Downhole rotary drilling apparatus with formation-interfacing members and control system
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E21B-007/06
E21B-007/04
E21B-017/10
출원번호
US-0229643
(2011-09-09)
등록번호
US-9016400
(2015-04-28)
발명자
/ 주소
Clausen, Jeffery
Prill, Jonathan Ryan
출원인 / 주소
National Oilwell Varco, L.P.
대리인 / 주소
Conley Rose, P.C.
인용정보
피인용 횟수 :
2인용 특허 :
126
초록▼
A steerable drilling apparatus includes a control system inside a cylindrical housing connected to a drill bit having radially-extendable pistons. A fluid-metering assembly directs a piston actuating fluid into fluid channels in the drill bit leading to respective pistons. The control system control
A steerable drilling apparatus includes a control system inside a cylindrical housing connected to a drill bit having radially-extendable pistons. A fluid-metering assembly directs a piston actuating fluid into fluid channels in the drill bit leading to respective pistons. The control system controls the fluid-metering assembly to selectively allow fluid flow through the fluid channels to the pistons and to exit through orifices in the fluid channels. The selective fluid flow causes the actuated piston to temporarily extend in the opposite direction to a desired wellbore deviation, thereby deflecting the drill bit away from the borehole centerline. An upper member in the fluid-metering assembly can be moved to stabilize, steer, and change TFA within the drill bit. The control system and drill bit are connected so as to facilitate removal to change the drill bit's steering section and cutting structure configuration or gauge simultaneously.
대표청구항▼
1. A rotary steerable drilling apparatus comprising: a control assembly disposed within a cylindrical housing;a steering section having a central axis, a first end coupled to the housing, a second end, a central channel, and one or more fluid channels radially-spaced from the central channel;one or
1. A rotary steerable drilling apparatus comprising: a control assembly disposed within a cylindrical housing;a steering section having a central axis, a first end coupled to the housing, a second end, a central channel, and one or more fluid channels radially-spaced from the central channel;one or more radially extendable pistons housed in the steering section;wherein the central channel extends axially from the first end and is configured to flow drilling fluid through the steering section;wherein each of the fluid channels extends to one of the pistons and is configured to flow drilling fluid to the corresponding piston; anda fluid-metering assembly configured to selectively meter the flow of drilling fluid into one or more of the fluid channels of the steering section;wherein the fluid-metering assembly includes a first component coupled to the control assembly and a second component coupled to the steering section;wherein the second component includes a central through bore and one or more fluid inlets disposed about the central through bore, wherein the central through bore of the second component is in fluid communication with the central channel of the steering section;wherein each fluid inlet of the second component is in fluid communication with at least one fluid channel of the steering section;wherein the control assembly is configured to move the first component relative to the second component to control the flow of drilling fluid into one or more of the fluid inlets of the second component;wherein the first component comprises a flange and a sleeve extending axially from the flange;wherein the sleeve extends into the central through bore of the second component and slidingly engages the lower component. 2. The rotary steerable drilling apparatus of claim 1, wherein the first end of the steering section is coupled to a lower end of the housing; and wherein the first component is positioned axially above the second component. 3. The rotary steerable drilling apparatus of claim 2, wherein the second end of the steering section comprises a cutting structure. 4. The rotary steerable drilling apparatus of claim 1, wherein the first component includes a central through bore extending axially through the flange and the sleeve, and a fluid-metering opening extending radially through the sleeve; wherein the central through bore of the first component is in fluid communication with the central through bore of the second component. 5. The rotary steerable drilling apparatus of claim 4, wherein the control assembly is configured to rotate the first component relative to the second component to place the fluid-metering opening of the first component into fluid communication with each fluid inlet of the lower component in sequence. 6. The rotary steerable drilling apparatus of claim 4, wherein the control assembly is configured to move the first component axially relative to the second component between: a first position allowing drilling fluid to flow from the central through bore of the first component into all of the fluid inlets of the second component simultaneously;a second position allowing drilling fluid to flow from the central through bore of the first component into at least one of the fluid inlets of the lower component at a time. 7. The rotary steerable drilling apparatus of claim 6, wherein the control assembly is configured to move the first component axially relative to the second component between the first position, the second position, and a third position preventing drilling fluid from flowing from the central through bore of the first component into any of the fluid inlets of the second component. 8. The rotary steerable drilling apparatus of claim 1, further comprising one or more reaction pads coupled to the steering section, wherein one reaction pad is provided for each piston; wherein each piston is configured to deflect the corresponding reaction pad radially away from the steering section in response to the flow of drilling fluid through the corresponding fluid channel. 9. The rotary steerable drilling apparatus of claim 8, wherein each reaction pad comprises a flexible member resiliently mounted to the steering section. 10. The rotary steerable drilling apparatus of claim 8, wherein each reaction pad comprises a hinged member pivotally coupled to the steering section and configured to pivot about a hinge axis oriented parallel to the central axis of the steering section. 11. The rotary steerable drilling apparatus of claim 1, further comprising a biasing means for each piston, wherein each biasing means is configured to bias the piston to a radially retracted position within the steering section. 12. The rotary steerable drilling apparatus of claim 1, wherein at least one of the one or more pistons is a two-piece piston assembly comprising: an inner member fixably coupled to the steering section; andan outer member disposed about the inner member and configured to move radially relative to the inner member and the steering section. 13. The rotary steerable drilling apparatus of claim 12, wherein the two-piece piston assembly includes a travel-limiting means for restricting the radial stroke of the outer member relative to the inner member and the steering section. 14. The rotary steerable drilling apparatus of claim 13, wherein the travel-limiting means comprises a plurality of first stop elements formed on the outer member and a plurality of second stop elements formed on the inner member, the first and second stop elements being configured and arranged such that each first stop element will react against one of the second stop elements when the stroke of the outer member reaches a preset limit. 15. The rotary steerable drilling apparatus of claim 1, wherein the control assembly is configured to be separated from the steering section with the first component remaining coupled to the control assembly. 16. The rotary steerable drilling apparatus of claim 1, wherein the first component includes a central through bore extending axially through the flange and the sleeve of the first component; wherein the central through bore of the first component and the central through bore of the second component are in fluid communication with the central channel of the steering section. 17. A rotary steerable drilling apparatus comprising: a steering section having a central axis, a first end, a second end comprising a cutting structure, a central channel, and a plurality of circumferentially-spaced fluid channels disposed about the central channel;a plurality of pistons housed in the steering section;wherein the central channel extends axially from the first end of the steering section and is configured to flow drilling fluid through the steering section to the cutting structure;wherein each of the fluid channels extends from the first end of the steering section to at least one of the pistons;wherein each piston is configured to move radially outward in response to drilling fluid supplied by one or more of the fluid channels;a fluid-metering assembly including a lower component fixably coupled to the steering section and an upper component coupled to a control assembly;wherein the upper component includes a central through bore in fluid communication with the central channel of the steering section;wherein the lower component includes a central through bore and a plurality of circumferentially-spaced fluid inlets disposed about the central through bore, wherein the central through bore of the lower component is in fluid communication with the central through bore of the upper component and the central channel of the steering section, wherein the central through bore of the upper component and the central through bore of the lower component are configured to continuously flow drilling fluid through the central channel of the steering section to the cutting structure, wherein each fluid inlet of the lower component is in fluid communication with at least one fluid channel of the steering section;wherein the control assembly is configured to move the upper component relative to the lower component to control the distribution of drilling fluid between the central through bore of the lower component and the fluid inlets of the lower component. 18. The rotary steerable drilling apparatus of claim 17, wherein the upper component comprises a flange and a sleeve extending axially from the flange; wherein the sleeve extends into the central through bore of the lower component and slidingly engages the lower component. 19. The rotary steerable drilling apparatus of claim 18, wherein the upper component includes a central through bore extending axially through the flange and the sleeve, and a fluid-metering opening extending radially from the central through bore to a radially outer surface of the sleeve; wherein the central through bore of the upper component is in fluid communication with the central through bore of the lower component. 20. The rotary steerable drilling apparatus of claim 19, wherein the control assembly is configured to rotate the upper component relative to the lower component to place the fluid-metering opening of the upper component into fluid communication with at least one of the fluid inlets of the lower component. 21. The rotary steerable drilling apparatus of claim 19, wherein the control assembly is configured to move the upper component axially relative to the lower component between: an upper position allowing drilling fluid to flow from the central through bore of the upper component into all of the fluid inlets of the lower component simultaneously; andan intermediate position allowing drilling fluid to flow from the central through bore of the upper component into at least one of the fluid inlets of the lower component at a time. 22. The rotary steerable drilling apparatus of claim 21, wherein the control assembly is configured to move the upper component axially relative to the lower component between the upper position, the intermediate position, and a lower position preventing drilling fluid from flowing from the central through bore of the upper component into any of the fluid inlets of the lower component. 23. The rotary steerable drilling apparatus of claim 17, wherein the upper component comprises an upper plate having a central through bore extending axially through the upper plate and an arcuate fluid-metering hole extending axially through the upper plate, wherein the fluid-metering hole is radially offset from the central through bore of the upper plate. 24. The rotary steerable drilling apparatus of claim 23, wherein the control assembly is configured to rotate the upper plate relative to the lower component to place the fluid-metering hole of the upper plate into fluid communication with at least one of the fluid inlets of the lower component. 25. The rotary steerable drilling apparatus of claim 24, wherein the control assembly is configured to move the upper plate axially away from the lower component to allow drilling fluid to flow through the central opening of the upper plate and into all of the fluid inlets of the lower plate simultaneously. 26. The rotary steerable drilling apparatus of claim 17, further comprising one or more reaction pads coupled to the steering section, wherein one reaction pad is provided for each piston; wherein each piston is configured to deflect the corresponding reaction pad radially away from the steering section in response to the flow of drilling fluid through the corresponding fluid channel. 27. The rotary steerable drilling apparatus of claim 17, further comprising a biasing means for each piston, wherein each biasing means is configured to bias the piston to a radially retracted position within the steering section. 28. The rotary steerable drilling apparatus of claim 17, wherein at least one of the one or more pistons is a two-piece piston assembly comprising: an inner member fixably coupled to the steering section; andan outer member disposed about the inner member and configured to move radially relative to the inner member and the steering section. 29. The rotary steerable drilling apparatus of claim 28, wherein the two-piece piston assembly includes a travel-limiting means for restricting the radial stroke of the outer member relative to the inner member and the steering section. 30. A method for drilling a borehole with a drill bit having a cutting structure, the method comprising: (a) flowing drilling fluid to a steering section having a central axis, a first end, and a second end opposite the first end, wherein the second end comprises the cutting structure;(b) selectively distributing the drilling fluid supplied to the steering section with a fluid-metering assembly, wherein the fluid-metering assembly includes a first component and a second component;(c) continuously flowing drilling fluid through a central passage in the first component, a central passage in the second component, and a central channel in the steering section to the cutting structure;(d) flowing drilling fluid through an outlet of the first component, a first inlet of the second component, and a first fluid channel in the steering section to a first piston housed in the steering section while flowing drilling fluid to the cutting structure in (c); and(e) moving the first piston radially outward from the steering section during (d). 31. The method of claim 30, further comprising: (f) flowing drilling fluid through the outlet of the first component, a second inlet of the second component, and a second fluid channel in the steering section to a second piston housed in the steering section after (d) and while flowing drilling fluid to the cutting structure in (c);(g) moving the second piston radially outward from the steering section during (f). 32. The method of claim 31, wherein (d) comprises rotating the first component to a first position aligning the outlet with the first inlet, and (f) comprise rotating the first component to a second position aligning the outlet with the second inlet. 33. The method of claim 31, further comprising: (h) flowing drilling fluid through the first component into both the first inlet and the second inlet simultaneously. 34. The method of claim 33, further comprising extending the first piston and the second piston radially outward from the steering section to centralize the drill bit in the borehole during (h). 35. The method of claim 33, further comprising: flowing drilling fluid through the first component and the second component while restricting drilling fluid from flowing into the first inlet and the second inlet. 36. The method of claim 30, wherein the outlet extends radially through the first component. 37. The method of claim 30, wherein the outlet extends axially through the first component and the first inlet extends axially through the second component. 38. The method of claim 30, further comprising rotating the first component relative to the second component to place the outlet in fluid communication with the first inlet. 39. A method for drilling a borehole with a drill bit having a cutting structure, the method comprising: (a) flowing drilling fluid to a steering section having a central axis, a first end, and a second end opposite the first end, wherein the second end comprises the cutting structure;(b) selectively distributing the drilling fluid supplied to the steering section with a fluid-metering assembly, wherein the fluid-metering assembly includes a first component and a second component;(c) continuously flowing drilling fluid through the first component, the second component, and the steering section to the cutting structure;(d) flowing drilling fluid through an outlet of the first component, a first inlet of the second component, and a first fluid channel in the steering section to a first piston housed in the steering section while flowing drilling fluid to the cutting structure in (c); and(e) moving the first piston radially outward from the steering section during (d);(f) moving the first component axially relative to the second component to place the outlet in fluid communication with the first inlet. 40. The method of claim 39, wherein (c) comprises continuously flowing drilling fluid through a central passage in the first component, a central passage in the second component, and a central channel in the steering section to the cutting structure.
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