Steering tools and drilling methods

Abstract

The present invention discloses a steering tool and a drilling method. A steering tool for use in a wellbore may include a tool housing having a bore and containing a guide cylinder, a guide vane, and an annular valve configured to control a fluid flowing to the guide cylinder. The annular valve may include a gearbox, a manifold coupling the bore fluid to the guide cylinder, a valve seat, a valve frame supporting the valve seat in a circumferential direction, an upper valve housing mechanically coupled to the gearbox, a lower valve housing mechanically coupled to the upper valve housing and reciprocatably coupled to the valve frame, and at least one biasing device located between the valve frame and the lower valve housing and configured to push the valve frame away from the lower valve housing.

Description

Technical Field

[0001] The present disclosure relates generally to downhole drilling tools, and particularly to energized annular valves for use therein. Background Art

[0002] When drilling a hydrocarbon production well, it may be necessary to maintain a specific drilling direction. Therefore, a steerable system may be utilized to control the direction of propagation of the wellbore. A typical steerable system may include a rotating portion, which includes the drill bit and any associated shaft, and a non-rotating portion, which remains substantially non-rotating relative to the surrounding formation.

[0003] Steerable drilling systems are generally classified as "spot drilling" or "press drilling" systems. In a spot drilling system, the axis of rotation of the drill bit is offset from the longitudinal axis of the drill string in the direction of the wellbore. The wellbore can be propagated according to a three-point geometry defined by the upper and lower contact points between the drill string and the wellbore (defined as the contact points) and the drill bit. The deflection angle of the drill bit axis, coupled with the distance between the drill bit and the lower contact point, results in a non-collinear condition that creates a curved wellbore as the drill bit advances through the formation. Summary of the invention

[0004] Some embodiments of a steering tool for use in a wellbore may include: a tool housing coupled to and positioned about a tubular mandrel having a bore therethrough, the tool housing being rotatable about the mandrel; a guide cylinder formed in the housing, wherein the guide cylinder may be fluidically coupled to a first guide port and contain fluid at a guide cylinder pressure; a guide vane coupled to the housing, the guide vane at least partially positioned within the guide cylinder, the guide vane being extendable to contact the wellbore by an extension force, wherein the extension force may be caused by a pressure differential between the guide cylinder pressure and a fluid pressure in the wellbore; and an annular valve. The annular valve may include: a gearbox; a manifold mechanically coupled to the tool housing, a valve seat, a valve frame mechanically coupled to the valve seat and having a valve frame upper surface and a valve frame lower surface, an upper valve housing mechanically coupled to the gearbox; a lower valve housing mechanically coupled to the upper valve housing and reciprocally coupled to the valve frame; at least one biasing device located between the valve frame and the lower valve housing and configured to push the valve seat away from the lower valve housing.

[0005] The manifold may include a manifold upper surface having at least one manifold orifice therein. The manifold orifice may provide fluid communication between the manifold upper surface and the first guide port, and may fluidly couple the orifice to the guide cylinder. The valve seat may have an annular lower surface positioned adjacent to the manifold upper surface. The valve seat may be rotatable relative to the manifold, and the annular lower surface may be configured such that rotation of the valve seat relative to the manifold selectively opens and closes the at least one manifold orifice. The valve carrier lower surface may circumferentially support the valve seat.

[0006] The valve rack may have an upper surface of the valve rack, and the lower valve housing may have a biasing surface configured to be supported on the upper surface of the valve rack. The biasing surface may include at least two receptacles, each of which is configured to accommodate a biasing device. The biasing surface may include at least sixteen receptacles, and the tool may include twelve biasing devices, each of which is partially accommodated in the receptacle and located between the valve rack and the lower valve housing. The tool may also include four sealing pins, each of which is partially accommodated in the receptacle and positioned between the valve rack and the lower valve housing. The receptacles may be evenly spaced around the circumference of the guide tool. Each biasing device may be selected from the group consisting of: a coil spring, a Belleville washer, an elastomeric member, and a leaf spring or a bow spring. The guide tool may also include a seal, an O-ring, a snap ring, and a thrust bearing between the lower valve housing and the upper valve housing.

[0007] In some embodiments, a method for drilling may include the following steps: a) providing a drill string including a downhole steering tool, b) using the downhole steering tool to guide while drilling, and c) using a pressure sensor to measure the pressure in the steering port and using the measured pressure to adjust the operation of the downhole steering tool.

[0008] A downhole steering tool may include a housing coupled to and positioned about a tubular mandrel, the housing being rotatable about the mandrel, the housing having a plurality of steering cylinders formed therein, each steering cylinder being fluidly coupled to a respective steering port; a plurality of steering vanes coupled to the housing, each steering vane being at least partially disposed within a respective steering cylinder, each steering vane being extendable by a pressure differential between a respective steering cylinder pressure and a pressure in a wellbore about the downhole tool, the pressure differential being caused by a fluid pressure in the respective steering port; a pressure sensor in at least one steering port; and an annular valve including a gearbox and a manifold mechanically coupled to the tool housing. The manifold may include a manifold upper surface having at least one manifold orifice therein, and the manifold orifice may provide fluid communication between the manifold upper surface and the steering port to fluidly couple the bore to the steering cylinder.

[0009] The annular valve may also include a valve seat having an annular lower surface positioned adjacent to the manifold upper surface. The valve seat may rotate relative to the manifold, and the annular lower surface may be configured such that rotation of the valve seat relative to the manifold selectively opens and closes at least one manifold orifice. The annular valve may also include a valve rack mechanically coupled to the valve seat and having an upper valve rack surface and a lower valve rack surface. The lower valve rack surface may support the valve seat in a circumferential direction. The annular valve may also include an upper valve housing mechanically coupled to the gearbox and a lower valve housing mechanically coupled to the upper valve housing and reciprocatingly coupled to the valve rack.

[0010] The annular valve may further include at least one biasing device located between the valve support and the lower valve housing and configured to push the valve support away from the lower valve housing.

[0011] In some embodiments, the downhole steering tool may include a pressure sensor in each guide port, and the method may include the following steps: d) using an annular valve to cause extension of the guide vane by controlling the pressure in each guide port; e) using the pressure measured in step c) as feedback to control the extension of the guide vane in step d). Additionally or alternatively, the method may include the following steps: d) using an annular valve to generate a pressure pulse shape for mud pulse telemetry, and e) using the pressure data measured in step c) as feedback to control the generation of the pressure pulse in step d). Additionally or alternatively, the method may include a step d) of using the pressure data measured in step c) to sense the mud pulse reaching the downhole tool. Additionally or alternatively, the method may include a step d) of using the pressure data measured in step c) to detect or diagnose a fault in the annular valve.

[0012] The downhole steering tool may include a pressure sensor in each guide port, and the method may further include using the pressure measured in step c) to perform at least two of the following: i) a steering feedback step, including ia) using an annular valve to cause extension of the guide vane by controlling the pressure in each guide port, and ib) using the pressure measured in step c) as feedback to control the extension of the guide vane in step ia); ii) a signal feedback step, including iia) using an annular valve to generate a pressure pulse shape for mud pulse telemetry; iib) using the pressure data measured in step c) as feedback to control the generation of the pressure pulse in step iia); iii) a sensing step, including using the pressure data measured in step c) to sense the mud pulse reaching the downhole tool; iv) a diagnostic step, including using the pressure data measured in step c) to detect or diagnose a fault in the annular valve.

[0013] Each of steps i), ii), iii) and iv) may be performed at least once during a single drilling operation. Step ib) may include adjusting the position of the valve seat relative to the manifold so as to adjust the fluid flow through at least one manifold orifice. Step iib) may include varying the valve movement speed. Step iv) may trigger a blockage relief step in which the annular valve opens and closes at least one manifold orifice. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The present disclosure can be best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, in accordance with standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of various features may be arbitrarily increased or reduced for clarity of discussion.

[0015] Figure 1 is a schematic diagram of a downhole steering tool in partial cross-section consistent with at least one embodiment of the present disclosure.

[0016] Figure 2A It is shown Figure 1 A schematic partial cross-sectional view of a construction of a downhole guidance tool.

[0017] Figure 2B It is located in the center of the wellbore Figure 1 Schematic cross-sectional view of a downhole guidance tool.

[0018] Figure 3A It is shown Figure 1 A schematic partial cross-sectional view of another construction of a downhole guidance tool.

[0019] Figure 3B It is located in the wellbore guide position. Figure 1 Schematic cross-sectional view of a downhole guidance tool.

[0020] Figure 4 is a cross-sectional view of a guide of a downhole steering tool consistent with at least one embodiment of the present disclosure.

[0021] Figure 5 is a perspective view of a manifold consistent with at least one embodiment of the present disclosure.

[0022] Figure 6 is a perspective view of an annular valve assembly consistent with at least one embodiment of the present disclosure.

[0023] Figure 7-8 is Figure 6 Exploded side view of the annular valve assembly.

[0024] Fig. 9 yes Figure 6 Isometric exploded view of the annular valve assembly.

[0025] Fig.10 yes Figure 6 End view of the annular valve assembly.

[0026] Figure 11 is along Fig.10 A cross section of line 11-11.

[0027] 12-13 are enlarged views of a portion of FIG. 11 .

[0028] Figure 14 is along Fig.10 A cross section of line 14-14.

[0029] FIG. 15 is an enlarged view of a portion of FIG. 14 .

[0030] Fig.16 is an enlarged view of a valve seat consistent with at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0031] It should be understood that the following disclosure provides many different embodiments or examples for realizing the different features of various embodiments. The following describes specific examples of components and arrangements to simplify the present disclosure. Of course, these are merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numbers and / or letters in various examples. This repetition is for the purpose of simplicity and clarity, and does not itself indicate the relationship between the various embodiments and / or configurations discussed.

[0032] like Figure 1 , a downhole steering tool 100 may be included as part of a drill string 10. In some embodiments, the downhole steering tool 100 may be included as part of a bottom hole assembly (BHA) of the drill string 10. In some embodiments, the downhole steering tool 100 may be positioned around a mandrel 12 as part of the drill string 10. The mandrel 12 may have a central hole 13 therethrough and may be coupled to a drill bit 14 and adapted to provide a rotational force thereto in order to drill a wellbore 15. In some embodiments, the mandrel 12 may be coupled to the drill string 10 such that rotation of the drill string 10 from the surface by, for example, but not limited to, a rotary table or a top drive causes rotation of the mandrel 12. In some embodiments, the mandrel 12 may be coupled to a downhole motor such as a mud motor or a downhole turbine (not shown) to provide a rotational force.

[0033] The downhole steering tool 100 may include a housing 101. In some embodiments, the housing 101 may be tubular or substantially tubular. The housing 101 may be positioned about the mandrel 12 and may be rotatably coupled thereto so that the mandrel 12 may rotate independently of the housing 101. In some embodiments, for example but not limited to, one or more bearings may be positioned between the housing 101 and the mandrel 12. Although shown as a single piece, those of ordinary skill in the art will appreciate, with the benefit of this disclosure, that the housing 101 may be formed from one or more pieces.

[0034] In some embodiments, the housing 101 may rotate at a speed that is less than the rotation rate of the drill bit 14 and the spindle 12. In some embodiments, the housing 101 may rotate at a speed that is less than the rotation speed of the spindle 12. For example, but not limited to, the housing 101 may rotate at a speed that is at least 50 RPM slower than the spindle 12. For example, but not limited to, in the case where the spindle 12 rotates at 51 RPM, the housing 101 may rotate at 1 RPM or less. In some embodiments, the housing 101 may be substantially non-rotating and may rotate at a speed that is less than a percentage of the rotation speed of the spindle 12. For example, but not limited to, the housing 101 may rotate at a speed that is less than 50% of the speed of the spindle 12. In some embodiments, the housing 101 may maintain the tool face orientation by being substantially non-rotating, regardless of the rotation of the drill string 10.

[0035] In some embodiments, the downhole steering tool 100 may include one or more guide vanes 103. The guide vanes 103 may be positioned around the periphery of the housing 101. The guide vanes 103 may extend radially to contact the wellbore 15. In some embodiments, the guide vanes 103 may be at least partially positioned within a corresponding guide cylinder 105 and may be sealed thereto. The guide cylinder 105 may be formed in the housing 101. In some embodiments, the guide cylinder 105 may be a cavity formed in the housing 101 in which the guide vanes 103 are at least partially positioned so that a fluid may flow into the guide cylinder 105 and apply a fluid pressure to the guide vanes 103. The fluid pressure (defined as the guide cylinder pressure) within each guide cylinder 105 may increase to be higher than the fluid pressure (defined as the wellbore pressure) in the surrounding wellbore 15, thereby causing a pressure differential on the guide vanes 103 located therein. The pressure differential may apply an extension force on the guide vanes 103. The extension force on the guide vanes 103 may push the guide vanes 103 to an extended position. When positioned within wellbore 15, the extension force may cause guide vanes 103 to contact the wall of wellbore 15. In some embodiments, guide vanes 103 may, for example but not limited to, at least partially prevent or arrest rotation of housing 101, for example but not limited to, less than 20 revolutions per hour.

[0036] In some embodiments, fluid may be supplied to each guide cylinder 105 through a guide port 107 formed in the housing 101. The fluid in each guide port 107 may be controlled by one or more adjustable orifices 109. The fluid may include, but is not limited to, drilling mud, such as oil-based drilling mud or water-based drilling mud, air, mist, foam, water, oil, including gear oil, hydraulic fluid, or other fluid within the wellbore 15. The adjustable orifice 109 may control the flow of fluid between the interior of the mandrel 12 and the guide port 107. In some embodiments, each guide cylinder 105 is controlled by an adjustable orifice 109. In some embodiments, one or more guide vanes 103 may be aligned around the downhole steering tool 100 and may be controlled by the same adjustable orifice 109. As used herein, "adjustable orifice" includes any valve or mechanism with an adjustable flow rate or flow restriction.

[0037] Fluid may be supplied to each adjustable orifice 109 from the bore 13 of the spindle 12. The adjustable orifice 109 may be in fluid communication with the bore 13 of the spindle 12. In some embodiments, for example and without limitation, one or more holes 111 may be formed in the spindle 12 and fluidly coupled to each adjustable orifice 109, thereby allowing fluid to flow to each adjustable orifice 109 when the spindle 12 rotates relative to the housing 101. In some embodiments, a flow diverter may be used, as discussed further below.

[0038] In some embodiments, the adjustable orifice 109 can be reconfigured between an open position and a partially open position. In some embodiments, the adjustable orifice 109 can further have a closed position. In the partially open position, the amount of fluid that can enter the corresponding guide cylinder 105 through the adjustable orifice 109 is less than the amount of fluid that can pass through in the fully open position. During certain operations, such as centering the downhole guide tool 100 within the wellbore 15, as schematically shown and not limited to Figure 2A In the structure in, each adjustable orifice 109a-d can be maintained in a partially open position. In some embodiments, the partially open position can allow between 0% and 50% of the flow rate of the open position, between 10% and 40% of the flow rate of the open position, or between 25% and 35% of the open position. Each adjustable orifice 109 can be in an open, partially open, or closed configuration independently of the other adjustable orifices 109. When the adjustable orifices 109 are all in the same configuration, each guide vane 103a-d can receive a substantially equal pressure differential thereon and can be extended to contact the wellbore 15 with approximately equal extension forces, graphically shown in the form of arrows depicting a first extension force f. The guide vanes 103a-d can therefore center the downhole steering tool 100 within the wellbore 15.

[0039] When pilot input is required, one or more adjustable orifices (in Figure 3A The adjustable orifice 109a′ shown in the figure can be fully opened. The adjustable orifices 109b-d that are not in the open position can be maintained in the partially open position. When the adjustable orifice 109a′ is in the open position, a larger amount of fluid may flow to the corresponding guide vane ( Figure 3B 103a'), so that the pressure difference on the guide vane 103a' is higher than the pressure difference on the other guide vanes 103, and thus a larger extension force is applied, which is represented as a second extension force F. The opposite guide vane (here 103c) (or multiple guide vanes, depending on the configuration) receives a smaller first extension force f, and its smaller extension can basically correspond to the larger extension of the guide vane 103a', resulting in the downhole steering tool 100 being pushed to the side of the wellbore 15 in the direction of the guide vane 103a'. The difference in extension force can therefore cause a change in the direction (referred to herein as the force vector direction) along which the downhole steering tool 100 is pushed relative to the wellbore 15, which in turn can change the drilling direction of the wellbore 15.

[0040] In some embodiments, when drilling a straight or nearly straight wellbore 15, all adjustable apertures 109a-d may be opened to apply substantially equal pressure to all guide vanes 103, thereby causing all guide vanes 103 to apply equal forces to the wellbore 15. Alternatively, when all adjustable apertures 109a-d are partially open, all guide vanes 103 may apply a gripping force to the wellbore 15.

[0041] In some embodiments, Figure 4 As shown in , fluid can be supplied from the interior of the mandrel 12 (shown as having two sub-components coupled to either side of the diverter assembly 141) through a diverter assembly 141. The fluid in the mandrel 12 can be supplied through the mandrel 12 by one or more pumps (not shown) at the surface, for example but not limited to operating one or more downhole tools and removing drill cuttings from the wellbore 15 during drilling operations. The fluid in the mandrel 12 can be at a higher pressure than the fluid in the wellbore 15. The diverter assembly 141 may include a diverter body 143 coupled to the mandrel 12 and rotatable with the mandrel 12. In some embodiments, the diverter assembly 141 may be integrally formed with the mandrel 12. In some embodiments, the diverter assembly 141 may include a drilling fluid filter 147. The diverter body 143 may include one or more holes 111 that couple the interior of the mandrel 12 to one or more fluid supply ports 106 formed in the housing 101. The fluid supply port 106 can supply fluid to an adjustable orifice 109, as described below. In some embodiments, approximately 4-5% of the fluid flow through mandrel 12 may be diverted by diverter assembly 141. In some embodiments, a portion of the diverted fluid may enter one or more bearings (not shown) and may exit the annulus around downhole steerable tool 100.

[0042] Reference again Figure 1In some embodiments, the downhole steering tool 100 may include a differential rotation sensor 112 and a housing rotation measuring device or sensor 116. The differential rotation sensor 112 may be used to measure the difference in rotation rate between the mandrel 12 and the housing 101. The housing rotation measuring device or sensor 116 may be used to measure the rotation rate of the housing 101. For example, in some embodiments, the differential rotation sensor 112 may include one or more infrared sensors, ultrasonic sensors, Hall effect sensors, fluxgate magnetometers, magnetoresistive magnetic field sensors, micro-electromechanical systems (MEMS) magnetometers, and / or pickup coils. The differential rotation sensor 112 may interact with one or more markers 114 coupled to the mandrel 12, such as infrared reflectors, ultrasonic reflectors, magnetic markers, permanent magnets, or electromagnets. The mandrel 12 may be, for example, but not limited to, one or more magnets or electromagnets to interact with the magnetic differential rotation sensor 112. The housing rotation measurement device or sensor 116 may include one or more accelerometers, magnetometers, and / or gyroscope sensors, including micro-electromechanical systems (MEMS) gyroscopes, MEMS accelerometers, Hall effect sensors, and / or other sensors that can measure lateral acceleration, magnetic field components, or a combination thereof. Gyroscope sensors and / or MEMS gyroscopes may be used to measure the rotational velocity of the housing 101 and irregular rotational velocity of the housing 101, such as torsional vibration and stick-slip.

[0043] Still refer to Figure 1, the accelerometers and magnetometers in the housing 101 can be used to calculate the tool face of the downhole steering tool 100. In some embodiments, the tool face of the downhole steering tool 100 can be referenced to a specific guide vane 103. In some embodiments, the tool face of the downhole steering tool 100 can be defined relative to a gravity field, referred to as a gravity tool face; defined relative to a magnetic field, referred to as a magnetic tool face; or a combination thereof. The differential rotation sensor 112 and the housing rotation measurement device or sensor 116 can be set at any position in the housing 101. The marker 114 can be set at a corresponding position on the mandrel 12, substantially adjacent to the differential rotation sensor 112. In some embodiments, a controller (not shown) can control the actuation of the adjustable orifice 109. The controller can include one or more microcontrollers, microprocessors, DSP (digital signal processing) chips, FPGAs (field programmable gate arrays), combinations of analog devices, such as analog integrated circuits (ICs), or any other device known in the art. In some embodiments, when the housing 101 rotates, the single guide vane or multiple guide vanes 103 that are substantially aligned with the target tool face change. The controller can be configured to actuate one or two adjacent guide vanes 103 to apply an eccentric guide force on the wellbore 15 to push the downhole guide tool 100 in a desired direction corresponding to the target tool face. In some embodiments, the guide vanes 103 not actuated by the controller can be extended to provide a gripping pressure when they are in a partially open position.

[0044] Pressure data sensors can be installed to measure fluid pressure at various points in the system and environment. The pressure data sensor may include a transducer or any other device capable of measuring pressure. By way of example only and not limitation, the following fluid pressures may be measured: annular pressure, internal pressure, annular valve pressure, manifold fluid pressure, compensating fluid pressure, or pad piston pressure. Pad piston pressure may be measured by a pressure sensor positioned in one or more guide ports 107, and the pad piston pressure indicates the force applied to each guide vane 103. In an embodiment where pad piston pressure is to be measured, the pressure sensor may be positioned to measure fluid pressure in one or more guide ports 107 or adjacent to one or more orifices 109. (For example, for three pads, four pads, or more pads), and so on. By way of example only, a suitable miniature pressure data recorder is described in U.S. Patent Application 20180066513 "Drilling Dynamics Data Recorder", which includes a pressure transducer and various drilling dynamics sensors. Optionally, these pressure recorders may be connected to a main controller of the rotary steerable system via a communication bus, and the main controller may be able to utilize the pressure data to better control the tool face (steering direction) and steering forces (folding line).

[0045] The annular valve system has a position sensor that allows precise control of the adjustable orifice position during normal operation. However, due to various circumstances, the pressure actually applied to each pad face may deviate from the expected pressure. Deviations may be caused, for example, by position sensor drift, misalignment of valve components, or debris in one or more fluid channels. With the help of a pressure sensor installed, for example, in each pad piston, the pad pressure can be fine-tuned to control the tool face and breakline, thereby improving control of the wellbore trajectory. The force is the pressure multiplied by the cross-sectional area of ​​the piston. In this case, the cross-sectional area is constant. Therefore, the force is essentially proportional to the applied pressure.

[0046] In addition, the RSS master controller / processor can optionally use the pressure sensor data of each pad to detect or diagnose valve blockage and / or piston blockage events. In this case, the processor can be programmed to execute a pre-programmed blockage mitigation algorithm, such as closing all orifices and opening orifices sequentially or simultaneously. For example, if a leaking valve is detected, that is, the valve is closed, but there is still piston pressure, the valve can be passed through a pre-programmed sequence to try to eliminate the cause of the problem. For example, the valve can be moved through the open / closed position of each orifice.

[0047] Another application of pad pressure information is in annular valve telemetry. Optionally, pressure transducer data can be transmitted to the surface via short jump and MWD mud pulse telemetry. Pressure transducer data can be used as feedback for the generation of an expected pressure waveform (e.g., a sine wave pressure pulse). Control based on pressure transducer data can be achieved by adjusting the valve movement speed based on the pressure difference between the measured valve top pressure and the piston pressure. The valve movement speed can be changed by adjusting the motor speed.

[0048] To generate the desired mud pressure change to signal, the annular valve can be moved from a fully closed position to a fully open position, where all four pads are actuated. The fully closed position produces the highest pressure value (telemetered upward), and the fully open position produces the lowest pressure value. By monitoring the valve top pressure or alternatively the pressure of all pads / pistons, the valve movement speed can be precisely controlled to produce the desired mud pulse waveform.

[0049] Optionally, pressure sensor data can be transmitted to the surface via short-hop and MWD mud pulse telemetry. The transmitted pressure data can be used to optimize the operation of the RSS and / or for diagnostics of the tool, such as calculating equivalent circulating density, identifying drilling fluid loss, detecting drill bit nozzle failures, etc.

[0050] RSS commands or other information may be sent from the surface. Optionally, a pressure transducer may be used to detect such flow rate and / or fluid pressure modulation downlink from the surface. For example, flow rate may be manually changed at the surface based on a coded sequence to give a downlink command or send a data point to the RSS. In some embodiments, the pad pressure data may include the received signal; in other embodiments, it may be used in conjunction with one or more secondary sensors elsewhere in the tool to improve the accuracy of the received signal.

[0051] Thus, the pad pressure data can be used to support various feedback, diagnostic, and sensing steps. For example, the pad pressure data can be used in a guide feedback step, which includes using an annular valve to cause the guide vane to extend by controlling the pressure in each guide port, and using the pad pressure data as feedback to control the extension of the guide vane. As another example, the pad pressure data can be used in a signaling feedback step, which includes using an annular valve to generate a pressure pulse shape for mud pulse telemetry, and using the pad pressure data as feedback to control the generation of the pressure pulse. As another example, the pad pressure data can be used in a sensing step, which includes using the pad pressure data to sense the mud pulse reaching the downhole tool. As another example, the pad pressure data can be used in a diagnostic step, which includes using the pressure data to detect or diagnose a fault in the annular valve.

[0052] Brief reference Figure 5 and Figure 6 , the fluid flow through the adjustable orifice 109 can be controlled by an annular valve assembly 215 working in conjunction with a manifold 217. As described in the commonly owned U.S. Patent 10,422,184, which is incorporated herein by reference in its entirety, the manifold 217 can be generally tubular and can include a manifold upper surface 219. The manifold upper surface 219 can be continuous, or can include one or more cutouts as shown. The manifold 217 may include a plurality of manifold orifice groups 221 arranged around the manifold upper surface 219. In some embodiments, each manifold orifice group 221 can be fluidly coupled to a single adjustable orifice 109. Each manifold orifice group 221 can also be fluidly coupled to a corresponding guide port 107. Each manifold orifice group 221 may include two or more orifices, and the two or more orifice manifold orifice groups may include one or more guide manifold orifices and one or more grip manifold orifices. In operation, the orifice can be selectively exposed to the fluid flow by adjusting the annular valve assembly 215.

[0053] Referring now to FIGS. 7-9, the annular valve assembly 215 may include a valve seat 150, a valve frame 160, a lower valve housing 170, an upper valve housing 180, an alignment pin 181, a gear box 190, a shaft housing assembly 200, and a seal 202. In some embodiments, the valve seat 150 may be made of a durable material such as carbide, including but not limited to tungsten carbide, titanium carbide, ceramic, and synthetic diamond. The upper valve housing 180 may include an outer shoulder 189. A second seal 182, an O-ring 184, a snap ring 186, and a bidirectional thrust bearing 188 may be located between the lower valve housing 170 and the upper valve housing 180. The snap ring 186 may hold the thrust bearing 188 in a desired position by engaging the shoulder 189 on the upper valve housing 180.

[0054] As in Figure 6 , Fig. 9 and Fig.10 As best shown in the figure, the valve seat 150, valve frame 160, lower valve housing 170, second seal 182, O-ring 184, retaining ring 186 and thrust bearing 188, upper valve housing 180, shaft housing assembly 200 and seal 202 can be concentrically arranged and housed in the gear box 190 to form an annular valve assembly 215.

[0055] It may be desirable to maintain alignment and tight clearance between the upper valve housing 180 and the gearbox 190. In some embodiments, the components may be bolted together. In addition, it may be desirable to transfer loads from the lower valve housing 170 to the upper valve housing 180 via the thrust bearing 188.

[0056] Referring now to FIG. 12 , the valve frame 160 can have an upper surface 160 b and a lower surface 160 a, respectively. The valve frame 160 can be mechanically coupled to the valve seat 150 by one or more coupling pins 162, which can extend radially through the opening 158 in the side wall of the valve frame 160 into the valve seat 150. The valve seat 150 can be shrink-fitted into the valve frame 160 by interference. During the shrink-fit process, the coupling pins 162 are used to maintain the valve seat 150 in a proper alignment. The valve frame lower surface 160 a can be configured to support the valve seat 150 over the entire circumference of the valve seat 150.

[0057] In some embodiments, the lower valve housing 170 may include a lower surface, hereinafter referred to as an offset surface 170a. The timing pin 164 may mechanically engage the valve frame 160 and the lower valve housing 170. The timing pin 164 may be substantially longitudinal. The lower end 164a of the timing pin 164 may be received in and / or substantially permanently fixed to the valve frame 160. The opposite end of the timing pin 164, i.e., the upper end 164b, may be slidably received in a corresponding receiving portion 174 in the offset surface 170a of the lower valve housing 170. The size of the receiving portion 174 may be set so that some longitudinal movement of the timing pin 164 is possible. In these embodiments, the valve frame 160 can move longitudinally relative to the lower valve housing 170, but is prevented from rotating or moving laterally relative to the lower valve housing 170.

[0058] As also shown in FIGS. 12 and 13 , one or more fasteners 176 may be used to rigidly couple the lower valve housing 170 to the upper valve housing 180 and sandwich the second seal 182, the O-ring 184, the snap ring 186, and the bidirectional thrust bearing 188 therebetween. Each fastener 176 may include a screw or other suitable device. The fastener 176 is preferably removable to allow disassembly of the annular valve assembly 215. In some embodiments, there may be a plurality of fasteners 176; in the illustrated embodiment, eight fasteners 176 are used. In other embodiments, other numbers of fasteners may be provided.

[0059] Referring now to FIG. 13 , one or more sealing pins 166 may also extend between the valve frame 160 and the lower valve housing 170. The lower end 166a of each sealing pin 166 may be received in the valve frame 160 and / or substantially permanently fixed to the valve frame 160. The upper end 166b of each sealing pin 166 may be slidably received in a corresponding receiving portion 177 in the lower valve housing 170. The timing pins 164 ensure that the valve is properly aligned with the manifold ( Figure 5 ). The sealing pin 166 ensures proper alignment and reduces radial movement in the valve. In some embodiments, there may be multiple sealing pins 166; in the illustrated embodiment, four sealing pins 166 are used. Using multiple sealing pins can reduce the possibility of jamming in the event of misalignment.

[0060] Referring now to FIGS. 14-15 , in some embodiments, one or more biasing devices 168 may also be included between the valve frame 160 and the lower valve housing 170. The biasing devices 168 are used to separate the valve frame 160 from the lower valve housing 170. To this end, the biasing devices 168 may include any device capable of elastically deforming when compressed, including but not limited to a coil spring, a Belleville washer, an elastomeric member, and a leaf spring or bow spring. In some embodiments, a first end of each biasing device 168 may be received in a corresponding receiving portion 169 in the valve frame 160 and / or substantially permanently fixed to the valve frame 160, and a second end of each biasing device 168 may be received in a corresponding receiving portion 179 in the lower valve housing 170.

[0061] The accommodating portions 177 and 179 in the lower valve housing 170 can be identical, and each accommodating portion can accommodate a sealing pin 166 or a biasing device 168. In some embodiments, there can be multiple sealing pins 166 and biasing devices 168; in the illustrated embodiment, the lower valve housing 170 includes sixteen accommodating portions evenly spaced around the biasing surface 170a, and four sealing pins 166 and twelve biasing devices 168 are accommodated in the accommodating portions. The number and relative proportions of the sealing pins 166 and biasing devices 168 can be changed as desired and are limited only by the number of accommodating portions provided. In embodiments with more than one biasing device 168, the biasing devices can be evenly spaced around the circumference of the tool. The sealing pin 166 ensures that the centerline of the annular valve is always aligned with the centerline of the manifold. In addition, the sealing pin 166 ensures that the annular valve surface and the manifold surface are parallel. The biasing device 168 maintains contact between the two surfaces.

[0062] The sealing pin 166 and the biasing device 168 together provide a balanced and distributed force that pushes the valve frame 160 away from the lower valve housing 170. The force acting on the valve frame 160 ensures that the fluid passage through the annular valve assembly 215 remains closed when required. One advantage of the energized valve is that when it is operated at a pressure drop less than the required pressure drop (for example, 400psi instead of the recommended 600psi), the valve will still activate the appropriate pads / vanes. This device ensures that the valve is pressed against the manifold surface, avoiding accidental or undesirable pad activation. The device also provides consistent operation even when tilted or affected by downhole dynamics; the valve remains pressed against the manifold, ensuring the correct activation of the required pads.

[0063] Due to the movement allowed between the valve frame 160 and the lower valve housing 170, the lower valve housing 170, the second seal 182, the O-ring 184, the snap ring 186, the thrust bearing 188 and the upper valve housing 180 can be securely coupled and sealed together, and the tolerances between the upper valve housing 180 and the gear box 190 can be tightened. For example, the components can be machined to fit and / or shimmed to fit.

[0064] Brief reference Fig.16 In some embodiments, the valve seat 150 may include a ring lower surface 151 having one or more radial grooves 152. The inner surface of the valve seat 150 may also include one or more inwardly extending bosses 155, and the upper surface of the valve seat 150 may include a notch 157. When the boss 155 is located above the manifold port, the boss 155 cuts off the drilling fluid to the control pad, thereby allowing the tool to have a "fully closed" position. The notch 157 accommodates the coupling pin 162 during the shrink fit process. This ensures that the valve is properly aligned.

[0065] When the tool is fully assembled, the ring lower surface 151 can abut the manifold upper surface 219 so that when the groove 152 is aligned with one or more orifices of the manifold orifice set 221, fluid can flow from the fluid supply port 106 coupled to the interior of the mandrel 12 through the aligned orifices, as previously discussed. In some embodiments, the groove 152 can be arranged so that the valve seat 150 only needs to be rotated a partial turn to actuate the adjustable orifice 109. In some embodiments, the groove 152 can be arranged around the valve seat 150 so that the adjustable orifices 109 opposite to each other are not opened at the same time. In some embodiments, the groove 152 can be arranged so that adjacent adjustable orifices 109 can be opened simultaneously. Thus, the annular valve assembly 215 can be used to control the flow of any fluid flowing through the mandrel 12.

[0066] The annular valve assembly 215 may be actuated by a motor and pinion that engages the rear of the gearbox 190, generally indicated at 241. The motor and pinion may be controlled by a controller (not shown) to move the slots 152 into and out of alignment with the manifold orifice set 221. In some embodiments, the valve seat 150 may rotate one or more full revolutions. The controller may include, for example, but not limited to, a combination of one or more microcontrollers, microprocessors, DSP (digital signal processing) chips, FPGAs (field programmable gate arrays), analog devices such as analog integrated circuits (ICs), or any other device known in the art that may be programmed with motor controller logic and algorithms, including angular position controller logic and algorithms.

[0067] When the annular valve assembly 215 is actuated and unactuated in its various open positions, the biasing device 168 applies a constant and distributed load to the valve frame 160, thereby serving to maintain contact between the valve seat 150 located on the valve frame 160 and the manifold 217. This in turn maintains the desired fluid flow path through the tool.

[0068] In some embodiments, the downhole steering tool 100 can transmit data to the surface. In some embodiments, for example but not limited to, a series of pressure pulses can be used to transmit communication signals. The pressure pulses can be generated by opening and closing one or more pilot ports 107 through the annular valve assembly 215.

[0069] In some embodiments, pressure pulses may be used to transmit binary signals. In some embodiments, Manchester encoding may be used to transmit data to the surface including, but not limited to, inclination, azimuth, case gravity / magnetic tool face, target tool face, actual tool face, case speed, bit speed, shock / vibration intensity, stick-slip severity, high frequency torsional vibration (HFTO) severity, temperature, pressure, other diagnostic information, etc. The advantage of the present device is that it makes the pressure pulse signal consistent and reliable in size by maintaining the desired fluid flow path through the tool.

[0070] The features of several embodiments are summarized above so that those of ordinary skill in the art can better understand the various aspects of the present disclosure. Such features can be replaced by any of a number of equivalent alternatives, only some of which are disclosed herein. Those of ordinary skill in the art should understand that they can easily use the present disclosure as a basis for designing or modifying other processes and structures to achieve the same purposes and / or achieve the same advantages as the embodiments introduced herein. Those of ordinary skill in the art will also understand that such equivalent constructions do not depart from the scope of the present disclosure, and that they can make various changes, substitutions and modifications to the devices disclosed herein without departing from the scope of the present disclosure.

Claims

1. A steering tool for a wellbore, comprising: a tool housing coupled to and positioned about a tubular mandrel having a bore therethrough, the tool housing being rotatable about the tubular mandrel; a guide cylinder formed in the tool housing, wherein the guide cylinder is fluidly coupled to the first guide port and contains fluid at a guide cylinder pressure; a guide vane coupled to the tool housing, the guide vane being at least partially positioned within the guide cylinder, the guide vane being extendable to contact the wellbore by an extension force, wherein the extension force is caused by a pressure differential between the guide cylinder pressure and a fluid pressure in the wellbore; and An annular valve, the annular valve comprising: Gearbox; a manifold mechanically coupled to the tool housing, wherein the manifold includes a manifold upper surface having at least one manifold orifice therein, wherein the manifold orifice provides fluid communication between the manifold upper surface and the first guide port and fluidly couples the bore of the tubular mandrel to the guide cylinder; a valve seat having an annular lower surface positioned adjacent to the manifold upper surface, wherein the valve seat is rotatable relative to the manifold, and wherein the annular lower surface is configured such that rotation of the valve seat relative to the manifold selectively opens and closes at least one manifold orifice; a valve frame mechanically coupled to the valve seat and having a valve frame upper surface and a valve frame lower surface, wherein the valve frame lower surface circumferentially supports the valve seat; An upper valve housing mechanically coupled to the gearbox; a lower valve housing mechanically coupled to the upper valve housing and reciprocably coupled to the valve frame; and At least one biasing device is located between the valve support and the lower valve housing and is configured to urge the valve support away from the lower valve housing.

2. The guide tool according to claim 1, wherein: The lower valve housing has a biasing surface configured to be supported on the upper surface of the valve frame, and wherein the biasing surface includes at least two receiving portions respectively configured to receive biasing devices.

3. The guide tool according to claim 2, wherein: The biasing surface includes at least sixteen receptacles, wherein the tool includes twelve biasing devices, each biasing device being partially received in a receptacle and positioned between the valve carrier and the lower valve housing.

4. The guide tool according to claim 3, wherein: The tool further includes four sealing pins, each of which is partially received in the receiving portion and is located between the valve frame and the lower valve housing.

5. The guide tool according to claim 2, wherein: The receptacles are evenly spaced around the circumference of the guide tool.

6. The guide tool according to claim 1, wherein: Each biasing device is selected from the group consisting of: a coil spring, a Belleville washer, an elastomeric member and a leaf spring or bow spring.

7. The guide tool according to claim 1, further comprising a seal, an O-ring, a snap ring and a thrust bearing between the lower valve housing and the upper valve housing.

8. The guide tool of claim 1, comprising at least one pressure sensor in the guide port.

9. The guide tool of claim 1, further comprising a plurality of guide openings formed in the tool housing, wherein: Each pilot port includes a pressure sensor.

10. A downhole steering tool comprising: a housing connected to and positioned about a tubular mandrel having a bore therethrough, the housing being rotatable about the tubular mandrel, the housing having a guide cylinder formed therein, the guide cylinder being fluidly coupled to the guide port; a guide vane coupled to the housing, the guide vane being at least partially positioned within the guide cylinder, the guide vane being extendable to contact the wellbore by an extension force caused by a pressure differential between the guide cylinder pressure and a pressure in the wellbore surrounding the downhole tool, the pressure differential being caused by a fluid pressure of a fluid within the guide cylinder; a pressure sensor in the guide port, and An annular valve, the annular valve comprising: Gearbox; a manifold mechanically coupled to a tool housing, wherein the manifold includes a manifold upper surface having at least one manifold orifice therein, wherein the manifold orifice provides fluid communication between the manifold upper surface and the guide port to fluidly couple the bore of the tubular mandrel to the guide cylinder; a valve seat having an annular lower surface positioned adjacent to the manifold upper surface, wherein the valve seat is rotatable relative to the manifold, and wherein the annular lower surface is configured such that rotation of the valve seat relative to the manifold selectively opens and closes at least one manifold orifice; a valve frame mechanically connected to the valve seat and having a valve frame upper surface and a valve frame lower surface, wherein the valve frame lower surface circumferentially supports the valve seat; an upper valve housing mechanically connected to the gearbox; and A lower valve housing is mechanically coupled to the upper valve housing and reciprocatably coupled to the valve frame.

11. A drilling method comprising the following steps: a) providing a drill string including a downhole steering tool, the downhole steering tool comprising: a housing coupled to and positioned about a tubular mandrel having a bore therethrough, the housing being rotatable about the tubular mandrel, the housing having a plurality of guide cylinders formed therein, each guide cylinder being fluidly coupled to a respective guide port; a plurality of guide vanes coupled to the housing, each guide vane being at least partially disposed within a corresponding guide cylinder, each guide vane being extendable by a pressure differential between a corresponding guide cylinder pressure and a pressure in a wellbore surrounding the downhole tool, the pressure differential being caused by a fluid pressure in a corresponding guide port; at least one pressure sensor in the pilot port, and An annular valve, the annular valve comprising: Gearbox; a manifold mechanically coupled to a tool housing, wherein the manifold includes a manifold upper surface having at least one manifold orifice therein, wherein the manifold orifice provides fluid communication between the manifold upper surface and the guide port to fluidly couple the bore of the tubular mandrel to the guide cylinder; a valve seat having an annular lower surface positioned adjacent to the manifold upper surface, wherein the valve seat is rotatable relative to the manifold, and wherein the annular lower surface is configured such that rotation of the valve seat relative to the manifold selectively opens and closes at least one manifold orifice; a valve frame mechanically coupled to the valve seat and having a valve frame upper surface and a valve frame lower surface, wherein the valve frame lower surface circumferentially supports the valve seat; an upper valve housing mechanically coupled to the gearbox; and a lower valve housing mechanically coupled to the upper valve housing and reciprocatably coupled to the valve frame; b) using downhole steering tools for steering during drilling; and c) Using a pressure sensor to measure the pressure in the steering port and using the measured pressure to adjust the operation of the downhole steering tool.

12. The method according to claim 11, wherein: The downhole steering tool includes a pressure sensor in each steering port, and further includes the following steps: d) extending the guide vanes using the annular valve by controlling the pressure in each guide port; and e) using the pressure measured in step c) as feedback to control the extension of the guide vanes in step d).

13. The method according to claim 11, further comprising the steps of: d) using the annular valve to generate a pressure pulse shape for mud pulse telemetry; as well as e) using the pressure data measured in step c) as feedback to control the generation of the pressure pulses in step d).

14. The method according to claim 11, further comprising the steps of: d) Using the pressure data measured in step c) to sense mud pulses reaching the downhole tool.

15. The method according to claim 11, further comprising the steps of: d) Using the pressure data measured in step c) to detect or diagnose a fault in the annular valve.

16. The method according to claim 11, wherein: The annular valve further comprises at least one biasing device located between the valve frame and the lower valve housing and configured to push the valve frame away from the lower valve housing, and wherein the downhole steering tool comprises a pressure sensor in each steering port, and further comprises using the pressure measured in step c) to perform at least two of the following: i) Guidance feedback steps, including: ia) extending the guide vanes using the annular valve by controlling the pressure in each guide port; and ib) using the pressure measured in step c) as feedback to control the extension of the guide vanes in step ia); ii) Signaling feedback step, including: iia) using the annular valve to generate a pressure pulse shape for mud pulse telemetry; and iib) using the pressure data measured in step c) as feedback to control the generation of the pressure pulses in step iia); and iii) a sensing step, comprising: using the pressure data measured in step c) to sense mud pulses reaching the downhole tool; iv) Diagnostic steps, including: The pressure data measured in step c) is used to detect or diagnose a malfunction of the annular valve.

17. The method according to claim 16, wherein: Each of steps i), ii), iii) and iv) is performed at least once during a single drilling operation.

18. The method according to claim 16, wherein: Step ib) comprises adjusting the position of the valve seat relative to the manifold so as to regulate fluid flow through at least one manifold orifice.

19. The method according to claim 16, wherein: Step iib) comprises varying the speed of movement of the valve.

20. The method according to claim 16, wherein: Step iv) triggers a blockage relief step in which the annular valve opens and closes at least one manifold orifice.

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