Abstract: A rotary valve can include a seat and a rotary actuator, each with a surface, the rotary actuator rotatably mounted to a housing. The surfaces can form a seal due to their engagement with an engagement force used to maintain the engagement. One biasing device can elevate pressure in a sealed volume in the valve at a constant level above an external pressure. The elevated pressure can produce a pressure differential across the rotary actuator, thereby producing at least a portion of the engagement force. Another biasing device can act between a splined hub and a mated splined shaft, thereby applying at least a portion of the engagement force through the shaft to the rotary actuator. Fluid flowing through a screen can create a pressure drop, thereby causing a pressure differential across the rotary actuator and applying at least a portion of the engagement force to the surfaces.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: Methods of manufacturing monolithic components with complex design features and functionally graded properties in any spatial direction may include forming of outer shell with an additive manufacturing process, loading the shell with bulk material and exposing the loaded shell to a hot isostatic pressing (HIP) process. The combination of the additive manufacturing process and the HIP process forms a diffusion bond between the outer shell and the bulk material resulting in a monolithic component with functionally graded properties. The outer shell may include an exterior surface and an inner passage formed with relatively hard surfaces to accommodate fluids in a wellbore.

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 directional drilling system includes a rotary steerable tool. The rotary steerable tool includes an extendable member configured to extend outwardly from the rotary steerable tool upon actuation, and a geolocation electronics device configured to track a position of the rotary steerable tool and the extendable member and control actuation of the extendable member. The geolocation electronics device and extendable member are configured to rotate with the rotary steerable tool.

Abstract: Rotary steerable drilling systems are subjected to harsh environments including high temperature and pressure. A metallic seal ring prevents or limits erosive wear by limiting the velocity of the fluid that traversers from the high pressure side of the metallic seal ring to the low pressure side of the metallic seal ring to a value that can be sustained by the material of the metallic seal ring. A metallic seal ring is capable of withstand the wear and tear of drilling mud or other fluids used for downhole drilling operations. A metallic seal ring includes a mating configuration that creates a seal as the metallic seal ring is contracted when or a tension is applied when disposed or positioned in the piston bore. The metallic seal ring maintains an adequate seal to protect the components of a pad assembly over the life or specified duration of a downhole drilling operation.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.

Abstract: A directional drilling system includes a rotary steerable tool. The rotary steerable tool includes an extendable member configured to extend outwardly from the rotary steerable tool upon actuation, and a geolocation electronics device configured to track a position of the rotary steerable tool and the extendable member and control actuation of the extendable member. The geolocation electronics device and extendable member are configured to rotate with the rotary steerable tool.

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: An actuation system to control flow of a fluid includes a body including an axial cavity and a valve in fluid communication with the axial cavity, the valve including a closing member moveable into and out of a closed position against the valve seat, and a resistance member. Fluid from the axial cavity can flow through and out of the valve when the closing member is out of the closed position and the closing member is biased into or out of the closed position by a force applied by the resistance member. The closing member is movable out of or into the closed position upon a rotational speed and fluid pressure within the axial cavity being sufficient to overcome the force applied by the resistance member.

Abstract: An example method for control of a drilling assembly includes receiving measurement data from at least one sensor coupled to an element of the drilling assembly positioned in a formation. An operating constraint for at least a portion of the drilling assembly may be determined based, at least in part, on a model of the formation and a set of offset data. A control signal may be generated to alter one or more drilling parameters of the drilling assembly based, at least in part, on the measurement data and the operating constraint. The control signal may be transmitted to a controllable element of the drilling assembly.

Abstract: Rotary steerable drilling systems are subjected to harsh environments including high temperature and pressure. A metallic seal ring prevents or limits erosive wear by limiting the velocity of the fluid that traversers from the high pressure side of the metallic seal ring to the low pressure side of the metallic seal ring to a value that can be sustained by the material of the metallic seal ring. A metallic seal ring is capable of withstand the wear and tear of drilling mud or other fluids used for downhole drilling operations. A metallic seal ring includes a mating configuration that creates a seal as the metallic seal ring is contracted when or a tension is applied when disposed or positioned in the piston bore. The metallic seal ring maintains an adequate seal to protect the components of a pad assembly over the life or specified duration of a downhole drilling operation.

Abstract: A system for controlling a downhole component within a borehole, the system including a transfer assembly coupled between a rotatable component and the downhole component, the transfer assembly including a swash plate assembly configured to control the downhole component and a member configured to engage the swash plate assembly. The member is configured to move radially based upon a rotational speed of the rotatable component to selectively engage the swash plate assembly.

Abstract: A directional drilling system includes a rotary steerable tool. The rotary steerable tool includes an extendable member configured to extend outwardly from the rotary steerable tool upon actuation, and a geolocation electronics device configured to track a position of the rotary steerable tool and the extendable member and control actuation of the extendable member. The geolocation electronics device and extendable member are configured to rotate with the rotary steerable tool.

Abstract: A rotary valve with increased resistance to degradation that can include, a manifold with multiple flow paths, a rotary actuator rotatably mounted within the valve, and a valve seat that is fixedly attached to the manifold, with an end (or component) of the rotary actuator made from silicon carbide diamond (ScD) and the end having a first surface. The valve seat can have a second surface that sealingly engages the first surface. Manufacturing a rotary valve can include combining diamond particles in a press with silicon and applying temperature and pressure to produce a piece of ScD. Interposing a compound between the piece and a structure and brazing them by heating the compound between 700-1200 degrees Celsius. Forming ports and flow paths in the piece by machining the piece with an Electrical Discharge Machining (EDM) tool.

Abstract: A rotary valve can include a seat and a rotary actuator, each with a surface, the rotary actuator rotatably mounted to a housing. The surfaces can form a seal due to their engagement with an engagement force used to maintain the engagement. One biasing device can elevate pressure in a sealed volume in the valve at a constant level above an external pressure. The elevated pressure can produce a pressure differential across the rotary actuator, thereby producing at least a portion of the engagement force. Another biasing device can act between a splined hub and a mated splined shaft, thereby applying at least a portion of the engagement force through the shaft to the rotary actuator. Fluid flowing through a screen can create a pressure drop, thereby causing a pressure differential across the rotary actuator and applying at least a portion of the engagement force to the surfaces.

Abstract: A rotary steerable drilling tool and a method according to which a universal joint is sealed. In one embodiment, the method includes providing the collar, the shaft, the universal joint, and first and second shoulders between which the universal joint is positioned; providing first and second self-energizing seals between the collar and the shaft on opposite sides of the universal joint; rotating the collar and the shaft; seating the first self-energizing seal against the first shoulder; and seating a second self-energizing seal against the second shoulder. In one embodiment, the universal joint includes a convex surface formed on the shaft; a first concave surface extending circumferentially about the shaft and adapted to mate with the convex surface to carry a first axial load; and a spacer ring defining a second concave surface adapted to mate with the convex surface to carry a second axial load.

Abstract: A directional drilling system includes a rotary steerable tool. The rotary steerable tool includes an extendable member configured to extend outwardly from the rotary steerable tool upon actuation, and a geolocation electronics device configured to track a position of the rotary steerable tool and the extendable member and control actuation of the extendable member. The geolocation electronics device and extendable member are configured to rotate with the rotary steerable tool.

Abstract: A rotary valve can include a housing, a manifold with multiple flow paths can be fixedly mounted to the housing. A rotary actuator with a first surface can be rotatably mounted within the housing, and a valve seat with a second surface can be fixedly attached to the manifold, where the second surface can sealingly engage the first surface. The rotary actuator can include a gap that selectively aligns with respective ones of valve seat ports as the rotary actuator rotates relative to the valve seat, thereby selectively pressurizing one or more actuators. A system and method can include a rotary valve that selectively causes pads to extend at a predetermined orientation in the wellbore to steer a drill bit. The azimuthal orientation of a rotary actuator of the valve can determine which pads are extended and which are retracted as the drill bit rotates.