Abstract: An extendable member diagnostic assembly determines performance of one or more components of a rotary steerable system. Based on the determined performance, an operation can be altered, such as a drilling operation. Performance may be based on measurements received from one or more sensors associated with components of the extendable member diagnostic assembly. For example, performance may be based on the time to transition a valve between states where the valve controls actuation of an extendable member, downhole temperature, downhole pressure or any other factors that affect performance of components that are used to perform the drilling operation. A controller receives the measurements from the one or more sensors and updates baseline parameters to determine an accurate performance. Using real time data to determine performance increases efficiency of an operation by eliminating unnecessary replacement of components and indicating that a downhole tool should be retrieved prior to failure.

Abstract: A drill string steering system includes a motor and a rotary valve body disposed in a tool body. The motor includes a motor shaft coupled to the motor and extending within a central bore of the tool body. The motor shaft has a downhole engagement portion that includes a first splined surface. The rotary valve body includes a disk-shaped component and a valve shaft coupled to the disk-shaped component and extending uphole of the disk-shaped component. The valve shaft includes a second splined surface engageable with the first splined surface for rotation of the motor shaft to be imparted to the rotary valve body.

Abstract: A rotary steerable tool for directional drilling includes a tool body including an outer surface and a flowbore therethrough, a pad movably coupled to the tool body and alternately movable between an extended position and a retracted position, and a piston engageable with the pad to move the pad. The tool further includes a pressurized fluid supply flow path to provide fluid pressure to the piston for the piston to controllably move the pad to the extended position, and a dump valve in fluid communication with the pressurized fluid supply flow path to selectively vent fluid pressure to allow the pad to move from the extended position toward the retracted position.

Abstract: Steering mechanisms for use in RSS systems may be devoid of an elastomeric piston seal. Pistons of the steering mechanisms have a convex cross-section that permit the piston to pivot along with a steering pad while moving laterally or radially along a piston axis defined by a piston bore. Hydraulic pressure may be maintained as the pad is extended since a limited gap size between the piston and the bore may be maintained throughout the motion of the pistons. The pistons may be retained to the steering pad in a T-slot and may be elongated in a direction orthogonal to the axis of the piston bore. A groove may be provided around the piston for a receiving a back-up seal therein. The back-up seal may include wear resistant balls embedded in a matrix, and balls may be preloaded to serve as flow restrictors even when worn.

Abstract: A drill string steering system includes a flow manifold and a rotary valve. An actuation flow channel and a backflow channel are rotatable with respect to piston flow channels of the flow manifold. The actuation flow channel is rotatable relative to the flow manifold to increase or decrease flow toward the piston for controlling actuation of the piston. The backflow channel is rotatable relative to the flow manifold to increase or decrease flow away from the piston to the annulus for controlling retraction of the piston.

Abstract: A drill string steering system includes a motor and a rotary valve body disposed in a tool body. The motor includes a motor shaft coupled to the motor and extending within a central bore of the tool body. The motor shaft has a downhole engagement portion that includes a first splined surface. The rotary valve body includes a disk-shaped component and a valve shaft coupled to the disk-shaped component and extending uphole of the disk-shaped component. The valve shaft includes a second splined surface engageable with the first splined surface for rotation of the motor shaft to be imparted to the rotary valve body.

Abstract: A drill string steering system includes a motor and a rotary valve body disposed in a tool body. The motor includes a motor shaft coupled to the motor and extending within a central bore of the tool body. The motor shaft has a downhole engagement portion that includes a first splined surface. The rotary valve body includes a disk-shaped component and a valve shaft coupled to the disk-shaped component and extending uphole of the disk-shaped component. The valve shaft includes a second splined surface engageable with the first splined surface for rotation of the motor shaft to be imparted to the rotary valve body.

Abstract: An extendable member diagnostic assembly determines performance of one or more components of a rotary steerable system. Based on the determined performance, an operation can be altered, such as a drilling operation. Performance may be based on measurements received from one or more sensors associated with components of the extendable member diagnostic assembly. For example, performance may be based on the time to transition a valve between states where the valve controls actuation of an extendable member, downhole temperature, downhole pressure or any other factors that affect performance of components that are used to perform the drilling operation. A controller receives the measurements from the one or more sensors and updates baseline parameters to determine an accurate performance. Using real time data to determine performance increases efficiency of an operation by eliminating unnecessary replacement of components and indicating that a downhole tool should be retrieved prior to failure.

Abstract: A rotary steerable tool for directional drilling includes a tool body including an outer surface and a flowbore therethrough, a pad movably coupled to the tool body and alternately movable between an extended position and a retracted position, and a piston engageable with the pad to move the pad. The tool further includes a pressurized fluid supply flow path to provide fluid pressure to the piston for the piston to controllably move the pad to the extended position, and a dump valve in fluid communication with the pressurized fluid supply flow path to selectively vent fluid pressure to allow the pad to move from the extended position toward the retracted position.

Abstract: Steering mechanisms for use in RSS systems may be devoid of an elastomeric piston seal. Pistons of the steering mechanisms have a convex cross-section that permit the piston to pivot along with a steering pad while moving laterally or radially along a piston axis defined by a piston bore. Hydraulic pressure may be maintained as the pad is extended since a limited gap size between the piston and the bore may be maintained throughout the motion of the pistons. The pistons may be retained to the steering pad in a T-slot and may be elongated in a direction orthogonal to the axis of the piston bore. A groove may be provided around the piston for a receiving a back-up seal therein. The back-up seal may include wear resistant balls embedded in a matrix, and balls may be preloaded to serve as flow restrictors even when worn.

Abstract: A device comprising a housing having a longitudinal dimension; a linear actuator including a casing coupled to the housing; an actuator shaft having an exterior surface and configured to be longitudinally translated relative to the casing; and a seal assembly engaging the housing and sealingly engaging the exterior surface. The device also comprising a motor assembly disposed within the housing, the motor assembly including a motor case and a motor shaft, the motor shaft configured to rotate one of the seal assembly or the actuator shaft.

Abstract: A drill string steering system includes a flow manifold and a rotary valve. An actuation flow channel and a backflow channel are rotatable with respect to piston flow channels of the flow manifold. The actuation flow channel is rotatable relative to the flow manifold to increase or decrease flow toward the piston for controlling actuation of the piston. The backflow channel is rotatable relative to the flow manifold to increase or decrease flow away from the piston to the annulus for controlling retraction of the piston.

Abstract: A drill string steering system includes a motor and a rotary valve body disposed in a tool body. The motor includes a motor shaft coupled to the motor and extending within a central bore of the tool body. The motor shaft has a downhole engagement portion that includes a first splined surface. The rotary valve body includes a disk-shaped component and a valve shaft coupled to the disk-shaped component and extending uphole of the disk-shaped component. The valve shaft includes a second splined surface engageable with the first splined surface for rotation of the motor shaft to be imparted to the rotary valve body.

Abstract: A method and apparatus according to which an output of a power generation system is controlled. In one embodiment, the power generation system includes a turbine and a feedback control system. The turbine includes a rotor to which a first portion of a power fluid is communicated, the first portion imparting torque to the rotor; a shaft to which the rotor is connected; a shroud extending circumferentially about the rotor and the shaft; and a bypass gap between the rotor and the shroud, through which a second portion of the power fluid is communicated. The feedback control system axially displaces the shroud relative to the rotor, thereby adjusting the size of the bypass gap and, consequently, the ratio of the first portion relative to the second portion.

Abstract: Well systems comprise communicating devices for use in subterranean formations. An example well system comprises a mud valve system having a stator and a rotor to modulate drilling mud flow to provide increased pulse amplitude signals up-hole for improved and faster signaling from down-hole tools while also providing for better detection capability up-hole. The improved signaling technique permits for deeper well applications.

Abstract: According to one embodiment, a mud pulse telemetry tool includes a body having a channel, a motor, and a valve coupled to the motor and disposed within the channel. The valve includes a plurality of lobes, with at least one of the plurality of lobes having a cavity formed therein.

Abstract: According to one embodiment, a mud pulse telemetry tool includes a body having a channel, a motor, and a valve coupled to the motor and disposed within the channel. The valve includes a plurality of lobes, with at least one of the plurality of lobes having a cavity formed therein.

Abstract: Methods and apparatus are disclosed for generating fluid pulses in a fluid column, such as within a well. A described example fluid pulse generator has a valve member comprising a piston that is linearly movable within a piston chamber to control flow by selectively obstructing a fluid passage. The fluid passage may extend around at least a portion of the piston chamber and intersect at an angle relative to the axis of movement of the valve member. The piston is linearly movable, such as from a closed or minimal-flow position to a maximal-flow position, and optionally to any of a number or range of positions therebetween. The position of the valve member may be varied to generate fluid pulses of a selected pattern of duration, amplitude, and so forth, to generate a signal within the fluid column detectable at a location remote from the fluid pulse generator.

Abstract: Well systems comprise communicating devices for use in subterranean formations. An example well system comprises a mud valve system having a stator and a rotor to modulate drilling mud flow to provide increased pulse amplitude signals up-hole for improved and faster signaling from down-hole tools while also providing for better detection capability up-hole. The improved signaling technique permits for deeper well applications.

Abstract: A downhole turbine assembly includes a stator housing having one or more stator blades positioned within the stator housing and extending radially inward therefrom. A rotor shaft having a first end and a second end is rotatably positioned within the stator housing and has a first portion exhibiting a first diameter and a second portion exhibiting a second diameter greater than the first diameter. One or more rotor blades are secured to the second portion for rotation with the rotor shaft, and a first bearing assembly is positioned at the first end and a second bearing assembly is positioned at the second end. At least one of the bearing housings provides a primary flow path and a secondary flow path, and one or more radial bearings and one or more thrust bearings are arranged in the secondary flow path.