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

Abstract: A real time telemetry system is disclosed for use with a drilling system including a rotary valve 28 controlling the supply of drilling fluid or mud to a downhole tool. The system comprises receiving data to be transmitted, encoding the data as a duration, and controlling the rotation the rotary valve 28 such that the rotary valve 28 is rotated for the said duration at a predetermined rotary speed to cause the formation of pressure fluctuations or waves in the drilling fluid or mud.

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: 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 specification describes a drill bit for drilling a cavity. The drill bit may include a chassis, a plurality of gauge pad sets, and at least one gauge pad structure. The chassis may be configured to rotate about an axis. The plurality of gauge pad sets may each include at least one gauge pad. The at least one gauge pad structure may moveably couple at least one of the gauge pads of at least one of the plurality of gauge pad sets with the chassis.

Abstract: A drill bit direction system and method is disclosed that modifies or biases the stochastic movement of the drill bit to change a drilling direction of a 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 or desired direction, stochastic motion of the drill bit in the borehole may be controlled and/or motion of the drill bit under a side force acting on the drill bit to direct the drilling may be focused or biased to modify the direction of drilling closer to the preferred direction. Any of a number of stochastic motion control mechanisms or biasing mechanisms can be used. Some embodiments can resort to conventional steering mechanisms to supplement the stochastic motion control or side force biasing mechanisms.

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: 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: 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: A downhole steering system comprises a first full gauge stabiliser 34, a bias unit 28, a universal joint 26, and a second full gauge stabiliser 22, the bias unit 28 and universal joint 26 being located between the first and second full gauge stabilisers 34, 22. Conveniently, the system further comprises a drill bit 10 and a fluid powered downhole motor 14, the motor being located, at least partially, between the drill bit 10 and the second stabiliser 22.

Abstract: A bi-stable actuator comprises a chamber 40 having a fluid inlet 34 and first and second fluid outlets 36, 38, a valve member 42 movable between a first position in which it co-operates with a first seat to close the first outlet 36 and a second position in which it co-operates with a second seat to close the second outlet 38, and an electromagnetic actuator 48 operable to drive the valve member 42 between its first and second positions, wherein the valve member 42 has a first surface 44 against which the fluid pressure within the chamber 40 acts when the valve member 42 is in its first position to resist movement of the valve member 42, and a second surface 46 against which the fluid pressure within the chamber 40 acts when the valve member 42 is in its second position to resist movement of the valve member 42.

Abstract: A downhole motor arrangement for a directional drilling comprises a first motor component (22), a second motor component (24) encircling at least part of the first motor component (22), and a third motor component (26) encircling at least part of the second motor component (24), the first and second motor components (22, 24) having surfaces associated therewith adapted to define isolated cavities, the application of fluid under pressure thereto causing relative rotation between the first and second motor components (22, 24), the second and third motor components (24, 26) having surfaces associated therewith adapted to define isolated cavities, the application of fluid under pressure thereto causing relative rotation between the second and third motor components (24, 26).

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 technique provides a drilling system and method in which a drilling assembly is delivered downhole on coiled tubing. The drilling assembly comprises a drill bit and a motor to rotate the drill bit for drilling of a borehole. A steerable system is used to steer the drill bit, thereby enabling formation of deviated boreholes.

Abstract: A steerable drilling system comprising 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 means permitting relative rotation between the drill string and the bent housing.

Abstract: A bottom hole assembly is rotatably adapted for drilling directional boreholes into an earthen formation. It has an upper stabilizer mounted to a collar, and a rotary steerable system. The rotary steerable system has an upper section connected to the collar, a steering section, and a drill bit arranged for drilling the borehole attached to the steering section. The steering section is joined at a swivel with the upper section. The steering section is actively tilted about the swivel. A lower stabilizer is mounted upon the steering section such that the swivel is intermediate the drill bit and the lower stabilizer.

Abstract: The present invention provides an apparatus for the communication of power or data signals across the rotating gap of two tubular members, such as the stator and rotor of a mud motor, and between said rotating members of a drill string through inductive couplers located axially along the drill string.

Abstract: In downhole drilling tools, a first set of inexpensive and/or relatively small sensors that typically have lower accuracy and higher drift than conventional downhole sensors are located in the drill string adjacent to the bit. A second set of highly accurate sensors is located in a more protected location higher in the drill string away from the drill bit. As drilling progresses these sensors pass through the same portion of the formation measured by the first set of sensors. Key properties are measured by the second set of sensors which allow a calibration offset to be applied the data measured by the first set of sensors.