Abstract: This disclosure relates in general to a method and a system for directionally drilling a borehole with a rotary drilling system. More specifically, but not by way of limitation, methods and system provide for controlling motion of the rotary drilling system in the borehole when a side force is applied to the drilling system to bias or focus the motion so that the drilling system directionally drills the borehole through an earth formation. In certain aspects, side cutting of a sidewall of the borehole by a drill bit under an applied side force is controlled by a geostationary element to provide for directional side cutting and, as a result, directional drilling of the borehole through the earth formation. In other aspects, a non-concentrically coupled gauge pad assembly may rotate with the drilling system and bias or focus the applied side force.

Abstract: The present invention relates to systems and methods for controlling downhole motors. One aspect of the invention provides a valve-controlled downhole motor including: a downhole motor and a spool valve. The downhole motor includes a sealed chamber having a first port and a second port, a stator received within the sealed chamber, and a rotor received within the stator. The spool valve includes a barrel and a spool received within the barrel. The barrel includes an inlet port, an exhaust port, a first feed port, a second feed port, a first return port, and a second return port. The inlet port is located in proximity to the first feed port and second port. The exhaust port is located in proximity to the first return port and the second return port. The spool includes a first gland and a second gland.

Abstract: The present invention relates to an automatic elastomer extrusion apparatus and method. An apparatus 400 for in-situ extrusion of an elastomeric coating 410 on a profiled helical surface 450 can include a template (100, 200) forming a gap between the profiled helical surface 450 and an adjacent profiled helical surface (102, 202) of a template (100, 200) itself to extrude an elastomer therethrough. A tracking mechanism 302 and/or carriage 300 can allow a template to follow the contours of the profiled helical surface 350. The apparatus can include means for providing relative movement between the profiled helical surface and the template. The apparatus (500, 600) can include a cleaning module (502, 602), an adhesive application module (504, 604), an elastomer deposition module (506, 606), and/or a curing module (508, 608). Each module can further include a template (100, 200) and/or a tracking mechanism 302.

Abstract: A steerable system comprises a fluid powered motor 10 having a rotor 16 and a stator 18, and a bias arrangement having a plurality of bias pads 34 connected to the stator 18 so as to be rotatable therewith, the bias pads 34 being moveable to allow the application of a side load to the steerable system.

Abstract: A drill bit direction system and method is disclosed that modifies or biases the stochastic movement of the drill bit and/or stochastic interactions between the drill bit and an inner-wall of a borehole being drilled by a drilling system to change the direction of drilling of the drilling system. The direction of the drill bit is monitored to determine if the direction happens to align in some way with a preferred direction. If the direction isn't close enough to a preferred direction, a biasing mechanism modifies the stochastic movement in an attempt to modify the direction closer to the preferred direction. Any of a number of biasing mechanisms can be used. Some embodiments can resort to conventional steering mechanisms to supplement the biasing mechanism.

Abstract: A steerable system comprises a fluid powered motor 10 having a rotor 16 and a stator 18, and a bias arrangement having a plurality of bias pads 34 connected to the stator 18 so as to be rotatable therewith, the bias pads 34 being moveable to allow the application of a side load to the steerable system.

Abstract: A steerable system comprises a fluid powered motor 10 having a rotor 16 and a stator 18, and a bias arrangement having a plurality of bias pads 34 connected to the stator 18 so as to be rotatable therewith, the bias pads 34 being moveable to allow the application of a side load to the steerable system.

Abstract: A steerable drilling system includes a drill string carrying a bent housing, the bent housing containing or having associated therewith a drive motor arranged to drive a drive shaft angled to an axis of part of the drill string adjacent the bent housing, and an orientating motor permitting relative rotation between the drill string and the bent housing, the orientating motor driving the output shaft in a reverse direction relative to a direction of rotation of the drill string to form a curve in a borehole being formed.

Abstract: An erosion resistant surface using a dense array of elastic whiskers to slow the velocity of erosive particles before impacting with the surface. A carbon nanotube forest is grown on the surface to provide the erosion resistance. In the alternative, a carbon nanotube forest is grown on a flexible substrate that is bonded to the surface.

Abstract: The present invention relates to a stator (100-1000) with a profiled helical bore (106,206,306,606,706,806,906,1006) having a cast material layer (102;202;302;602;702;802;902;1002) with transducers (104A-104D;304;604A-604D;710;804;904A-904C;1010) disposed therein and describes the methods of forming such stators. Cast material can be fluidic during displacing of a transducer therein. Cast material layer 202 can include housings (218,222) disposed therein and/or a cavity 226 formed therein. Transducer can be a sensor (104A-104C) and/or an actuator 104D. Transducer 804 can extend axially along a length of the stator 800. Transducer or plurality of transducers (904A-904C) can extend along a helical path. Additionally or alternatively, sleeve 1008 can include a transducer 1010.

Abstract: A method of sensing and transmitting hole depth information comprises monitoring, at the surface, the extension of the hole as drilling progresses, determining when the hole depth has extended by a predetermined distance, and sending an increment signal to a telemetry device.

Abstract: The rotor of a downhole motor includes a mandrel having at least one radial lobe, and an elastomeric tubular sleeve compressed about the mandrel so as to establish frictional engagement therebetween. The sleeve is compressed about the mandrel through one of various processes, including heat shrinking, vacuum shrinking, and stretching.

Abstract: A system and a method manage and use data related to a wellbore or a drill string. The system and the method may provide remote access to tools in a drill string using a network. In addition, the tools have access to the data. In a disclosed embodiment, the tools are able to automatically access the data needed to optimize or improve function of the tools. An example of the network is a wireless network where the tools may be monitored and/or controlled remotely by an application. A linking tool is optionally provided to communicate with the network and one or more of the tools.

Abstract: A bottom hole assembly for drilling a cavity including a chassis configured to rotate is provided. The chassis may include a conduit, a circuit, a pressure transfer device, a plurality of pistons, a plurality of valves, and a plurality of cutters. The conduit may accept a first flow of a primary fluid. The circuit may have a second flow of a secondary fluid. The pressure transfer device may be configured to transfer pressure between the flows. The pistons may be operably coupled with the circuit, and each piston may be configured to move based at least in part on a pressure of the circuit at that piston, with the valves possibly configured to control a pressure of the circuit at each piston. Each cutter may be coupled with one of the pistons.

Abstract: Methods and apparatuses to direct a drill bit of a directional drilling assembly are disclosed. The methods and apparatuses employ the use of bi-directional actuators that are capable of displacing a hybrid steering sleeve in positive and negative directions. The bi-directional actuators are capable of greater control and precision in their actuations than traditional “engaged-disengaged” unidirectional actuators, thereby allowing for more precise directional drilling operations. The bi-directional actuators are preferably driven by drilling fluids and may optionally be shielded to lessen the erosive effects thereof.

Abstract: A method for creating a programmable pressure zone adjacent a drill bit bottom hole assembly by sealing near a drilling assembly, adjusting the pressure to approximately or slightly below the pore pressure of the well bore face to permit flow out of the formation, and, while drilling, adjusting by pumping out of, or choking fluid flow into, the drilling assembly between the programmable pressure zone and the well bore annulus to avoid overpressuring the programmable pressure zone unless required to control the well.

Abstract: The instant invention provides apparatus and methods for directional drilling. One embodiment of the invention provides a drill control system including an uphole control device and a downhole control device. The uphole control device is configured to: transmit a reference trajectory to the downhole control device and receive information about an actual trajectory from the downhole control device. The downhole control device is configured to: receive the reference trajectory from the uphole control device, measure the actual trajectory, correct deviations between the reference trajectory and the actual trajectory, and transmit information about the actual trajectory to the uphole control device.

Abstract: The present invention relates to systems and methods for controlling downhole motors. One aspect of the invention provides a valve-controlled downhole motor including: a downhole motor and a spool valve. The downhole motor includes a sealed chamber having a first port and a second port, a stator received within the sealed chamber, and a rotor received within the stator. The spool valve includes a barrel and a spool received within the barrel. The barrel includes an inlet port, an exhaust port, a first feed port, a second feed port, a first return port, and a second return port. The inlet port is located in proximity to the first feed port and second port. The exhaust port is located in proximity to the first return port and the second return port. The spool includes a first gland and a second gland.

Abstract: Exhaust pressure from at least one actuator (34,36) which can tilt joint 6 of a bottom hole assembly 4 can be utilized to determine the direction 26 tiltable joint 6 is pointing (e.g., orientation, angular displacement, and/or inclination and azimuth). In one embodiment, a known exhaust pressure can be correlated to a known orientation and/or angular displacement, and the measured exhaust pressure can be compared to the known exhaust pressure to determine the orientation and/or angular displacement. In another embodiment, the flow rate of fluid exhausted from an actuator (34,36) can be derived from the exhaust pressure. The exhaust flow rate can then be used to calculate the state of actuation, which can allow determination of the angular displacement of the tiltable joint 6. Orientation and/or angular displacement with respect to the bottom hole assembly 4 can be resolved into an inclination and azimuth with respect to a formation 14.

Abstract: The present invention provides apparatus and methods for controlled steering. One embodiment of the invention provides a bit body comprising a trailing end, a pilot section, and a reaming section. The trailing end is adapted to be detachably secured to a drill string. The pilot section is located on a leading, opposite end of the bit body. The reaming section is located intermediate to the leading and trailing ends. The pilot section comprises at least one steering device for steering the pilot section of the bit body, thereby steering the entire bit body. Another embodiment of the invention provides a wellsite system comprising a drill string; a kelly coupled to the drill string; and a bit body as described above. Another embodiment of the invention provides a method of drilling a curved borehole in a subsurface formation.