Abstract: A rotary steerable system including a steering section having at least one piston, at least one distribution flow passage extending from a valve to one of the pistons, and two main flow passages bypassing the pistons. At least a portion of each main flow passage is closer to a central point of the steering section than an outer boundary of the distribution flow passage. At least a portion of each main flow passage may also be closer to the central point of the steering section than an inner boundary of the pistons in a retracted position. The distribution flow passages are contained within a central area, with a ratio of a central area diameter to steering section diameter being 0.5 or less, preferably 0.4 or less. The steering section may include two piston sets and two distribution flow passages each extending from the valve to a piston.

Abstract: A self-sufficient rotary steerable system configured to provide a bottom hole assembly with a build-up rate of at least 25 degrees per 100 feet of drilling distance. The rotary steerable system has a reduced length without the removal or omission of functional components, including a power module, a control module, a communication module, a filter module, a valve module, and/or a pressure regulation module. The build-up rate is defined as a function of a length between a first contact point on a drill bit of the bottom hole assembly and a second contact point at a piston assembly of the rotary steerable system; length between the second contact point and a third contact point at a stabilizer of the rotary steerable system; the drill bit outer diameter; the piston assembly outer diameter; and the stabilizer outer diameter.

Abstract: A self-sufficient rotary steerable system configured to provide a bottom hole assembly with a build-up rate of at least 25 degrees per 100 feet of drilling distance. The rotary steerable system has a reduced length without the removal or omission of functional components, including a power module, a control module, a communication module, a filter module, a valve module, and/or a pressure regulation module. The build-up rate is defined as a function of a length between a first contact point on a drill bit of the bottom hole assembly and a second contact point at a piston assembly of the rotary steerable system; length between the second contact point and a third contact point at a stabilizer of the rotary steerable system; the drill bit outer diameter; the piston assembly outer diameter; and the stabilizer outer diameter.

Abstract: A rotary steerable system including a steering section and a control section. The control section includes a modular control system that is field detachable from a remainder of the control section. The modular control system includes one or more modules that are field detachable from the other modules and a remainder of the modular control system. Examples of the modules of the modular control system include a power module configured to generate electrical power or electromagnetic field rotation from hydraulic power, a control module configured to control actuation of one or more pistons in the steering section, and/or a flow control module configured to selectively allow fluid flow into one or more distribution channels leading to the one or more pistons of the steering unit.

Abstract: A method for calibrating the sensors present within a drilling tool, whereby the calibration occurs downhole and in-situ within the drilling tool. The calibration method may use the rotation of the drilling tool which typically occurs during drilling operations, whereby the drilling tool is rotating along the axis which follows the drilling trajectory. Direction and speed of rotation of the drilling tool may contribute to the in-situ calibration of the sensors, which may include angular rate sensors, magnetometers, and accelerometers.

Abstract: A rotary steerable system including a steering section and a control section. The control section includes a modular control system that is field detachable from a remainder of the control section. The modular control system includes one or more modules that are field detachable from the other modules and a remainder of the modular control system. Examples of the modules of the modular control system include a power module configured to generate electrical power or electromagnetic field rotation from hydraulic power, a control module configured to control actuation of one or more pistons in the steering section, and/or a flow control module configured to selectively allow fluid flow into one or more distribution channels leading to the one or more pistons of the steering unit.

Abstract: A self-sufficient rotary steerable system configured to provide a bottom hole assembly with a build-up rate of at least 25 degrees per 100 feet of drilling distance. The rotary steerable system has a reduced length without the removal or omission of functional components, including a power module, a control module, a communication module, a filter module, a valve module, and/or a pressure regulation module. The build-up rate is defined as a function of a length between a first contact point on a drill bit of the bottom hole assembly and a second contact point at a piston assembly of the rotary steerable system; length between the second contact point and a third contact point at a stabilizer of the rotary steerable system; the drill bit outer diameter; the piston assembly outer diameter; and the stabilizer outer diameter.

Abstract: A rotary steerable system including a steering section having at least one piston, at least one distribution flow passage extending from a valve to one of the pistons, and two main flow passages bypassing the pistons. At least a portion of each main flow passage is closer to a central point of the steering section than an outer boundary of the distribution flow passage. At least a portion of each main flow passage may also be closer to the central point of the steering section than an inner boundary of the pistons in a retracted position. The distribution flow passages are contained within a central area, with a ratio of a central area diameter to steering section diameter being 0.5 or less, preferably 0.4 or less. The steering section may include two piston sets and two distribution flow passages each extending from the valve to a piston.

Abstract: A rotary steerable system including a steering section having at least one piston, at least one distribution flow passage extending from a valve to one of the pistons, and two main flow passages bypassing the pistons. At least a portion of each main flow passage is closer to a central point of the steering section than an outer boundary of the distribution flow passage. At least a portion of each main flow passage may also be closer to the central point of the steering section than an inner boundary of the pistons in a retracted position. The distribution flow passages are contained within a central area, with a ratio of a central area diameter to steering section diameter being 0.5 or less, preferably 0.4 or less. The steering section may include two piston sets and two distribution flow passages each extending from the valve to a piston.

Abstract: A rotary steerable system including a steering section having not more than one piston or not more than two pistons in a transverse cross-sectional plane of the steering section. The steering section includes two distribution flow passages each extending from a valve to a piston. A ratio of a distribution flow passage diameter to steering section diameter is at least 0.07. The distribution flow passages are contained within a central area of the steering section, with a ratio of a central area diameter to steering section diameter being 0.5 or less, preferably 0.4 or less. The steering section may include two pistons having center points that are separated by an angle greater than 120 degrees, preferably about 180 degrees. A duration for which only one of the sets of pistons is activated is greater than 110 degrees of rotation of a valve rotor, preferably greater than 150 degrees.