. stabilisers
- E21B17/1014—Flexible or expansible centering means, e.g. with pistons pressing against the wall of the well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/10—Valve arrangements in drilling-fluid circulation systems
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/06—Valve arrangements for boreholes or wells in wells
- E21B34/066—Valve arrangements for boreholes or wells in wells electrically actuated
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
- E21B7/06—Deflecting the direction of boreholes
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
- E21B7/06—Deflecting the direction of boreholes
- E21B7/061—Deflecting the direction of boreholes the tool shaft advancing relative to a guide, e.g. a curved tube or a whipstock
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
- E21B7/06—Deflecting the direction of boreholes
- E21B7/067—Deflecting the direction of boreholes with means for locking sections of a pipe or of a guide for a shaft in angular relation, e.g. adjustable bent sub
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/04—Directional drilling
- E21B7/06—Deflecting the direction of boreholes
- E21B7/068—Deflecting the direction of boreholes drilled by a down-hole drilling motor
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B44/00—Automatic control systems specially adapted for drilling operations, i.e. self-operating systems which function to carry out or modify a drilling operation without intervention of a human operator, e.g. computer-controlled drilling systems; Systems specially adapted for monitoring a plurality of drilling variables or conditions
- E21B44/005—Below-ground automatic control systems
Definitions
- rotary steerable systems are used to control and adjust the direction in which a well is drilled.
- Conventional rotary steerable systems are well over 150 inches in length and include three or more sets of extending pistons. These large systems require frequent maintenance.
- the conventional rotary steerable systems' long length presents challenges in the maintenance, including transporting the system from a drilling location to a shop.
- FIG. 1 is a side view of a rotary steerable system of the present invention.
- FIG. 2 is a sectional view of the rotary steerable system.
- FIG. 3 is a sectional view of a control sleeve and a steering section of the rotary steerable system.
- FIG. 4 is a partially exploded view of a control insert configured to fit within the control sleeve.
- FIG. 5 is a partial sectional view of an upper control unit of the control insert within the control sleeve.
- FIG. 6 is an exploded view of a lower control unit of the control insert.
- FIG. 7 is a sectional view of the lower control unit of the control insert.
- FIG. 8 is a sectional view of the steering section.
- FIG. 9 is a sectional view of the steering section taken along a perpendicular plane as compared to FIG. 8 .
- FIG. 10 is a sectional view of a lower portion of the control section and the steering section.
- FIG. 11 is a top view of a valve stator of the rotary steerable system.
- FIG. 12 is a sectional view of the valve stator of the rotary steerable system taken along line 12 - 12 in FIG. 11 .
- FIG. 13 is bottom view of the valve stator of the rotary steerable system.
- FIG. 14 is a top view of an alternate embodiment of the valve stator of the rotary steerable system.
- FIG. 15 is a sectional view of the alternate embodiment of the valve stator of the rotary steerable system taken along line 15 - 15 in FIG. 14 .
- FIG. 16 is bottom view of the alternate embodiment of the valve stator of the rotary steerable system.
- FIG. 17 is a top view of a valve rotor of the rotary steerable system.
- FIG. 18 is a sectional view of the valve rotor of the rotary steerable system taken along line 18 - 18 in FIG. 17 .
- FIG. 19 is bottom view of the valve rotor of the rotary steerable system.
- FIG. 20 is a top view of the valve assembly including the valve rotor and the valve stator, with the valve rotor in a first position.
- FIG. 21 is a sectional view of the valve assembly with the valve rotor in the first position taken along line 21 - 21 in FIG. 20 .
- FIG. 22 is a top view of the valve assembly with the valve rotor in a second position.
- FIG. 23 is a schematic view of the valve assembly with the valve rotor in a sequence of positions as it rotates relative to the valve stator.
- FIG. 24 is a side view of the steering section in a default position.
- FIG. 25 is a sectional view of the steering section in the default position, taken along line 25 - 25 in FIG. 24 .
- FIG. 26 is a side view of the steering section in a first extended position.
- FIG. 27 is a sectional view of the steering section in the first extended position, taken along line 27 - 27 in FIG. 26 .
- FIG. 28 is a side view of the steering section in a neutral position.
- FIG. 29 is a sectional view of the steering section in the neutral position, taken along line 29 - 29 in FIG. 28 .
- FIG. 30 is a side view of the steering section in a second extended position.
- FIG. 31 is a sectional view of the steering section in the second extended position, taken along line 31 - 31 in FIG. 30 .
- FIG. 32 is a side view of an alternate embodiment of the steering section.
- FIG. 33 is a sectional view of the alternate embodiment of the steering section.
- FIG. 34 is a sectional view of the alternate embodiment of the steering section taken along line 34 - 34 in FIG. 32 .
- FIG. 35 is a sectional view of the alternate embodiment of the steering section taken along line 35 - 35 in FIG. 32 .
- FIG. 36 is a side view of the rotary steerable system connected between a flex shaft and a drill bit.
- FIG. 37 is another side view of the rotary steerable system connected between the flex shaft and the drill bit.
- a rotary steerable system including a steering section.
- the steering section includes at least one piston.
- the steering section includes only two pistons in each transverse cross-sectional plane. A center point of a first piston is separated from a center point of a second piston by an angle greater than 120 degrees.
- the rotary steerable system also includes a valve assembly configured to direct a portion of a drilling fluid flowing through the rotary steerable system into a distribution flow passage, thereby activating one of the pistons and causing the piston to extend in a radially outward direction.
- a ratio of the diameter of each distribution flow passage to the steering section diameter is at least 0.07.
- the distribution flow passages are contained within a central area of the steering section.
- a ratio of the diameter of the central area to the steering section diameter is 0.5 or less.
- An activation duration of each set of pistons is about 180 degrees of rotation of a valve rotor.
- a ratio of the stroke length of each piston to the diameter of the steering section is greater than 0.06.
- diameter of the steering section and “steering section diameter” both mean the minimum outer diameter of any portion of the assembled steering section (i.e., the outer diameter of the smallest portion of the assembled steering section).
- the steering section diameter may be the outer diameter of steering housing 22 .
- the rotary steerable system also includes a control section.
- a combined length of the control section and the steering section is below 150 inches, preferably below 80 inches.
- FIGS. 1-37 illustrate embodiments of the rotary steerable system disclosed herein, with many other embodiments within the scope of the claims being readily apparent to skilled artisans after reviewing this disclosure.
- rotary steerable system 10 includes control section 12 and steering section 14 , each having a generally cylindrical shape.
- Control section 12 includes electronic components, sensors, and actuators for determining a drilling direction or tool face required and for orienting the steering section.
- Control section 12 includes control sleeve 16 and control insert 18 disposed within inner bore 20 of control sleeve 16 .
- Control insert 18 is configured for rotation relative to control sleeve 12 .
- control insert 18 is configured to remain stationary with respect to a surrounding subterranean formation, such that control sleeve 16 rotates around control insert 18 .
- control insert 18 may be configured to remain geo-stationary.
- a lower end of control sleeve 16 is secured to an upper end of steering housing 22 of steering section 14 . In this way, control sleeve 16 is rotationally secured to steering housing 22 .
- rotationally secured means secured together such that two components rotate together (i.e., there is no relative rotation between two components under normal operating conditions).
- control insert 18 includes a valve rotor 24 , which cooperates with valve stator 26 secured to steering housing 22 .
- Valve rotor 24 rotates relative to valve stator 26 as control insert 18 rotates relative to control sleeve 16 and steering housing 22 .
- control insert 18 may include upper control unit 28 , electronics unit 30 , and lower control unit 32 .
- Control insert 18 may also include guide 34 secured to upper control unit 28 and guide 36 secured to lower control unit 32 .
- Guide 34 and 36 may be rotationally secured to control sleeve 16 , while upper and lower control units 28 and 32 rotate within guides 34 and 36 , respectively.
- Control insert 18 may further include upper impeller 38 rotationally secured to upper control unit 28 and lower impeller 40 rotationally secured to lower control unit 32 .
- Upper and lower impellers 38 and 40 may be sized and configured such that the outer ends of impellers 38 and 40 are in close proximity a surface of inner bore 20 of control sleeve 16 .
- Guides 34 and 36 and impellers 38 and 40 may stabilize a position of control insert 18 within inner bore 20 of control sleeve 16 while control insert 18 therein.
- upper control unit 28 may include a magnetic brake 41 , which functions as an actuator to apply rotational torque in a direction that is opposite to a rotational direction of control sleeve 16 and steering housing 22 .
- the magnetic brake assembly adjusts the rotation rate of control insert 18 relative to control sleeve 16 .
- upper control unit 28 also includes a power generation mechanism.
- the magnetic brake assembly may be the only actuator in rotary steerable system 10 .
- upper control unit 28 may also include upper filter 44 .
- upper filter 44 may be formed of rings with shoulders such that the stacking of the rings creates small interstices that function to filter. As drilling fluid flow through inner bore 20 of control sleeve 16 , a small amount of drilling fluid may flow through upper filter 44 and through intermediate spaces 43 a , 43 b , 43 c , and 43 d surrounding antenna 42 and magnetic brake 41 . Upper filter 44 removes larger particles from the drilling fluid to allow a small amount of clean fluid to flow in the intermediate spaces 43 a - 43 d .
- Allowing only clean fluid to flow in intermediate spaces 43 a - 43 d prevents the two parts of upper control unit 28 from seizing up and/or from creating additional drag between the two parts of upper control unit 28 .
- the majority of the drilling fluid flows around the exterior surface of filter 44 and through the spaces in impeller 38 .
- Electronics unit 30 may include sensors.
- electronics unit 30 may include a magnetometer for sensing a north-south direction, an accelerometer for sensing inclination, and a gyrometer for sensing rotation of the control unit relative to a surrounding subterranean formation.
- Control insert 18 may be configured to adjust the magnetic brake assembly in the upper control unit 28 based on measurements taken by the sensors in electronics unit 30 .
- the rotary steerable system 10 includes no batteries and only a small amount of memory (e.g., flash memory only).
- the electronics unit 30 may include antenna 42 for transmitting measurement data and other data to a measurement-while-drilling (“MWD”) unit secured above the rotary steerable system 10 , and the MWD unit may store the received data in a memory.
- Antenna 42 of the electronics unit 30 may be formed of an electromagnetic antenna.
- lower control unit 32 may include housing 45 with flow passages 46 .
- Flow passages 46 are configured to allow a drilling fluid in an annular space between control sleeve 16 and housing 45 to flow into inner space 48 within housing 45 .
- Lower control unit 32 may also include lower filter 49 configured to surround and cover flow passages 46 in order to filter drilling fluid as it flows through flow passages 46 and enters inner space 48 .
- lower filter 49 may be formed of rings with shoulders such that the stacking of the rings creates small interstices that function to filter.
- Lower control unit 32 may further include spring 50 disposed within inner space 48 and configured to bias valve rotor 24 in a direction toward the valve stator 26 and steering section 14 .
- an upper end of spring 50 may engage transverse surface 52 of housing 45 , while lower end of spring 50 engages an upper end of spacer 54 to apply a downward force on the valve rotor 24 , which is secured to a lower end of spacer 54 .
- a drilling fluid flows through the annular space between control sleeve 16 and housing 45 , a portion of the drilling fluid may flow through flow passages 46 , into inner space 48 , and through a rotor port 56 of valve rotor 24 . The remainder of the drilling fluid flowing through the annular space may flow through spaces in impeller 40 outside of housing 45 .
- steering section 14 includes parallel main flow passages and distribution flow passages.
- Steering housing 22 includes two main flow passages 66 extending from upper inner bore 68 to lower inner bore 70 .
- Steering housing 22 also includes two distribution flow passages 72 , each extending from a stator port 73 of valve stator 26 to one or more feed channels 74 .
- Steering section 14 also includes two piston assemblies 76 , each at least partially secured within a receptacle 78 in an outer surface of steering housing 22 .
- Each piston assembly 76 includes one or more pistons 80 each disposed within a piston sleeve 85 , all disposed within piston clamp 81 , which is configured to be secured within piston receptacle 82 in steering housing 22 .
- Pistons 80 are configured to slide in a radial direction within piston receptacles 82 .
- Each feed channel 74 extends from a distribution flow passage 72 to a piston receptacle 82 .
- Steering section 14 of rotary steerable system 10 may include not more than two pistons in each transverse cross-sectional plane, with the center points of the pistons separated by an angle greater than 120 degrees.
- Steering section 14 may include not more than two sets of pistons.
- Steering section 14 may further include spacers 84 , each at least partially disposed within spacer receptacles 86 in an outer surface of steering housing 22 .
- spacers 84 are secured to steering housing 22 using bolts or screws.
- “piston” means any structure configured to extend, when activated, in a radial direction from a tool to which it is secured or in which it is incorporated.
- “piston” includes a pad, a wedge arrangement, and a cam arrangement.
- a portion of the drilling fluid may flow through flow passages 46 and into inner space 48 of housing 45 .
- the drilling fluid within inner space 48 may flow through rotor port 56 of valve rotor 24 and through a stator port 73 of valve stator 26 that is aligned with rotor port 56 .
- rotor port 56 aligns with each of the stator ports 73 in sequence over time. Accordingly, the drilling fluid flowing through rotor port 56 will flow through each of the stator ports 73 in sequence over time.
- Drilling fluid that flows through one of the stator ports 73 flows through the connecting distribution flow passage 72 , through each of the connected feed channels 74 , and into connected piston receptacles 82 in order to apply a force and displace piston 80 in a radial outward direction.
- the drilling fluid can flow through leak channels 90 between pistons 80 and piston receptacles 82 , or in another embodiment, it may leak between the piston and the guide sleeve, through diametral space between the two or through a channel formed in the sleeve or in the piston that connect piston receptacles 82 to the wellbore.
- the leak channels may be located through the piston body to connect piston receptacles 82 to the wellbore.
- the leak channel may be located between the guide sleeve and the steering body.
- FIGS. 11-13 illustrate one embodiment of valve stator 26 , which includes two stator ports 73 positioned on opposite sides of valve stator 26 .
- the central point of the outer boundary of one stator port 73 is 180 degrees from the central point of the outer boundary of the second stator port 73 .
- the shape of each stator port 73 varies across the thickness of valve stator 26 .
- each stator port 73 may be defined by a wedge-shaped opening 92 on first side 94 of valve stator 26 and defined by a circular opening 96 on second side 98 of valve stator 26 .
- First side 94 is configured to engage valve rotor 24
- second side 96 is configured to engage distribution flow passages 72 .
- each stator port 73 may be defined by wedge-shaped opening 92 on first side 94 of valve stator 26 and defined by a polygon-shaped opening on second side 98 of valve stator 26 .
- stator ports 73 may have the same shape across the thickness of valve stator 26 .
- FIGS. 14-16 illustrate an alternate embodiment of valve stator 26 a .
- each stator port 73 a is defined by a wedge-shaped opening 92 a on first side 94 a of valve stator 26 a .
- Each stator port 73 a is defined by a polygon-shaped opening 99 on second side 98 a of valve stator 26 a.
- FIGS. 17-19 illustrate one embodiment of valve rotor 24 , which includes only one rotor port 56 .
- the shape of rotor port 56 varies across the thickness of valve rotor 24 .
- rotor port 56 may be defined by inner boundary 102 , outer boundary 106 , and side boundaries 108 and 110 on first side 104 of valve rotor 24 .
- Side boundaries 108 and 110 interconnect inner and outer boundaries 102 and 106 on first side 104 .
- a center point of first side 104 is positioned between inner boundary 102 and outer boundary 106 .
- rotor port 56 includes the center point of first side 104 .
- Inner boundary 102 of rotor port 56 remains constant throughout the thickness of valve rotor 24 .
- rotor port 56 may be defined by outer boundary 106 , inner boundary 114 , and side boundaries 116 and 118 .
- Side boundaries 116 and 118 interconnect inner and outer boundaries 102 and 106 on second side 112 .
- Inner boundary 114 is positioned between outer boundary 106 and a center point of second side 112 . In other words, the center point of second side 112 is not included within rotor port 56 .
- Valve rotor 24 may include sloped surface 120 in the transitions between inner boundaries 102 and 114 , side boundaries 108 and 116 , and side boundaries 110 and 118 , respectively.
- Side boundaries 116 and 118 of first side 104 of rotor port 56 may have the same shape as the side boundaries of wedge-shaped openings 92 of stator ports 73 .
- each of the side boundaries 116 and 118 and each of the side boundaries of wedge-shaped openings 92 may be formed of a straight line extending in a radial direction.
- valve assembly 124 may include valve rotor 24 and valve stator 26 , with valve rotor 24 rotating relative to valve stator 26 .
- outer boundary 106 of rotor port 56 aligns with the outer boundary of wedge-shaped openings 92 of stator ports 73
- inner boundary 114 of rotor port 56 aligns with the inner boundary of wedge-shaped openings 92 of stator ports 73 .
- rotor port 56 is aligned with all of the wedge-shaped opening 92 of a single stator port 73 .
- a first stator port 73 a is “open” and a second stator port 73 b (not shown in this view) is “closed.”
- valve rotor 24 rotates, the side boundaries 116 and 118 of rotor port 56 cross over the side boundaries of wedge-shaped openings 92 of stator ports 73 , thereby alternately opening and closing stator ports 73 a and 73 b .
- the angular separation of side boundary 116 from side boundary 118 and the angular separation of the two side boundaries of each wedge-shaped opening 92 together define the duration for which each stator port 73 is open (i.e., activation duration of each stator port 73 ).
- the opening angle of the rotor port 56 (i.e., the angular distance between side boundaries 116 and 118 within rotor port 56 ) is at least 110 degrees.
- opening angle is the rotational distance between two radial boundaries within an opening.
- the side boundaries of the two wedge-shaped openings 92 are separated by at least 110 degrees or between 110 degrees and 170 degrees, or any subrange therein. In certain embodiments, the side boundaries of the two wedge-shaped openings 92 are separated by at least 125 degrees.
- the side boundaries of the two wedge-shaped openings 92 are separated by an angle between 140 degrees and 170 degrees.
- rotor port 56 is aligned with a portion of stator port 73 a and a portion of stator port 73 b.
- FIG. 23 illustrates valve assembly 124 with valve rotor 24 in various sequential positions relative to valve stator 26 over time.
- valve rotor 24 rotates in a counter-clockwise direction.
- valve rotor 24 rotates in a clockwise direction.
- valve rotor 24 is maintained in a geostationary position while valve stator 26 rotates with steering unit 14 and control sleeve 16 in a clockwise direction.
- FIG. 23( a ) illustrates the first position shown in FIGS. 20 and 21 , in which rotor port 56 is aligned with first stator port 73 a such that first stator port 73 a is fully open and second stator port 73 b is closed.
- First stator port 73 a remains fully open through the time when side boundary 116 of rotor port 56 aligns with a side boundary of the wedge-shaped opening of first stator port 73 a , as shown in FIG. 23( b ) .
- valve rotor 24 causes side boundary 116 of rotor port 56 to move across first stator port 73 a thereby reducing the open cross-sectional area of first stator port 73 a and reducing the fluid flow rate through first stator port 73 a .
- the first stator port 73 a is partially open and the second stator port 73 b is closed through the time when side boundary 118 of rotor port 56 aligns with a first side boundary of the wedge-shaped opening of second stator port 73 b , as shown in FIG. 23( c ) .
- valve assembly is configured to have first and second stator ports 73 a and 73 b partially open simultaneously as shown in FIG. 23( d ) .
- the valve assembly remains in this simultaneous partially open position until side boundary 116 aligns with a second side boundary of first stator port 73 a to place first stator port 73 a in the closed position, as shown in FIG. 23( e ) .
- first stator port 73 a is closed and second stator port 73 b is partially open.
- second stator port 73 b is placed in a fully open position when side boundary 118 of rotor port 56 aligns with a second side boundary of second stator port 73 b .
- Second stator port 73 b remains in the fully open position through the time when side boundary 116 of rotor port 56 aligns with the first side boundary of second stator port 73 b as shown in FIG. 23( g ) .
- valve rotor 24 causes side boundary 116 of rotor port 56 to move across second stator port 73 b , thereby reducing the open cross-sectional area of second stator port 73 b and reducing the fluid flow rate therethrough.
- the first stator port 73 a is closed and the second stator port 73 b is partially open through the time when side boundary 118 of rotor port 56 aligns with the first side boundary of first stator port 73 a , as shown in FIG. 23( h ) .
- valve rotor 24 Further rotation of valve rotor 24 causes side boundary 118 of rotor port 56 to move past the first side boundary of first stator port 73 a to place both stator ports 73 a and 73 b in partially open positions, as shown in FIG. 23( i ) .
- the valve assembly remains in this simultaneous partially open position until side boundary 116 of rotor port 56 aligns with the second side boundary of second stator port 73 b to place second stator port 73 b in the closed position, as shown in FIG. 23( j ) .
- first stator port 73 a is further opened and the fluid flow rate through the first stator port 73 a increases. During this time, first stator port 73 a is partially open and second stator port 73 b is closed. As shown in FIG. 23( k ) , first stator port 73 a is placed in the fully open position when side boundary 118 of rotor port 56 aligns with the second side boundary of first stator port 73 a .
- FIG. 23( l ) again illustrates the valve assembly in the first position, in which first stator port 73 a is fully open and second stator port 73 b is closed. Table 1 lists the positions of the stator ports in each view of FIG. 23 .
- each stator port 73 a , 73 b may be greater than 120 degrees, preferably greater than 150 degrees, and most preferably about 180 degrees.
- the embodiment illustrated in FIG. 23 provides a theoretical activation duration of about 180 degrees.
- Second stator port 73 b is partially or fully open from the time that side boundary 118 of rotor port 56 crosses the first side boundary of second stator port 73 b (immediately after the position illustrated in FIG. 23( c ) ) until the time that side boundary 116 crosses the second side boundary of second stator port 73 b (immediately before FIG. 23( j ) ).
- FIGS. 24 and 25 illustrate steering section 14 in a default position in which pistons 80 are in retracted positions.
- This embodiment of rotary steerable system 10 includes two pistons 80 , with the center points of the two pistons 80 separated by about 180 degrees.
- distribution flow passages 72 a and 72 b may be positioned within a central area of steering housing 22 .
- main flow passages 66 may extend from the central area outward radially.
- Distribution flow passages 72 a , 72 b and main flow passages 66 may be positioned between piston receptacles 82 .
- main flow passages 66 may also extend beyond the space between piston receptacles 82 .
- the position of the distribution flow passages 72 a , 72 b in the central area within the same transverse cross-sectional plane as pistons 80 eliminates the need for a spider to rearrange flow lines through a length of the steering unit (i.e., distribution flow passages remain in the central area from the valve assembly 124 to the feed channels 74 and pistons 80 ).
- the central area may be defined by a circular path that includes the center of the inner boundary of each piston receptacle 82 and is centered on the center of the steering unit 14 .
- the central area may be defined by a central diameter surrounding the center of the steering unit 14 .
- the central diameter may be in the range of 1.5 inches to 3.0 inches, preferably about 1.75 inches to about 2.5 inches, or any subrange therein.
- the central diameter may be about 1.75 inches in a steering unit having a diameter less than or equal to 5.25 inches, about 2 inches in a steering unit having a diameter less than or equal to 6.75 inches, and about 2.5 inches in a steering unit having a diameter less than or equal to 9 inches.
- a ratio of the central diameter to the steering section diameter may be 0.5 or less, 0.4 or less, preferably 0.33 or less, more preferably 0.3 or less.
- steering section 14 includes axis x and axis y intersecting at the central point of steering section 14 as shown.
- the central area in which distribution flow passages 72 are positioned is defined by distribution distance 90 between the central point and a line D extending from an outer most point on one of the distribution flow passages 72 .
- Line M is defined by the inner boundary of one of the main flow passages 66 .
- Line M is spaced apart from the central point by main distance 92 .
- Line P is defined by the inner boundary of one of the piston receptacles 82 .
- Line P is spaced apart from the central point by piston distance 94 .
- distribution distance 90 is greater than main distance 92
- piston distance 94 is greater than distribution distance 90 .
- each main flow passage 66 is closer to the central point of the steering section than the outer boundary of the distribution flow passages 72 . Additionally, at least a portion of each main flow passage 66 is closer to the central point of the steering section than the inner boundary of the piston receptacle 82 and the position of the piston in its retracted position.
- the rotary steerable system disclosed herein includes distribution flow passages 72 a , 72 b having larger diameters and main flow passages 66 having larger diameters than in conventional rotary steerable systems.
- the larger diameters of these flow lines reduce the fluid flow speed, prevent a water hammer effect, reduce erosion, and reduce pressure drop in order to preserve energy.
- a ratio of a diameter of each distribution flow passage 72 a , 72 b to a diameter of steering section 14 may be at least 0.07.
- a diameter of each distribution flow passage 72 a , 72 b is about 0.35 inches in a steering section 14 having a diameter of at least 5.25 inches, about 0.5 inches in a steering section 14 having a diameter of at least 6.75 inches, and about 0.67 inches in a steering section 14 having a diameter of at least 9 inches.
- valve assembly 124 (shown in FIGS. 20-23 ) may be positioned at the upper end of the distribution flow passages (shown in FIG. 10 ) such that circular openings 96 on the second side 98 of stator ports 73 (shown in FIG. 13 ) align with distribution flow passages 72 .
- circular opening 96 of stator port 73 a aligns with distribution flow passage 72 a
- circular opening 96 of stator port 73 b aligns with distribution flow passage 72 b .
- stator ports 73 a and 73 b circulate through fully open, partially open, and closed positions, thereby directing fluid flowing through inner space 48 within housing 45 of lower control unit 32 into first distribution flow passage 72 a , second distribution flow passage 72 b , or a combination thereof.
- FIGS. 26 and 27 illustrate steering assembly 14 in a first extended position when first stator port 73 a is fully open (as shown in FIGS. 23( a ) and 23( b ) ).
- valve assembly 124 directs the fluid within inner space 48 of lower control unit 32 into first distribution flow passage 72 a .
- the drilling fluid that has entered inner space 48 of lower control unit 32 flows through rotor port 56 of valve rotor 24 , through first stator port 73 a , through first distribution flow passage 72 a , through feed channels 74 , and into first piston receptacles 82 a .
- first pistons 80 a may engage a wall of a wellbore being drilled through a subterranean formation in order to adjust the direction in which the wellbore is drilled further.
- the drilling fluid that flows through the spaces in impeller 40 flows through main flow passages 66 , thereby bypassing the piston assemblies 76 .
- each piston 80 a and 80 b may have a length of L p and a diameter of D.
- a ratio of each piston's length to the piston's width is between 1 and 1.4, preferably between 1.1 and 1.3, or any subrange therein.
- each of the pistons may have a length of 2.09 inches and a diameter of 1.73 inches, resulting in a ratio of about 1.2.
- the pistons may have a length of 2.88 inches and a diameter of 2.43 inches, resulting in a ratio of about 1.2.
- the pistons may have a length of 3.78 inches and a diameter of 3.12 inches, resulting in a ratio of about 1.2.
- each piston 80 a and 80 b extends a stroke length S from its default position when activated.
- the pistons may have a ratio of stroke length to piston diameter that is greater than 0.06, preferably greater than 0.7, or about 0.08.
- the stroke length of the piston may be between 0.3 inches and 0.5 inches in an embodiment having a steering section diameter of at least 5.25 inches.
- the stroke length of the piston may be between 0.4 inches and 0.6 inches in an embodiment having a steering section diameter of at least 6.75 inches.
- the stroke length of the piston may be between 0.6 inches and 0.8 inches in an embodiment having a steering section diameter of at least 9 inches
- FIGS. 28 and 29 illustrate steering assembly 14 in a neutral position when first and second stator ports 73 a , 73 b are both partially open (as shown in FIGS. 23( d ) and 23( i ) ). In this position, valve assembly 124 directs the fluid within inner space 48 of lower control unit 32 into both first and second distribution flow passages 72 a , 72 b .
- first stator ports 73 a and ultimately into piston receptacles 82 a decreases, a force exerted by a wall of a wellbore on pistons 80 a may overcome the outward force of the fluid flow into piston receptacles 82 a , which may force pistons 80 a to retract in a radially inward direction into piston receptacles 82 a .
- the excess fluid in receptacle 82 a is expelled through the exhaust port.
- the drilling fluid flowing through second stator port 73 b flows through second distribution flow passage 72 b , through feed channels 74 , and into piston receptacles 82 b .
- the fluid flowing into piston receptacles 82 b begins to apply a radial outward force on second pistons 80 b , thereby causing second pistons 80 b to begin moving in a radially outward direction.
- FIGS. 30 and 31 illustrate steering assembly 14 in a second extended position when second stator port 73 b is fully open (as shown in FIGS. 23( f ) and 23( g ) ).
- valve assembly 124 directs all fluid within inner space 48 of lower control unit 32 into second distribution flow passage 72 b .
- the fluid flow applies a greater radial outward force on second pistons 80 b , thereby causing second pistons 80 b to fully extend in the radially outward direction.
- second pistons 80 b may engage the wall of the wellbore in order to adjust the drilling in an opposite direction.
- the drilling fluid that flows through the spaces in impeller 40 flows through main flow passages 66 , thereby bypassing the piston assemblies 76 .
- Rotary steerable system 10 may be configured to provide a theoretical activation duration of each piston 80 a , 80 b that is greater than 120 degrees, preferably greater than 150 degrees, and most preferably about 180 degrees.
- the actual observed activation duration of each piston 80 a , 80 b may be less than the theoretical activation duration because of actuation timing delays.
- activation duration means the angle of rotation of valve rotor 24 during which a specified component is activated by or receives by fluid flow.
- the two-piston configuration of the rotary steerable system disclosed herein may provide a greater activation duration of each piston as compared to conventional rotary steerable systems including three-piston configurations due to fewer transitions in each rotation of the valve and due to larger angular separation of the side boundaries of each stator port.
- Steering section 14 may include any number of pistons within the piston assemblies.
- steering section 14 includes a first piston assembly 76 a including two pistons 80 a and a second piston assembly 76 b including three pistons 80 b .
- pistons 80 a may be staggered along the axial length of steering housing 22 relative to pistons 80 b , as shown in FIG. 33 .
- the steering section 14 includes only one piston in a transverse cross-sectional plane, such as plane A—A.
- the offset pistons are separated by a length that is equal to the steering section diameter.
- the steering section 14 may include only a one piston.
- rotary steerable system 10 may be secured below flex shaft 152 and drill bit 154 in a bottom hole assembly.
- the rotary steerable system of the present invention which includes a steering section and a control section, is significantly shorter than conventional rotary steerable systems.
- the combined length of the steering section and the control section is less than 150 inches, less than 125 inches, less than 100 inches, less than 80 inches, less than 75 inches, less than 70 inches, less than 65 inches, or any subrange therein.
- the rotary steerable system has a minimum diameter of about 5.25 inches, and a combined length of about 63 inches.
- the rotary steerable system has a minimum diameter of about 6.75 inches, and a combined length of about 67 inches.
- the rotary steerable system has a minimum diameter of about 9 inches, and a combined length of about 74 inches.
- the rotary steerable system has a length to steering section diameter ratio of less than 16, less than 14, less than 11, less than 10, less than 9, or any subrange therein.
- “length to steering section diameter ratio” means a ratio of the combined length of the steering section and control section to the minimum outer diameter of the steering section or the control section (in inches).
- the rotary steerable system may have a diameter less than or equal to 5.25 inches, and a length to steering section diameter ratio of less than 13, less than 12, or any subrange therein.
- the rotary steerable system may have a diameter less than or equal to 6.75 inches, and a length to steering section diameter ratio of less than 11, less than 10, or any subrange therein.
- the rotary steerable system may have a diameter less than or equal to 9 inches, and a length to steering section diameter ratio of less than 9.
- flex shaft 152 may be secured above rotary steerable system 10
- drill bit 154 may be secured below rotary steerable system 10 .
- the reduced length of the rotary steerable system 10 positions flex shaft 152 closer to drill bit 154 than in conventional rotary steerable systems, thereby enabling the rotary steerable system to turn the drill bit path by a smaller radius.
- the rotary steerable system disclosed herein may enable a maximum turn rate of 14 degrees per 100 feet.
- the rotary steerable system disclosed herein may enable a maximum turn rate of 18 degrees per 100 feet.
- the rotary steerable system disclosed herein may enable a maximum turn rate of 24 degrees per 100 feet.
- the reduced length rotary steerable system 10 behaves as a hybrid push-the-bit/point-the-bit system as control unit 12 and steering unit 14 are deflected (i.e., pushed) as one and become pointed in the desired direction.
- the maximum turn rate values may be affected by environmental conditions, including conditions within a wellbore or conditions of a subterranean formation.
- the reduced length of the rotary steerable system of the present invention is achieved due to several features.
- lower filter 49 and valve assembly including valve rotor 24 and valve stator 26 are incorporated into a single module, as shown in FIG. 10 .
- conventional rotary steerable systems include separate modules for filters and valves.
- the absence of a battery reduces the length of control section 12 .
- Another example is the use of smaller memory components, such as micro-electromechanical systems (“MEMS”), in the control section 12 .
- MEMS micro-electromechanical systems
- Conventional rotary steerable systems teach away from smaller memory components in favor of larger memory components capable of storing data required for well surveys.
- the rotary steerable system disclosed herein includes only three sensors in control section 12 , thereby reducing the length of the control section 12 .
- Conventional rotary steerable systems include a greater number of sensors, which require a greater length of the control section.
- Another example is the transition of the shape of stator ports 73 across the thickness of valve stator 26 , which reduces the length of transition flow lines needed in steering housing 22 between the valve assembly and the pistons 80 .
- the central position of distribution flow receptacles 72 within steering section 14 eliminates the requirement for a spider, which transposes the main flow and distribution flow lines between the valve and pistons in conventional rotary steerable systems.
- the reduced length of the rotary steerable system disclosed herein provides the commercial advantage of requiring less material for construction, thereby reducing costs of manufacturing and maintenance.
- the components of the rotary steerable system disclosed herein are more accessible from outside of the rotary steerable system, which enables users to perform certain additional maintenance tasks in any location without the need for transporting the rotary steerable system to a shop.
- the rotary steerable system of the present invention includes only a steering section without a control section.
- the elements of the control section may be incorporated into the steering section, positioned in adjacent devices in the drill string, eliminated, or any combination thereof.
- the rotary steerable system disclosed herein such as rotary steerable system 10 , includes nine modules, with each module comprising a unit that may be maintained, assembled, disassembled, or exchanged independently of the other modules.
- the modules of the rotary steerable system disclosed herein are listed in Table 2 below.
- upper and lower are to be interpreted broadly to include “proximal” and “distal” such that the structures may not be positioned in a vertical arrangement. Additionally, the elements described as “upper” and “lower” may be reversed such that the structures may be configured in the opposite vertical arrangement.
- each of the components in this device has a generally cylindrical shape and may be formed of steel, another metal, or any other durable material. Portions of the rotary steerable system may be formed of a wear resistant material, such as tungsten carbide or ceramic coated steel.
- Each device described in this disclosure may include any combination of the described components, features, and/or functions of each of the individual device embodiments.
- Each method described in this disclosure may include any combination of the described steps in any order, including the absence of certain described steps and combinations of steps used in separate embodiments. Any range of numeric values disclosed herein includes any subrange therein. “Plurality” means two or more. “Above” and “below” shall each be construed to mean upstream and downstream, such that the directional orientation of the device is not limited to a vertical arrangement.
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Mechanical Engineering (AREA)
- Power Steering Mechanism (AREA)
- Multiple-Way Valves (AREA)
Abstract
Description
- This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63/207,487, filed on Mar. 2, 2021, which is incorporated herein by reference.
- In the process of drilling and producing oil and gas wells, rotary steerable systems are used to control and adjust the direction in which a well is drilled. Conventional rotary steerable systems are well over 150 inches in length and include three or more sets of extending pistons. These large systems require frequent maintenance. The conventional rotary steerable systems' long length presents challenges in the maintenance, including transporting the system from a drilling location to a shop.
-
FIG. 1 is a side view of a rotary steerable system of the present invention. -
FIG. 2 is a sectional view of the rotary steerable system. -
FIG. 3 is a sectional view of a control sleeve and a steering section of the rotary steerable system. -
FIG. 4 is a partially exploded view of a control insert configured to fit within the control sleeve. -
FIG. 5 is a partial sectional view of an upper control unit of the control insert within the control sleeve. -
FIG. 6 is an exploded view of a lower control unit of the control insert. -
FIG. 7 is a sectional view of the lower control unit of the control insert. -
FIG. 8 is a sectional view of the steering section. -
FIG. 9 is a sectional view of the steering section taken along a perpendicular plane as compared toFIG. 8 . -
FIG. 10 is a sectional view of a lower portion of the control section and the steering section. -
FIG. 11 is a top view of a valve stator of the rotary steerable system. -
FIG. 12 is a sectional view of the valve stator of the rotary steerable system taken along line 12-12 inFIG. 11 . -
FIG. 13 is bottom view of the valve stator of the rotary steerable system. -
FIG. 14 is a top view of an alternate embodiment of the valve stator of the rotary steerable system. -
FIG. 15 is a sectional view of the alternate embodiment of the valve stator of the rotary steerable system taken along line 15-15 inFIG. 14 . -
FIG. 16 is bottom view of the alternate embodiment of the valve stator of the rotary steerable system. -
FIG. 17 is a top view of a valve rotor of the rotary steerable system. -
FIG. 18 is a sectional view of the valve rotor of the rotary steerable system taken along line 18-18 inFIG. 17 . -
FIG. 19 is bottom view of the valve rotor of the rotary steerable system. -
FIG. 20 is a top view of the valve assembly including the valve rotor and the valve stator, with the valve rotor in a first position. -
FIG. 21 is a sectional view of the valve assembly with the valve rotor in the first position taken along line 21-21 inFIG. 20 . -
FIG. 22 is a top view of the valve assembly with the valve rotor in a second position. -
FIG. 23 is a schematic view of the valve assembly with the valve rotor in a sequence of positions as it rotates relative to the valve stator. -
FIG. 24 is a side view of the steering section in a default position. -
FIG. 25 is a sectional view of the steering section in the default position, taken along line 25-25 inFIG. 24 . -
FIG. 26 is a side view of the steering section in a first extended position. -
FIG. 27 is a sectional view of the steering section in the first extended position, taken along line 27-27 inFIG. 26 . -
FIG. 28 is a side view of the steering section in a neutral position. -
FIG. 29 is a sectional view of the steering section in the neutral position, taken along line 29-29 inFIG. 28 . -
FIG. 30 is a side view of the steering section in a second extended position. -
FIG. 31 is a sectional view of the steering section in the second extended position, taken along line 31-31 inFIG. 30 . -
FIG. 32 is a side view of an alternate embodiment of the steering section. -
FIG. 33 is a sectional view of the alternate embodiment of the steering section. -
FIG. 34 is a sectional view of the alternate embodiment of the steering section taken along line 34-34 inFIG. 32 . -
FIG. 35 is a sectional view of the alternate embodiment of the steering section taken along line 35-35 inFIG. 32 . -
FIG. 36 is a side view of the rotary steerable system connected between a flex shaft and a drill bit. -
FIG. 37 is another side view of the rotary steerable system connected between the flex shaft and the drill bit. - Disclosed herein is a rotary steerable system including a steering section. The steering section includes at least one piston. In some embodiments, the steering section includes only two pistons in each transverse cross-sectional plane. A center point of a first piston is separated from a center point of a second piston by an angle greater than 120 degrees.
- The rotary steerable system also includes a valve assembly configured to direct a portion of a drilling fluid flowing through the rotary steerable system into a distribution flow passage, thereby activating one of the pistons and causing the piston to extend in a radially outward direction. A ratio of the diameter of each distribution flow passage to the steering section diameter is at least 0.07. The distribution flow passages are contained within a central area of the steering section. A ratio of the diameter of the central area to the steering section diameter is 0.5 or less. An activation duration of each set of pistons is about 180 degrees of rotation of a valve rotor. A ratio of the stroke length of each piston to the diameter of the steering section is greater than 0.06. As used herein, “diameter of the steering section” and “steering section diameter” both mean the minimum outer diameter of any portion of the assembled steering section (i.e., the outer diameter of the smallest portion of the assembled steering section). For example, in some embodiments, the steering section diameter may be the outer diameter of
steering housing 22. - In some embodiments, the rotary steerable system also includes a control section. A combined length of the control section and the steering section is below 150 inches, preferably below 80 inches.
-
FIGS. 1-37 illustrate embodiments of the rotary steerable system disclosed herein, with many other embodiments within the scope of the claims being readily apparent to skilled artisans after reviewing this disclosure. - With reference to
FIGS. 1-3 , rotarysteerable system 10 includescontrol section 12 andsteering section 14, each having a generally cylindrical shape.Control section 12 includes electronic components, sensors, and actuators for determining a drilling direction or tool face required and for orienting the steering section. -
Control section 12 includescontrol sleeve 16 andcontrol insert 18 disposed withininner bore 20 ofcontrol sleeve 16.Control insert 18 is configured for rotation relative tocontrol sleeve 12. In one embodiment, control insert 18 is configured to remain stationary with respect to a surrounding subterranean formation, such thatcontrol sleeve 16 rotates aroundcontrol insert 18. In other words, controlinsert 18 may be configured to remain geo-stationary. A lower end ofcontrol sleeve 16 is secured to an upper end of steeringhousing 22 ofsteering section 14. In this way,control sleeve 16 is rotationally secured to steeringhousing 22. As used herein, “rotationally secured” means secured together such that two components rotate together (i.e., there is no relative rotation between two components under normal operating conditions). - A lower end of
control insert 18 includes avalve rotor 24, which cooperates withvalve stator 26 secured to steeringhousing 22.Valve rotor 24 rotates relative tovalve stator 26 as control insert 18 rotates relative to controlsleeve 16 and steeringhousing 22. - Referring now to
FIGS. 2 and 4-6 , control insert 18 may includeupper control unit 28,electronics unit 30, andlower control unit 32.Control insert 18 may also includeguide 34 secured toupper control unit 28 and guide 36 secured tolower control unit 32.Guide sleeve 16, while upper andlower control units guides Control insert 18 may further includeupper impeller 38 rotationally secured toupper control unit 28 andlower impeller 40 rotationally secured tolower control unit 32. Upper andlower impellers impellers inner bore 20 ofcontrol sleeve 16.Guides impellers inner bore 20 ofcontrol sleeve 16 while control insert 18 therein. - Referring again to
FIG. 2 ,upper control unit 28 may include amagnetic brake 41, which functions as an actuator to apply rotational torque in a direction that is opposite to a rotational direction ofcontrol sleeve 16 and steeringhousing 22. In this way, the magnetic brake assembly adjusts the rotation rate of control insert 18 relative to controlsleeve 16. As a drilling fluid flows throughinner bore 20 ofcontrol sleeve 16, the drilling fluid flows through spaces inimpeller 38, thereby applying a rotational force onimpeller 38 andupper control unit 28. In one embodiment,upper control unit 28 also includes a power generation mechanism. The magnetic brake assembly may be the only actuator in rotarysteerable system 10. - With reference to
FIGS. 4 and 5 ,upper control unit 28 may also includeupper filter 44. In one embodiment,upper filter 44 may be formed of rings with shoulders such that the stacking of the rings creates small interstices that function to filter. As drilling fluid flow throughinner bore 20 ofcontrol sleeve 16, a small amount of drilling fluid may flow throughupper filter 44 and throughintermediate spaces d surrounding antenna 42 andmagnetic brake 41.Upper filter 44 removes larger particles from the drilling fluid to allow a small amount of clean fluid to flow in the intermediate spaces 43 a-43 d. Allowing only clean fluid to flow in intermediate spaces 43 a-43 d prevents the two parts ofupper control unit 28 from seizing up and/or from creating additional drag between the two parts ofupper control unit 28. The majority of the drilling fluid flows around the exterior surface offilter 44 and through the spaces inimpeller 38. -
Electronics unit 30 may include sensors. For example,electronics unit 30 may include a magnetometer for sensing a north-south direction, an accelerometer for sensing inclination, and a gyrometer for sensing rotation of the control unit relative to a surrounding subterranean formation.Control insert 18 may be configured to adjust the magnetic brake assembly in theupper control unit 28 based on measurements taken by the sensors inelectronics unit 30. In some embodiments, the rotarysteerable system 10 includes no batteries and only a small amount of memory (e.g., flash memory only). In these embodiments, theelectronics unit 30 may includeantenna 42 for transmitting measurement data and other data to a measurement-while-drilling (“MWD”) unit secured above the rotarysteerable system 10, and the MWD unit may store the received data in a memory.Antenna 42 of theelectronics unit 30 may be formed of an electromagnetic antenna. - With reference to
FIGS. 6 and 7 ,lower control unit 32 may includehousing 45 withflow passages 46.Flow passages 46 are configured to allow a drilling fluid in an annular space betweencontrol sleeve 16 andhousing 45 to flow intoinner space 48 withinhousing 45.Lower control unit 32 may also includelower filter 49 configured to surround and coverflow passages 46 in order to filter drilling fluid as it flows throughflow passages 46 and entersinner space 48. In one embodiment,lower filter 49 may be formed of rings with shoulders such that the stacking of the rings creates small interstices that function to filter.Lower control unit 32 may further includespring 50 disposed withininner space 48 and configured to biasvalve rotor 24 in a direction toward thevalve stator 26 andsteering section 14. For example, an upper end ofspring 50 may engagetransverse surface 52 ofhousing 45, while lower end ofspring 50 engages an upper end ofspacer 54 to apply a downward force on thevalve rotor 24, which is secured to a lower end ofspacer 54. As a drilling fluid flows through the annular space betweencontrol sleeve 16 andhousing 45, a portion of the drilling fluid may flow throughflow passages 46, intoinner space 48, and through arotor port 56 ofvalve rotor 24. The remainder of the drilling fluid flowing through the annular space may flow through spaces inimpeller 40 outside ofhousing 45. - With reference now to
FIGS. 8 and 9 ,steering section 14 includes parallel main flow passages and distribution flow passages. Steeringhousing 22 includes twomain flow passages 66 extending from upper inner bore 68 to lowerinner bore 70. Steeringhousing 22 also includes twodistribution flow passages 72, each extending from astator port 73 ofvalve stator 26 to one ormore feed channels 74.Steering section 14 also includes twopiston assemblies 76, each at least partially secured within areceptacle 78 in an outer surface of steeringhousing 22. Eachpiston assembly 76 includes one ormore pistons 80 each disposed within apiston sleeve 85, all disposed withinpiston clamp 81, which is configured to be secured withinpiston receptacle 82 in steeringhousing 22.Pistons 80 are configured to slide in a radial direction withinpiston receptacles 82. Eachfeed channel 74 extends from adistribution flow passage 72 to apiston receptacle 82.Steering section 14 of rotarysteerable system 10 may include not more than two pistons in each transverse cross-sectional plane, with the center points of the pistons separated by an angle greater than 120 degrees.Steering section 14 may include not more than two sets of pistons. -
Steering section 14 may further includespacers 84, each at least partially disposed withinspacer receptacles 86 in an outer surface of steeringhousing 22. In one embodiment, spacers 84 are secured to steeringhousing 22 using bolts or screws. As used herein, “piston” means any structure configured to extend, when activated, in a radial direction from a tool to which it is secured or in which it is incorporated. For example, “piston” includes a pad, a wedge arrangement, and a cam arrangement. - Referring to
FIG. 10 , as a drilling fluid flows through the annular space betweencontrol sleeve 16 andcontrol insert 18, a portion of the drilling fluid may flow throughflow passages 46 and intoinner space 48 ofhousing 45. The drilling fluid withininner space 48 may flow throughrotor port 56 ofvalve rotor 24 and through astator port 73 ofvalve stator 26 that is aligned withrotor port 56. Asvalve rotor 24 rotates relative tovalve stator 26,rotor port 56 aligns with each of thestator ports 73 in sequence over time. Accordingly, the drilling fluid flowing throughrotor port 56 will flow through each of thestator ports 73 in sequence over time. Drilling fluid that flows through one of thestator ports 73 flows through the connectingdistribution flow passage 72, through each of the connectedfeed channels 74, and into connectedpiston receptacles 82 in order to apply a force and displacepiston 80 in a radial outward direction. In some embodiments, and in order to provide an exhaust path for when the piston retracts from an open position, the drilling fluid can flow throughleak channels 90 betweenpistons 80 andpiston receptacles 82, or in another embodiment, it may leak between the piston and the guide sleeve, through diametral space between the two or through a channel formed in the sleeve or in the piston that connectpiston receptacles 82 to the wellbore. In another embodiment, the leak channels may be located through the piston body to connectpiston receptacles 82 to the wellbore. In another embodiment, the leak channel may be located between the guide sleeve and the steering body. -
FIGS. 11-13 illustrate one embodiment ofvalve stator 26, which includes twostator ports 73 positioned on opposite sides ofvalve stator 26. In other words, the central point of the outer boundary of onestator port 73 is 180 degrees from the central point of the outer boundary of thesecond stator port 73. In this embodiment, the shape of eachstator port 73 varies across the thickness ofvalve stator 26. For example, eachstator port 73 may be defined by a wedge-shapedopening 92 onfirst side 94 ofvalve stator 26 and defined by acircular opening 96 onsecond side 98 ofvalve stator 26.First side 94 is configured to engagevalve rotor 24, andsecond side 96 is configured to engagedistribution flow passages 72. The sides of the wedge-shapedopening 92 may be formed of straight lines, which align with side boundaries ofrotor port 56 to provide sharper actuations of pistons. While thecircular openings 96 are configured to align with thedistribution flow passages 72. The transition of the shape ofstator ports 73 across the thickness ofvalve stator 26 reduces the length of transition flow lines needed between the valve assembly and thepistons 80. In other embodiments, eachstator port 73 may be defined by wedge-shapedopening 92 onfirst side 94 ofvalve stator 26 and defined by a polygon-shaped opening onsecond side 98 ofvalve stator 26. In still other embodiments,stator ports 73 may have the same shape across the thickness ofvalve stator 26. -
FIGS. 14-16 illustrate an alternate embodiment ofvalve stator 26 a. In this embodiment, eachstator port 73 a is defined by a wedge-shapedopening 92 a onfirst side 94 a ofvalve stator 26 a. Eachstator port 73 a is defined by a polygon-shapedopening 99 onsecond side 98 a ofvalve stator 26 a. -
FIGS. 17-19 illustrate one embodiment ofvalve rotor 24, which includes only onerotor port 56. In this embodiment, the shape ofrotor port 56 varies across the thickness ofvalve rotor 24. For example,rotor port 56 may be defined byinner boundary 102,outer boundary 106, andside boundaries first side 104 ofvalve rotor 24.Side boundaries outer boundaries first side 104. A center point offirst side 104 is positioned betweeninner boundary 102 andouter boundary 106. In other words,rotor port 56 includes the center point offirst side 104.Inner boundary 102 ofrotor port 56 remains constant throughout the thickness ofvalve rotor 24. Onsecond side 112 ofvalve rotor 24,rotor port 56 may be defined byouter boundary 106,inner boundary 114, andside boundaries Side boundaries outer boundaries second side 112.Inner boundary 114 is positioned betweenouter boundary 106 and a center point ofsecond side 112. In other words, the center point ofsecond side 112 is not included withinrotor port 56.Valve rotor 24 may include slopedsurface 120 in the transitions betweeninner boundaries side boundaries side boundaries -
Side boundaries first side 104 ofrotor port 56 may have the same shape as the side boundaries of wedge-shapedopenings 92 ofstator ports 73. For example, each of theside boundaries openings 92 may be formed of a straight line extending in a radial direction. - Referring now to
FIGS. 20-22 ,valve assembly 124 may includevalve rotor 24 andvalve stator 26, withvalve rotor 24 rotating relative tovalve stator 26. In this embodiment,outer boundary 106 ofrotor port 56 aligns with the outer boundary of wedge-shapedopenings 92 ofstator ports 73, andinner boundary 114 ofrotor port 56 aligns with the inner boundary of wedge-shapedopenings 92 ofstator ports 73. In a first position shown inFIGS. 20 and 21 ,rotor port 56 is aligned with all of the wedge-shapedopening 92 of asingle stator port 73. In this first position, afirst stator port 73 a is “open” and asecond stator port 73 b (not shown in this view) is “closed.” Asvalve rotor 24 rotates, theside boundaries rotor port 56 cross over the side boundaries of wedge-shapedopenings 92 ofstator ports 73, thereby alternately opening and closingstator ports side boundary 116 fromside boundary 118 and the angular separation of the two side boundaries of each wedge-shapedopening 92 together define the duration for which eachstator port 73 is open (i.e., activation duration of each stator port 73). These angular separations also define whether bothstator ports 73 are partially open at a single point in time, and if so, the duration for which bothstator ports 73 are simultaneously partially open. In certain embodiments, the opening angle of the rotor port 56 (i.e., the angular distance betweenside boundaries openings 92 are separated by at least 110 degrees or between 110 degrees and 170 degrees, or any subrange therein. In certain embodiments, the side boundaries of the two wedge-shapedopenings 92 are separated by at least 125 degrees. In further embodiments, the side boundaries of the two wedge-shapedopenings 92 are separated by an angle between 140 degrees and 170 degrees. In a second position shown inFIG. 22 ,rotor port 56 is aligned with a portion ofstator port 73 a and a portion ofstator port 73 b. -
FIG. 23 illustratesvalve assembly 124 withvalve rotor 24 in various sequential positions relative tovalve stator 26 over time. In this embodiment,valve rotor 24 rotates in a counter-clockwise direction. In other embodiments,valve rotor 24 rotates in a clockwise direction. In still other embodiments,valve rotor 24 is maintained in a geostationary position whilevalve stator 26 rotates withsteering unit 14 andcontrol sleeve 16 in a clockwise direction.FIG. 23(a) illustrates the first position shown inFIGS. 20 and 21 , in whichrotor port 56 is aligned withfirst stator port 73 a such thatfirst stator port 73 a is fully open andsecond stator port 73 b is closed.First stator port 73 a remains fully open through the time whenside boundary 116 ofrotor port 56 aligns with a side boundary of the wedge-shaped opening offirst stator port 73 a, as shown inFIG. 23(b) . - As shown in
FIG. 23(c) , further rotation ofvalve rotor 24 causesside boundary 116 ofrotor port 56 to move acrossfirst stator port 73 a thereby reducing the open cross-sectional area offirst stator port 73 a and reducing the fluid flow rate throughfirst stator port 73 a. Thefirst stator port 73 a is partially open and thesecond stator port 73 b is closed through the time whenside boundary 118 ofrotor port 56 aligns with a first side boundary of the wedge-shaped opening ofsecond stator port 73 b, as shown inFIG. 23(c) . Further rotation ofvalve rotor 24 causesside boundary 118 ofrotor port 56 to move past the first side boundary ofsecond stator port 73 b, thereby placing both first andsecond stator ports FIG. 23(d) . In this embodiment, the valve assembly is configured to have first andsecond stator ports FIG. 23(d) . The valve assembly remains in this simultaneous partially open position untilside boundary 116 aligns with a second side boundary offirst stator port 73 a to placefirst stator port 73 a in the closed position, as shown inFIG. 23(e) . Asvalve rotor 24 rotates further andside boundary 118 ofrotor port 56 moves across thesecond stator port 73 b,second stator port 73 b is further opened and the fluid flow rate through thesecond stator port 73 b increases. During this time,first stator port 73 a is closed andsecond stator port 73 b is partially open. - As shown in
FIG. 23(f) ,second stator port 73 b is placed in a fully open position whenside boundary 118 ofrotor port 56 aligns with a second side boundary ofsecond stator port 73 b.Second stator port 73 b remains in the fully open position through the time whenside boundary 116 ofrotor port 56 aligns with the first side boundary ofsecond stator port 73 b as shown inFIG. 23(g) . - As shown in
FIG. 23(h) , further rotation ofvalve rotor 24 causesside boundary 116 ofrotor port 56 to move acrosssecond stator port 73 b, thereby reducing the open cross-sectional area ofsecond stator port 73 b and reducing the fluid flow rate therethrough. Thefirst stator port 73 a is closed and thesecond stator port 73 b is partially open through the time whenside boundary 118 ofrotor port 56 aligns with the first side boundary offirst stator port 73 a, as shown inFIG. 23(h) . Further rotation ofvalve rotor 24 causesside boundary 118 ofrotor port 56 to move past the first side boundary offirst stator port 73 a to place bothstator ports FIG. 23(i) . The valve assembly remains in this simultaneous partially open position untilside boundary 116 ofrotor port 56 aligns with the second side boundary ofsecond stator port 73 b to placesecond stator port 73 b in the closed position, as shown inFIG. 23(j) . Asvalve rotor 24 continues to rotate andside boundary 118 ofrotor port 50 moves across thefirst stator port 73 a,first stator port 73 a is further opened and the fluid flow rate through thefirst stator port 73 a increases. During this time,first stator port 73 a is partially open andsecond stator port 73 b is closed. As shown inFIG. 23(k) ,first stator port 73 a is placed in the fully open position whenside boundary 118 ofrotor port 56 aligns with the second side boundary offirst stator port 73 a.FIG. 23(l) again illustrates the valve assembly in the first position, in whichfirst stator port 73 a is fully open andsecond stator port 73 b is closed. Table 1 lists the positions of the stator ports in each view ofFIG. 23 . -
TABLE 1 Position of Position of FIG. First stator port 73aSecond stator port 73bFIG. 23(a) Fully open Closed FIG. 23(b) Fully open Closed FIG. 23(c) Partially open Closed FIG. 23(d) Partially open Partially open FIG. 23(e) Closed Partially open FIG. 23(f) Closed Fully open FIG. 23(g) Closed Fully open FIG. 23(h) Closed Partially open FIG. 23(i) Partially open Partially open FIG. 23(j) Partially open Closed FIG. 23(k) Fully open Closed FIG. 23(l) Fully open Closed - The theoretical activation duration of each
stator port valve rotor 24 for whichsuch stator port FIG. 23 provides a theoretical activation duration of about 180 degrees.Second stator port 73 b is partially or fully open from the time thatside boundary 118 ofrotor port 56 crosses the first side boundary ofsecond stator port 73 b (immediately after the position illustrated inFIG. 23(c) ) until the time thatside boundary 116 crosses the second side boundary ofsecond stator port 73 b (immediately beforeFIG. 23(j) ). -
FIGS. 24 and 25 illustratesteering section 14 in a default position in whichpistons 80 are in retracted positions. This embodiment of rotarysteerable system 10 includes twopistons 80, with the center points of the twopistons 80 separated by about 180 degrees. Becausesteering section 14 includes only twopistons 80 in each transverse cross-sectional plane,distribution flow passages housing 22. In some embodiments,main flow passages 66 may extend from the central area outward radially.Distribution flow passages main flow passages 66 may be positioned betweenpiston receptacles 82. Optionally,main flow passages 66 may also extend beyond the space betweenpiston receptacles 82. The position of thedistribution flow passages pistons 80 eliminates the need for a spider to rearrange flow lines through a length of the steering unit (i.e., distribution flow passages remain in the central area from thevalve assembly 124 to thefeed channels 74 and pistons 80). - In certain embodiments, the central area may be defined by a circular path that includes the center of the inner boundary of each
piston receptacle 82 and is centered on the center of thesteering unit 14. In other embodiments, the central area may be defined by a central diameter surrounding the center of thesteering unit 14. The central diameter may be in the range of 1.5 inches to 3.0 inches, preferably about 1.75 inches to about 2.5 inches, or any subrange therein. In certain embodiments, the central diameter may be about 1.75 inches in a steering unit having a diameter less than or equal to 5.25 inches, about 2 inches in a steering unit having a diameter less than or equal to 6.75 inches, and about 2.5 inches in a steering unit having a diameter less than or equal to 9 inches. A ratio of the central diameter to the steering section diameter may be 0.5 or less, 0.4 or less, preferably 0.33 or less, more preferably 0.3 or less. - In the embodiment illustrated in
FIG. 25 ,steering section 14 includes axis x and axis y intersecting at the central point ofsteering section 14 as shown. The central area in which distribution flowpassages 72 are positioned is defined bydistribution distance 90 between the central point and a line D extending from an outer most point on one of thedistribution flow passages 72. Line M is defined by the inner boundary of one of themain flow passages 66. Line M is spaced apart from the central point bymain distance 92. Line P is defined by the inner boundary of one of thepiston receptacles 82. Line P is spaced apart from the central point bypiston distance 94. In this embodiment,distribution distance 90 is greater thanmain distance 92, andpiston distance 94 is greater thandistribution distance 90. In other words, at least a portion of eachmain flow passage 66 is closer to the central point of the steering section than the outer boundary of thedistribution flow passages 72. Additionally, at least a portion of eachmain flow passage 66 is closer to the central point of the steering section than the inner boundary of thepiston receptacle 82 and the position of the piston in its retracted position. - The rotary steerable system disclosed herein includes
distribution flow passages main flow passages 66 having larger diameters than in conventional rotary steerable systems. The larger diameters of these flow lines reduce the fluid flow speed, prevent a water hammer effect, reduce erosion, and reduce pressure drop in order to preserve energy. A ratio of a diameter of eachdistribution flow passage steering section 14 may be at least 0.07. In certain embodiments, a diameter of eachdistribution flow passage steering section 14 having a diameter of at least 5.25 inches, about 0.5 inches in asteering section 14 having a diameter of at least 6.75 inches, and about 0.67 inches in asteering section 14 having a diameter of at least 9 inches. - With reference to
FIGS. 10, 13, and 20-23 , valve assembly 124 (shown inFIGS. 20-23 ) may be positioned at the upper end of the distribution flow passages (shown inFIG. 10 ) such thatcircular openings 96 on thesecond side 98 of stator ports 73 (shown inFIG. 13 ) align withdistribution flow passages 72. Specifically,circular opening 96 ofstator port 73 a aligns withdistribution flow passage 72 a, andcircular opening 96 ofstator port 73 b aligns withdistribution flow passage 72 b. Asvalve rotor 24 rotates relative to valve stator 26 (as shown inFIG. 23 ),stator ports inner space 48 withinhousing 45 oflower control unit 32 into firstdistribution flow passage 72 a, seconddistribution flow passage 72 b, or a combination thereof. -
FIGS. 26 and 27 illustrate steeringassembly 14 in a first extended position whenfirst stator port 73 a is fully open (as shown inFIGS. 23(a) and 23(b) ). In this position,valve assembly 124 directs the fluid withininner space 48 oflower control unit 32 into firstdistribution flow passage 72 a. Specifically, the drilling fluid that has enteredinner space 48 oflower control unit 32 flows throughrotor port 56 ofvalve rotor 24, throughfirst stator port 73 a, through firstdistribution flow passage 72 a, throughfeed channels 74, and intofirst piston receptacles 82 a. The fluid flowing intofirst piston receptacles 82 a applies a radial outward force onfirst pistons 80 a, thereby causingfirst pistons 80 a to move in a radially outward direction. In this first extended position,first pistons 80 a may engage a wall of a wellbore being drilled through a subterranean formation in order to adjust the direction in which the wellbore is drilled further. The drilling fluid that flows through the spaces inimpeller 40 flows throughmain flow passages 66, thereby bypassing thepiston assemblies 76. - Referring again to
FIG. 27 , eachpiston - Additionally, each
piston -
FIGS. 28 and 29 illustrate steeringassembly 14 in a neutral position when first andsecond stator ports FIGS. 23(d) and 23(i) ). In this position,valve assembly 124 directs the fluid withininner space 48 oflower control unit 32 into both first and seconddistribution flow passages first stator ports 73 a and ultimately intopiston receptacles 82 a decreases, a force exerted by a wall of a wellbore onpistons 80 a may overcome the outward force of the fluid flow intopiston receptacles 82 a, which may forcepistons 80 a to retract in a radially inward direction intopiston receptacles 82 a. The excess fluid inreceptacle 82 a is expelled through the exhaust port. Simultaneously, the drilling fluid flowing throughsecond stator port 73 b flows through seconddistribution flow passage 72 b, throughfeed channels 74, and intopiston receptacles 82 b. The fluid flowing intopiston receptacles 82 b begins to apply a radial outward force onsecond pistons 80 b, thereby causingsecond pistons 80 b to begin moving in a radially outward direction. -
FIGS. 30 and 31 illustrate steeringassembly 14 in a second extended position whensecond stator port 73 b is fully open (as shown inFIGS. 23(f) and 23(g) ). In this position,valve assembly 124 directs all fluid withininner space 48 oflower control unit 32 into seconddistribution flow passage 72 b. As the fluid flow throughsecond stator ports 73 b and ultimately intopiston receptacles 82 b increases, the fluid flow applies a greater radial outward force onsecond pistons 80 b, thereby causingsecond pistons 80 b to fully extend in the radially outward direction. In this second extended position,second pistons 80 b may engage the wall of the wellbore in order to adjust the drilling in an opposite direction. In all positions of thesteering assembly 14, the drilling fluid that flows through the spaces inimpeller 40 flows throughmain flow passages 66, thereby bypassing thepiston assemblies 76. - The theoretical activation duration of each
piston valve rotor 24 for which eachpiston stator port steerable system 10 may be configured to provide a theoretical activation duration of eachpiston piston valve rotor 24 during which a specified component is activated by or receives by fluid flow. The two-piston configuration of the rotary steerable system disclosed herein may provide a greater activation duration of each piston as compared to conventional rotary steerable systems including three-piston configurations due to fewer transitions in each rotation of the valve and due to larger angular separation of the side boundaries of each stator port. -
Steering section 14 may include any number of pistons within the piston assemblies. In this embodiment illustrated inFIGS. 32-35 ,steering section 14 includes afirst piston assembly 76 a including twopistons 80 a and asecond piston assembly 76 b including threepistons 80 b. In the illustratedembodiment pistons 80 a may be staggered along the axial length of steeringhousing 22 relative topistons 80 b, as shown inFIG. 33 . In other words, thesteering section 14 includes only one piston in a transverse cross-sectional plane, such as plane A—A. In other embodiments, the offset pistons are separated by a length that is equal to the steering section diameter. Alternatively, thesteering section 14 may include only a one piston. - Referring now to
FIGS. 36 and 37 , rotarysteerable system 10 may be secured belowflex shaft 152 anddrill bit 154 in a bottom hole assembly. - The rotary steerable system of the present invention, which includes a steering section and a control section, is significantly shorter than conventional rotary steerable systems. The combined length of the steering section and the control section is less than 150 inches, less than 125 inches, less than 100 inches, less than 80 inches, less than 75 inches, less than 70 inches, less than 65 inches, or any subrange therein. In one embodiment, the rotary steerable system has a minimum diameter of about 5.25 inches, and a combined length of about 63 inches. In another embodiment, the rotary steerable system has a minimum diameter of about 6.75 inches, and a combined length of about 67 inches. In still another embodiment, the rotary steerable system has a minimum diameter of about 9 inches, and a combined length of about 74 inches.
- Alternatively, the rotary steerable system has a length to steering section diameter ratio of less than 16, less than 14, less than 11, less than 10, less than 9, or any subrange therein. As used herein, “length to steering section diameter ratio” means a ratio of the combined length of the steering section and control section to the minimum outer diameter of the steering section or the control section (in inches). For example, but not by way of limitation, the rotary steerable system may have a diameter less than or equal to 5.25 inches, and a length to steering section diameter ratio of less than 13, less than 12, or any subrange therein. Alternatively, the rotary steerable system may have a diameter less than or equal to 6.75 inches, and a length to steering section diameter ratio of less than 11, less than 10, or any subrange therein. In other embodiments, the rotary steerable system may have a diameter less than or equal to 9 inches, and a length to steering section diameter ratio of less than 9.
- With reference again to
FIGS. 36 and 37 ,flex shaft 152 may be secured above rotarysteerable system 10, anddrill bit 154 may be secured below rotarysteerable system 10. The reduced length of the rotarysteerable system 10positions flex shaft 152 closer to drillbit 154 than in conventional rotary steerable systems, thereby enabling the rotary steerable system to turn the drill bit path by a smaller radius. For example, the rotary steerable system disclosed herein may enable a maximum turn rate of 14 degrees per 100 feet. In another embodiment, the rotary steerable system disclosed herein may enable a maximum turn rate of 18 degrees per 100 feet. In yet another embodiment, the rotary steerable system disclosed herein may enable a maximum turn rate of 24 degrees per 100 feet. In effect, the reduced lengthrotary steerable system 10 behaves as a hybrid push-the-bit/point-the-bit system ascontrol unit 12 andsteering unit 14 are deflected (i.e., pushed) as one and become pointed in the desired direction. The maximum turn rate values may be affected by environmental conditions, including conditions within a wellbore or conditions of a subterranean formation. - The reduced length of the rotary steerable system of the present invention is achieved due to several features. For example,
lower filter 49 and valve assembly includingvalve rotor 24 andvalve stator 26 are incorporated into a single module, as shown inFIG. 10 . In contrast, conventional rotary steerable systems include separate modules for filters and valves. Additionally, the absence of a battery reduces the length ofcontrol section 12. Another example is the use of smaller memory components, such as micro-electromechanical systems (“MEMS”), in thecontrol section 12. Conventional rotary steerable systems teach away from smaller memory components in favor of larger memory components capable of storing data required for well surveys. Further, the rotary steerable system disclosed herein includes only three sensors incontrol section 12, thereby reducing the length of thecontrol section 12. Conventional rotary steerable systems include a greater number of sensors, which require a greater length of the control section. Another example is the transition of the shape ofstator ports 73 across the thickness ofvalve stator 26, which reduces the length of transition flow lines needed in steeringhousing 22 between the valve assembly and thepistons 80. Furthermore, the central position ofdistribution flow receptacles 72 withinsteering section 14 eliminates the requirement for a spider, which transposes the main flow and distribution flow lines between the valve and pistons in conventional rotary steerable systems. - The reduced length of the rotary steerable system disclosed herein provides the commercial advantage of requiring less material for construction, thereby reducing costs of manufacturing and maintenance. In some embodiments, the components of the rotary steerable system disclosed herein are more accessible from outside of the rotary steerable system, which enables users to perform certain additional maintenance tasks in any location without the need for transporting the rotary steerable system to a shop.
- In other embodiments, the rotary steerable system of the present invention includes only a steering section without a control section. In this embodiment, the elements of the control section may be incorporated into the steering section, positioned in adjacent devices in the drill string, eliminated, or any combination thereof.
- As illustrated in
FIGS. 2-9 , the rotary steerable system disclosed herein, such as rotarysteerable system 10, includes nine modules, with each module comprising a unit that may be maintained, assembled, disassembled, or exchanged independently of the other modules. The modules of the rotary steerable system disclosed herein are listed in Table 2 below. -
TABLE 2 Modules of steering Steering housing 22section 14Pistons 80Piston clamps 81 Spacers 84Screw sets for spacers 84Modules of control Control sleeve 16 section 12Guides bolts Electronics 30, lower control unit 32,and inner portions of upper control unit 28Housing of upper control unit 28 - As used herein, “upper” and “lower” are to be interpreted broadly to include “proximal” and “distal” such that the structures may not be positioned in a vertical arrangement. Additionally, the elements described as “upper” and “lower” may be reversed such that the structures may be configured in the opposite vertical arrangement.
- Except as otherwise described or illustrated, each of the components in this device has a generally cylindrical shape and may be formed of steel, another metal, or any other durable material. Portions of the rotary steerable system may be formed of a wear resistant material, such as tungsten carbide or ceramic coated steel.
- Each device described in this disclosure may include any combination of the described components, features, and/or functions of each of the individual device embodiments. Each method described in this disclosure may include any combination of the described steps in any order, including the absence of certain described steps and combinations of steps used in separate embodiments. Any range of numeric values disclosed herein includes any subrange therein. “Plurality” means two or more. “Above” and “below” shall each be construed to mean upstream and downstream, such that the directional orientation of the device is not limited to a vertical arrangement.
- While preferred embodiments have been described, it is to be understood that the embodiments are illustrative only and that the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalents, many variations and modifications naturally occurring to those skilled in the art from a review hereof.
Claims (20)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US17/682,383 US20220282573A1 (en) | 2021-03-02 | 2022-02-28 | Rotary steerable system with optimized piston extension |
PCT/US2022/018463 WO2022187321A1 (en) | 2021-03-02 | 2022-03-02 | Rotary steerable system with optimized piston extension |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202163207487P | 2021-03-02 | 2021-03-02 | |
US17/682,383 US20220282573A1 (en) | 2021-03-02 | 2022-02-28 | Rotary steerable system with optimized piston extension |
Publications (1)
Publication Number | Publication Date |
---|---|
US20220282573A1 true US20220282573A1 (en) | 2022-09-08 |
Family
ID=83116963
Family Applications (4)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/682,383 Abandoned US20220282573A1 (en) | 2021-03-02 | 2022-02-28 | Rotary steerable system with optimized piston extension |
US17/682,127 Active US11952894B2 (en) | 2021-03-02 | 2022-02-28 | Dual piston rotary steerable system |
US17/682,503 Active US11970942B2 (en) | 2021-03-02 | 2022-02-28 | Rotary steerable system with central distribution passages |
US17/682,041 Abandoned US20220282571A1 (en) | 2021-03-02 | 2022-02-28 | Compact rotary steerable system |
Family Applications After (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/682,127 Active US11952894B2 (en) | 2021-03-02 | 2022-02-28 | Dual piston rotary steerable system |
US17/682,503 Active US11970942B2 (en) | 2021-03-02 | 2022-02-28 | Rotary steerable system with central distribution passages |
US17/682,041 Abandoned US20220282571A1 (en) | 2021-03-02 | 2022-02-28 | Compact rotary steerable system |
Country Status (5)
Country | Link |
---|---|
US (4) | US20220282573A1 (en) |
CN (2) | CN116964294A (en) |
CA (2) | CA3211825A1 (en) |
GB (2) | GB2618940A (en) |
WO (4) | WO2022187335A1 (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9624727B1 (en) * | 2016-02-18 | 2017-04-18 | D-Tech (Uk) Ltd. | Rotary bit pushing system |
Family Cites Families (32)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4637479A (en) | 1985-05-31 | 1987-01-20 | Schlumberger Technology Corporation | Methods and apparatus for controlled directional drilling of boreholes |
FR2648861B1 (en) | 1989-06-26 | 1996-06-14 | Inst Francais Du Petrole | DEVICE FOR GUIDING A ROD TRAIN IN A WELL |
US5265682A (en) | 1991-06-25 | 1993-11-30 | Camco Drilling Group Limited | Steerable rotary drilling systems |
US5553678A (en) | 1991-08-30 | 1996-09-10 | Camco International Inc. | Modulated bias units for steerable rotary drilling systems |
GB9411228D0 (en) | 1994-06-04 | 1994-07-27 | Camco Drilling Group Ltd | A modulated bias unit for rotary drilling |
GB9503827D0 (en) | 1995-02-25 | 1995-04-19 | Camco Drilling Group Ltd | "Improvements in or relating to steerable rotary drilling systems |
GB9503828D0 (en) | 1995-02-25 | 1995-04-19 | Camco Drilling Group Ltd | "Improvements in or relating to steerable rotary drilling systems" |
US6467557B1 (en) * | 1998-12-18 | 2002-10-22 | Western Well Tool, Inc. | Long reach rotary drilling assembly |
US6257356B1 (en) | 1999-10-06 | 2001-07-10 | Aps Technology, Inc. | Magnetorheological fluid apparatus, especially adapted for use in a steerable drill string, and a method of using same |
US20010052428A1 (en) | 2000-06-15 | 2001-12-20 | Larronde Michael L. | Steerable drilling tool |
US6550548B2 (en) | 2001-02-16 | 2003-04-22 | Kyle Lamar Taylor | Rotary steering tool system for directional drilling |
GB0111124D0 (en) | 2001-05-05 | 2001-06-27 | Spring Gregson W M | Torque-generating apparatus |
CA2506808C (en) | 2003-01-07 | 2010-10-12 | Gregson William Martin Spring | Communication system for down hole use |
US6997258B2 (en) | 2003-09-15 | 2006-02-14 | Schlumberger Technology Corporation | Apparatus and methods for pressure compensated contact with the borehole wall |
GB2408526B (en) | 2003-11-26 | 2007-10-17 | Schlumberger Holdings | Steerable drilling system |
US7133325B2 (en) | 2004-03-09 | 2006-11-07 | Schlumberger Technology Corporation | Apparatus and method for generating electrical power in a borehole |
US7389830B2 (en) * | 2005-04-29 | 2008-06-24 | Aps Technology, Inc. | Rotary steerable motor system for underground drilling |
GB2426265B (en) | 2005-05-21 | 2011-01-05 | Schlumberger Holdings | Roll stabilised unit |
US7503405B2 (en) | 2005-11-21 | 2009-03-17 | Hall David R | Rotary valve for steering a drill string |
CA2810266C (en) | 2010-09-09 | 2016-05-03 | National Oilwell Varco, L.P. | Downhole rotary drilling apparatus with formation-interfacing members and control system |
US8869916B2 (en) | 2010-09-09 | 2014-10-28 | National Oilwell Varco, L.P. | Rotary steerable push-the-bit drilling apparatus with self-cleaning fluid filter |
US8708064B2 (en) | 2010-12-23 | 2014-04-29 | Schlumberger Technology Corporation | System and method to control steering and additional functionality in a rotary steerable system |
CA2850018C (en) | 2011-09-27 | 2019-08-27 | Richard Hutton | Point the bit rotary steerable system |
US9869140B2 (en) | 2014-07-07 | 2018-01-16 | Schlumberger Technology Corporation | Steering system for drill string |
US10830004B2 (en) | 2015-05-20 | 2020-11-10 | Schlumberger Technology Corporation | Steering pads with shaped front faces |
US9624727B1 (en) | 2016-02-18 | 2017-04-18 | D-Tech (Uk) Ltd. | Rotary bit pushing system |
EP3478923B1 (en) | 2016-06-30 | 2021-05-26 | Services Pétroliers Schlumberger | Devices and systems for reducing cyclical torque on directional drilling actuators |
US11035174B2 (en) | 2017-05-31 | 2021-06-15 | Halliburton Energy Services, Inc. | Strategic flexible section for a rotary steerable system |
WO2019100116A1 (en) | 2017-11-27 | 2019-05-31 | Ian Gray | Simple rotary steerable drilling system |
US11365586B2 (en) * | 2017-12-29 | 2022-06-21 | Halliburton Energy Services, Inc. | Steering system for use with a drill string |
WO2019190484A1 (en) | 2018-03-27 | 2019-10-03 | Halliburton Energy Services, Inc. | Autonomously driven rotary steering system |
WO2020018816A1 (en) | 2018-07-20 | 2020-01-23 | Doublebarrel Downhole Technologies Llc | Improved bha |
-
2022
- 2022-02-28 US US17/682,383 patent/US20220282573A1/en not_active Abandoned
- 2022-02-28 US US17/682,127 patent/US11952894B2/en active Active
- 2022-02-28 US US17/682,503 patent/US11970942B2/en active Active
- 2022-02-28 US US17/682,041 patent/US20220282571A1/en not_active Abandoned
- 2022-03-02 WO PCT/US2022/018482 patent/WO2022187335A1/en active Application Filing
- 2022-03-02 CN CN202280018654.XA patent/CN116964294A/en active Pending
- 2022-03-02 CA CA3211825A patent/CA3211825A1/en active Pending
- 2022-03-02 GB GB2313358.0A patent/GB2618940A/en active Pending
- 2022-03-02 GB GB2313794.6A patent/GB2618963A/en active Pending
- 2022-03-02 WO PCT/US2022/018442 patent/WO2022187309A1/en active Application Filing
- 2022-03-02 CN CN202280018669.6A patent/CN117043439A/en active Pending
- 2022-03-02 CA CA3211809A patent/CA3211809A1/en active Pending
- 2022-03-02 WO PCT/US2022/018433 patent/WO2022187304A1/en active Application Filing
- 2022-03-02 WO PCT/US2022/018463 patent/WO2022187321A1/en active Application Filing
Also Published As
Publication number | Publication date |
---|---|
WO2022187321A1 (en) | 2022-09-09 |
CN116964294A (en) | 2023-10-27 |
CA3211809A1 (en) | 2022-09-09 |
US20220282574A1 (en) | 2022-09-08 |
GB2618940A (en) | 2023-11-22 |
CA3211825A1 (en) | 2022-09-09 |
GB202313358D0 (en) | 2023-10-18 |
US11952894B2 (en) | 2024-04-09 |
CN117043439A (en) | 2023-11-10 |
GB2618963A (en) | 2023-11-22 |
GB202313794D0 (en) | 2023-10-25 |
WO2022187335A1 (en) | 2022-09-09 |
US20220282571A1 (en) | 2022-09-08 |
US11970942B2 (en) | 2024-04-30 |
US20220282572A1 (en) | 2022-09-08 |
WO2022187309A1 (en) | 2022-09-09 |
WO2022187304A1 (en) | 2022-09-09 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11788359B2 (en) | Downhole steering system and methods | |
US20020179336A1 (en) | Drilling tool with non-rotating sleeve | |
US11506018B2 (en) | Steering assembly control valve | |
US20220282573A1 (en) | Rotary steerable system with optimized piston extension | |
US11608719B2 (en) | Controlling fluid flow through a valve | |
US10316598B2 (en) | Valve system for distributing actuating fluid | |
EP3701118B1 (en) | Rotating disk valve for rotary steerable tool | |
WO2021016282A1 (en) | On demand flow pulsing system | |
AU2017423296B2 (en) | Steering assembly control valve | |
US20210087929A1 (en) | Activation and Control of Downhole Tools Including a Non-Rotating Power Section Option | |
US20230366271A1 (en) | Cartridge for a rotary drill bit | |
CA2428458C (en) | Hydraulic cam motor | |
US11851991B2 (en) | Downhole concentric friction reduction system | |
US11686158B2 (en) | Fluid control valve for rotary steerable tool |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: INFINITY DRILLING TECHNOLOGIES, LLC, TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:BEDOUET, SYLVAIN;REEL/FRAME:059150/0396 Effective date: 20220225 |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |
|
STPP | Information on status: patent application and granting procedure in general |
Free format text: NON FINAL ACTION MAILED |
|
AS | Assignment |
Owner name: ONTARGET DRILLING, LLC, TEXAS Free format text: CHANGE OF NAME;ASSIGNOR:INFINITY DRILLING TECHNOLOGIES, LLC;REEL/FRAME:063982/0089 Effective date: 20220727 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |