Pressure regulators for downhole tools

Abstract

A downhole tool comprises a housing and a housing chamber. The housing chamber is separated from a fluid chamber by a seal. The seal maintains a pressure difference between the housing chamber and the fluid chamber. A pressure regulator between the housing chamber and the fluid chamber maintains the pressure difference below a maximum pressure difference.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Non-Provisional Application No. 62 / 842,836, filed on May 3, 2019, entitled “Pressure Adjuster for a Downhole Tool,” the disclosure of which is incorporated herein by reference. Background Art

[0003] Wellbores may be drilled into a surface location or seabed for various exploration or extraction purposes. For example, wellbores may be drilled to access fluids stored in underground formations, such as liquid and gaseous hydrocarbons, and to extract fluids from the formations. Wellbores used to produce or extract fluids may be lined with casing surrounding the wellbore walls. A variety of drilling methods may be utilized depending in part on the characteristics of the formation through which the wellbore is drilled.

[0004] Wellbores can be drilled by a drilling system that bores downward from the surface through earthen materials. Some wellbores are drilled vertically downward, and some wellbores have one or more bends in the wellbore to follow desired geological formations, avoid problematic geological formations, or a combination of both. Summary of the invention

[0005] In some embodiments, a downhole tool includes a housing, wherein a housing chamber is located inside the housing. A fluid chamber is located outside the housing. A seal separates the housing chamber from the fluid chamber, and the seal at least partially maintains a pressure difference between the housing chamber and the fluid chamber. A pressure regulator between the housing chamber and the fluid chamber maintains the pressure difference below a maximum pressure difference.

[0006] In other embodiments, a downhole tool includes a housing, wherein a housing chamber is located inside the housing. A partition connected to the housing separates a fluid chamber outside the housing from the housing chamber. The partition prevents particles from passing between the housing chamber and the fluid chamber. A pressure regulator between the housing chamber and the fluid chamber maintains the pressure differential below a maximum pressure differential.

[0007] In other embodiments, a downhole tool includes a housing having a first end and a second end. A movable member is connected to the housing at the first end of the housing by a bearing. The bearing has a gap of less than 500 μm between the bearing and the movable member. The movable member is capable of rotating relative to the housing. The movable member includes a central support. A bearing surface at the second end inside the housing supports the central support.

[0008] This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0009] Other features and advantages of the embodiments of the present disclosure will be set forth in the following description and will be apparent in part from the description or may be understood by the practice of such embodiments. The features and advantages of such embodiments may be realized and obtained by means of the instruments and combinations specifically indicated in the appended claims. These and other features will become more fully apparent from the following description and the appended claims or may be understood by the practice of such embodiments as set forth below. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] In order to describe the manner in which the above-mentioned features and other features of the present disclosure can be obtained, a more specific description will be presented by reference to specific embodiments of the present disclosure shown in the accompanying drawings. For better understanding, the same elements have been represented by the same reference numerals throughout the various drawings. Although some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. It should be understood that the drawings depict some example embodiments, and the embodiments will be described and explained in more detail and detail through the use of the drawings, in which:

[0011] Figure 1 is a representation of a drilling system according to at least one embodiment of the present disclosure;

[0012] Figure 2-1 is a cross-sectional view of a pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0013] Figure 2-2 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0014] Figure 3-1 is a cross-sectional view of yet another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0015] Figure 3-2 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0016] Figure 4 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0017] Figure 5 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0018] Figure 6 is a cross-sectional view of yet another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0019] Figure 7 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0020] Figure 8-1 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0021] Figure 8-2 is a cross-sectional view of yet another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0022] Fig. 9 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0023] Fig.10 is a cross-sectional view of another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure;

[0024] Fig.11 is a cross-sectional view of yet another pressure regulator on a downhole tool according to at least one embodiment of the present disclosure; and

[0025] Fig.12 is a method diagram of a method for operating a downhole tool in accordance with at least one embodiment of the present disclosure. DETAILED DESCRIPTION

[0026] The present disclosure generally relates to devices, systems, and methods for pressure regulation between a movable member and a fluid chamber. Figure 1 One example of a drilling system 100 for drilling an Earth formation 101 to form a wellbore 102 is shown. The drilling system 100 includes a drilling rig 103 for rotating a drilling tool assembly 104 extending downwardly into the wellbore 102. The drilling tool assembly 104 may include a drill string 105, a bottom hole assembly ("BHA") 106, and a drill bit 110 attached to the downhole end of the drill string 105.

[0027] The drill string 105 may include several joints of drill pipe 108 connected end to end by tool joints 109. The drill string 105 transmits drilling fluid through a central hole and transmits rotational power from the drilling rig 103 to the BHA 106. In some embodiments, the drill string 105 may also include additional components, such as joints, short joints, etc. The drill pipe 108 provides a hydraulic passage through which the drilling fluid is pumped from the surface. The drilling fluid is discharged through a nozzle, orifice or other orifice of a selected size in the drill bit 110 to cool the drill bit 110 and the cutting structure thereon, and to lift the drill cuttings out of the wellbore 102 while drilling.

[0028] The BHA 106 may include a drill bit 110 or other components. The example BHA 106 may include additional components or other components (e.g., coupled between the drill string 105 and the drill bit 110). Examples of additional BHA components include drill collars, stabilizers, measurement while drilling (“MWD”) tools, logging while drilling (“LWD”) tools, downhole motors, underreamers, cross-sectioning shoes, hydraulic disconnects, jars, vibration or damping tools, other components, or combinations thereof.

[0029] In general, the drilling system 100 may include other drilling components and accessories, such as specialized valves (e.g., kelly cocks, blowout preventers, and safety valves). The additional components included in the drilling system 100 may be considered part of the drilling tool assembly 104, the drill string 105, or the BHA 106, depending on their location in the drilling system 100.

[0030] The drill bit 110 in the BHA 106 can be any type of drill bit suitable for stripping downhole material. For example, the drill bit 110 can be a drill bit suitable for drilling into the earth formation 101. An example type of drill bit used to drill into the earth formation is a fixed cutter or drag drill bit. In other embodiments, the drill bit 110 can be a milling shoe for removing metals, composites, elastomers, other materials downhole, or a combination thereof. For example, the drill bit 110 can be used with a whipstock to mill into a casing 107 lining the wellbore 102. The drill bit 110 can also be a flat-head milling shoe for milling out tools, plugs, cement, other materials, or a combination thereof within the wellbore 102. The cuttings or other drill cuttings formed by the use of the milling shoe can be lifted to the surface, or can be allowed to fall downhole.

[0031] Figure 2-1 212 is a representation of an embodiment of a downhole tool 212 according to at least one embodiment of the present disclosure. The downhole tool 212 may include a housing 214. In at least one embodiment, the housing 214 may be a single, integral structure that encloses other features / components of the present disclosure. In other embodiments, the housing 214 may include two or more structures that are connected by mechanical connections, seals, welding, brazing, and other connections to enclose other features / components of the present disclosure. The housing 214 may include a housing chamber 216 positioned inside the housing 214. A divider 218 may be positioned between the housing chamber 216 and the fluid chamber 220 in the housing 214. The divider 218 may be sealed against the housing using one or more rows of sealing members 221 (such as O-rings).

[0032] In at least one embodiment, fluid can enter the downhole tool 212 through one or more housing ports 213 positioned in the sidewall of the housing 214. The fluid entering through the housing port 213 can engage the movable member 222. For example, the movable member 222 can be a turbine for a generator, and the fluid entering through the housing port 213 can rotate the turbine. In other examples, the movable member 222 can be a valve, and the valve can block the housing port 213 in a first valve configuration and open the housing port 213 in a second valve configuration. The fluid can then be directed to the housing passage 215 at the first end 217 of the housing. The fluid can be discharged from the housing passage 215 to the fluid chamber 220. In other embodiments, the fluid can enter the housing path and the housing passage 215 from the fluid chamber 220 and exit the housing port 213. In at least one embodiment, the housing 214 can be permanently or selectively closed at the second end 219 of the housing.

[0033] exist Figure 2-1 In the illustrated embodiment, the movable member 222 may be a rotary valve. The movable member 222 may include one or more flow restrictors 223 located at the upper end of the movable member 222. The flow restrictors 223 may extend along the outer periphery of the movable member 222 through the top surface of the movable member 222. Figure 2-1 In the view shown, the restrictor 223 is rotated out of alignment with the housing port 213. In this way, the movable member 222 can be in an open configuration and fluid can flow from the housing port 213 into the housing passage 215 where it can be further directed to other portions of the downhole tool 212 or other locations in the BHA.

[0034] When the movable member 222 rotates, the restrictor 223 can block or occlude the housing port 213, thereby cutting off the flow of fluid from the housing passage 215. For example, the movable member 222 may include two restrictors 223, and the downhole tool 212 may include two housing ports 213. When the movable member rotates 90°, the restrictor 223 can block or open the housing port 213. In other examples, the movable member 222 may include a single restrictor 223, or more than two restrictors 223, including three, four, five, six, seven or eight restrictors. The housing 214 may include the same number of housing ports 213.

[0035] The fluid chamber 220 may include any source of fluid. For example, the fluid chamber 220 may be positioned inside the drill pipe and include drilling fluid positioned inside the drill pipe. In other examples, the fluid chamber 220 may be positioned outside the drill pipe and include drilling fluid positioned in the wellbore annulus between the drill pipe and the wellbore wall. In other examples, the fluid chamber 220 may include a hydraulic reservoir pressurized by a hydraulic pump. In some embodiments, the fluid from the fluid chamber 220 may be a water-based drilling fluid, an oil-based drilling fluid, water, hydraulic oil, or any other fluid.

[0036] In at least one embodiment, the partition 218 can prevent the passage of fluid between the housing chamber 216 and the fluid chamber 220. In other embodiments, the partition 218 can allow the passage of fluid between the housing chamber 216 and the fluid chamber 220 while preventing the passage of solids or particles suspended in the fluid. For example, the partition 218 can be a seal between the housing chamber 216 and the partition 218. In some embodiments, the partition 218 can be a seal that maintains a pressure differential between the fluid chamber 220 and the housing chamber 216.

[0037] The movable member 222 may be positioned in the housing 214. The movable member 222 may be translatable or movable relative to the housing 214 through the partition 218. For example, the movable member 222 may be rotatable relative to the housing 214. In other examples, the movable member 222 may be translatable relative to the housing 214. In other examples, the movable member 222 may be both rotatable and translatable relative to the housing 214.

[0038] The movable member 222 may be any component of a downhole tool. For example, the movable member 222 may be a turbine from a generator. In other examples, the movable member 222 may be a rotor in a rotary valve. In yet other examples, the movable member 222 may be a shuttle in a linear valve. In other examples, the movable member 222 may be any movable component of a downhole tool.

[0039] In at least one embodiment, the separator 218 can be or include a support between the movable member 222 and the housing 214. For example, one or both of the separator 218 and the movable member 222 can be made of a superhard material. As used herein, the term "superhard" should be understood to refer to those materials known in the art having a particle hardness of about 1,500 HV (Vickers hardness in kg / mm2) or greater. Such superhard materials may include, but are not limited to, diamond, sapphire, moissanite, hexagonal diamond (Lonsdaleite), cubic boron nitride (cBN), polycrystalline cBN (PcBN), Q-carbon, binderless PcBN, diamond-like carbon, suboxide boron, aluminum manganese boride, metal borides, carbonitride, PCD (including, for example, leached metal catalyst PCD, non-metallic catalyst PCD and binderless PCD or nano polycrystalline diamond (NPD)) and other materials showing hardness values ​​higher than 1,500 HV in the boron-nitrogen-carbon-oxygen system, superhard ceramics, and combinations of the above materials and / or coatings of any of the above materials on a substrate. In some embodiments, the superhard material may have a hardness value higher than 3,000 HV. In other embodiments, the superhard material may have a hardness value higher than 4,000 HV. In other embodiments, the superhard material may have a hardness value greater than 80 HRa (Rockwell hardness A). For example, both the spacer 218 and the movable member 222 may be made of PCD, and the PCD on PCD interface has a low coefficient of friction. Therefore, the movable member 222 may easily rotate against the spacer 218 and may have a long life due to the durability of the movable member 222 and the spacer 218. This allows for a tight gap between the movable member 222 and the spacer 218. In at least one embodiment, the spacer 218 may include a superhard bearing surface against which the movable member 222 may move.

[0040] The housing 214 may include a passage 224 through the partition 218 that hydraulically connects the fluid chamber 220 to the housing chamber 216. The partition 218 has a partition size. The movable member 222 has a movable member size. The movable member 222 can be inserted into the partition 218. There can be a gap between the movable member 222 and the partition 218, which can be the difference between the partition size and the movable member size. For example, in at least one embodiment, the cylindrical movable member 222 can be inserted into the cylindrical hole of the partition 218. The partition size can be the diameter of the cylindrical hole, and the movable member size can be the diameter of the movable member 222. The gap can be the difference between the diameter of the cylindrical hole and the diameter of the movable member 222. In at least one embodiment, the gap can be considered as a tolerance between the partition 218 and the movable member 222.

[0041] The tight gap between the movable member 222 and the divider 218 can form a seal between the fluid chamber 220 and the housing chamber 216. The movable member 222 can be inserted into the channel 224. In at least one embodiment, the movable member 222 and the divider 218 can form a seal between the fluid chamber 220 and the housing chamber 216. The seal can partially or completely reduce the flow of fluid between the fluid chamber 220 and the housing chamber 216. The seal can be formed by the tight gap between the movable member 222 and the divider 218. In some embodiments, the gap between the movable member 222 and the partition 218 may be within a range having an upper limit, a lower limit, or an upper and lower limit including any one of 0 micrometers (μm), 5 μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, or any value therebetween. For example, the gap may be 0 μm, or completely sealed. In another example, the gap may be less than 500 μm. In yet another example, the gap may be any value within a range between completely sealed and 500 μm. In at least one embodiment, a gap of 20 μm or less may be critical to preventing microparticles from migrating between the fluid chamber 220 and the housing chamber 216.

[0042] The partition 218 may include a seal that maintains a pressure differential between the fluid chamber 220 and the housing chamber 216. Thus, a pressure differential may exist across the movable member 222. In at least one embodiment, a tight gap between the movable member 222 and the partition 218 may help maintain a pressure differential due to restricted fluid flow between the fluid chamber 220 and the housing chamber 216. A larger gap may result in a lower pressure differential, while a smaller gap may result in a higher pressure differential.

[0043] In at least one embodiment, when the movable member 222 rotates or translates relative to the partition 218, at least some of the fluid can be transferred between the fluid chamber 220 and the housing chamber 216. The transfer of fluid between the fluid chamber 220 and the housing chamber 216 can adjust the pressure differential. In this way, when the movable member 222 moves relative to the partition 218, a steady-state pressure differential can be achieved despite changes in drilling conditions, such as an increase in fluid static pressure. In addition, the movement of the movable member 222 relative to the partition 218 can prevent particles or solids suspended in the fluid from accumulating at the interface between the movable member and the partition 218. In other words, moving the movable member 222 can flush the gap between the movable member 222 and the partition 218.

[0044] When movable member 222 does not move relative to divider 218, when pressure difference increases, fluid may be forced to pass through the gap between movable member 222 and divider 218. In some embodiments, when forcing fluid to pass through the gap, particles or solids suspended in the fluid may not be washed away from the gap. These particles or solids may accumulate at the gap. When particles or solids accumulate and increase, the fluid that can be transferred through the gap will be less. This may increase the pressure difference. In at least one embodiment, enough particles or solids can accumulate until the gap is blocked or effectively sealed. Therefore, when the pressure difference at both ends of movable member 222 increases, fluid may not be transferred between fluid chamber 220 and housing chamber to adjust the pressure difference.

[0045] In various cases, the movable member 222 may not move relative to the partition 218. For example, when the downhole tool 212 is lowered into the wellbore, the movable member 222 may not move relative to the partition 218. At the surface, the housing chamber 216 and the fluid chamber 220 may be at or near the same pressure (e.g., surface pressure). In other words, at the surface, the pressure difference may be zero or approximately zero. When the downhole tool 212 is lowered into the hole, the hydrostatic pressure increases. When particles in the drilling fluid plug the gap, the pressure difference may increase at the same or nearly the same rate as the hydrostatic pressure. In addition, the geological pressure of the surrounding formations may begin to increase the hydrostatic pressure, thereby creating a combined pressure. In some embodiments, the combined pressure, and therefore the pressure differential, may be equal to or greater than 5,000 PSI (34.5 MPa), 10,000 PSI (68.9 MPa), 15,000 PSI (103 MPa), 20,000 PSI (138 MPa), 25,000 PSI (172 MPa), 30,000 PSI (207 MPa), or greater.

[0046] The pressure differential may place a load on the movable member 222 against the housing 214 and / or the partition 218. This load may increase the initial force required to move the movable member 222. In some embodiments, the initial force may be greater than the actuation force. For example, if the movable member 222 is a turbine on a generator, the movable member 222 may be rotated by the drilling fluid. The drilling fluid may apply a torque on the movable member 222. If the initial force required to move the movable member 222 is greater than the torque applied by the drilling fluid, the movable member 222 may be stuck. In other words, a large pressure differential may pressure lock the movable member 222. This may cause the downhole tool 212 to malfunction. The pressure differential at which the downhole tool 212 can reliably function may be the maximum pressure differential.

[0047] In some embodiments, the maximum pressure difference can be in the range of 50PSI (345KPa), 100PSI (689KPa), 250PSI (1.72MPa), 500PSI (3.44MPa), 750PSI (5.17MPa), 1,000PSI (6.89MPa), 1,250PSI (8.62MPa), 1,500PSI (10.3MPa), 1,750PSI (12.1MPa), 2,000PSI (13.8 In some embodiments, the maximum pressure difference may be any value within the range of 50PSI (345KPa) to 20,000PSI (138MPa). In some embodiments, the maximum pressure difference may be any value within the range of 50PSI (345KPa) to 20,000PSI (138MPa). In some embodiments, the maximum pressure differential may be greater than 20,000 PSI (138 MPa) or less than 50 PSI (345 KPa). In some embodiments, a maximum pressure differential of less than 5,000 PSI may be critical for the movable member 222 to reliably move when actuated. In some embodiments, the maximum pressure differential may be the same or approximately the same as the operating pressure of the downhole tool 212. In other embodiments, the maximum pressure differential may be greater than the operating pressure of the downhole tool 212.

[0048] The pressure regulator 226 may be connected to the partition 218 and / or the housing 214. The pressure regulator 226 may maintain the pressure difference below the maximum pressure difference. In other words, the pressure regulator 226 may automatically adjust the pressure difference to below the maximum pressure difference. In some embodiments, the pressure regulator 226 may include a regulator housing 228 including a flow path 230. The regulator housing 228 may extend from the partition 218 and be connected to the partition, or may be formed integrally with the partition 218. A regulator housing cover 229 may be sleeved on the regulator housing 228. The regulator housing 228 may be sealed to the regulator housing cover 229 with one or more regulator sealing members 225 (such as O-rings). The regulator sealing member 225 may seal the interior of the regulator housing 228 (such as the flow path 230) from the fluid chamber 220. The flow path 230 may travel through the regulator housing 228, enter the partition 218 and lead to the housing chamber 216. The flow path 230 may include a regulator chamber 244 in the regulator housing 228. The regulator chamber 244 may be in fluid communication with the housing chamber 216 and the fluid chamber 220. In other words, the regulator chamber 244 may be positioned in the flow path 230 between the housing chamber and the fluid chamber 220.

[0049] The restrictor 232 may be positioned in the regulator chamber 244. In some embodiments, the restrictor 232 may be cylindrical, such as a piston. In other embodiments, the restrictor 232 may be spherical. In other embodiments, the restrictor 232 may be conical or pyramidal. In yet other embodiments, the restrictor 232 may be any three-dimensional shape.

[0050] The resilient member 234 can exert a force on the restrictor 232 to push or urge the restrictor 232 against the seat 236. The seat 236 can be positioned on the high pressure side of the regulator chamber 244 and can be part of or integral with the regulator housing 228. The resilient member 234 can be any type of resilient member. For example, the resilient member 234 can be one or more coil springs, one or more wave springs, one or more Belleville washers, one or more pneumatic or hydraulic pistons, a bellows, a flexible material such as an elastomer, any other resilient member 234, or a combination of the foregoing.

[0051] The resilient member 234 can push or urge the restrictor 232 against the seat 236 with a force sufficient to seal the flow path 230 to prevent fluid from passing between the fluid chamber 220 and the housing chamber 216. For example, the opening 238 of the flow path 230 at the seat 236 can have an opening cross-sectional area. The portion of the restrictor 232 that contacts the seat 236 can have a restrictor cross-sectional area that is greater than the opening cross-sectional area. Therefore, when the resilient member 234 pushes the restrictor 232 against the seat 236, the restrictor 232 can partially or completely block the transfer of fluid between the fluid chamber 220 and the housing chamber 216.

[0052] The elastic member force of the elastic member 234 to push the restrictor 232 against the seat 236 can be sufficient to overcome the pressure difference between the fluid chamber 220 and the housing chamber 216. In at least one embodiment, the force of the elastic member 234 can depend at least in part on the cross-sectional area of ​​the opening. For example, a larger cross-sectional area of ​​the opening 238 may require less force to seal the opening 238 than a smaller cross-sectional area of ​​the opening. The elastic member 234 can be specifically selected or sized to exert an elastic member force that can seal the opening 238.

[0053] When the pressure differential increases, the hydraulic force acting on the restrictor 232 due to the pressure differential can overcome the elastic member force, thereby pushing the restrictor 232 into the regulator chamber 244. This can allow fluid to enter the flow path 230. In at least one embodiment, one or more restrictor fluid paths 240 can be positioned inside the restrictor 232. One or more restrictor fluid paths 240 can pass through the restrictor from a first side of the restrictor 232 near the seat 236 to an opposite side or second side of the restrictor 232 near the housing chamber 216. Therefore, the restrictor 232 can have a through fluid conduit that can hydraulically connect the fluid chamber 220 to the housing chamber 216. In other embodiments, the fluid can bypass the outside of the restrictor 232 or pass in the annulus in the flow path 230 between the restrictor and the regulator housing 228. In some embodiments, the fluid can pass through the restrictor fluid path 240 in the restrictor 232 and around the outside of the restrictor 232.

[0054] When the restrictor 232 is pushed against the seat 236, the flow to the restrictor fluid path 240 can be blocked. When the pressure difference increases, the restrictor 232 can move into the regulator chamber 244 in response to the pressure difference. When the restrictor 232 is pushed into the flow path 230, the fluid can enter one or more of the restrictor fluid paths 240. This can reduce the pressure difference. When the pressure difference is reduced, the elastic member 234 can overcome the force applied by the reduced pressure difference and seal the flow path 230 again. Therefore, the elastic member 234 can be selected to maintain a release pressure difference or a pressure difference, and the pressure difference force above the pressure difference is sufficient to overcome the elastic member force. Above the release pressure difference, the pressure regulator can release the pressure difference between the fluid chamber 220 and the housing chamber 216. Therefore, in some embodiments, the pressure regulator 226 can be a pressure relief valve.

[0055] In some embodiments, the release pressure difference can be in the range of 50PSI (345KPa), 100PSI (689KPa), 250PSI (1.72MPa), 500PSI (3.44MPa), 750PSI (5.17MPa), 1,000PSI (6.89MPa), 1,250PSI (8.62MPa), 1,500PSI (10.3MPa), 1,750PSI (12.1MPa), 2,000PSI (13.8 In some embodiments, the release pressure differential may be within the range of an upper limit value, a lower limit value, or both of any one of 2,250 PSI (15.5 MPa), 2,500 PSI (17.2 MPa), 3,000 PSI (20.7 MPa), 4,000 PSI (27.6 MPa), 5,000 PSI (34.5 MPa), 10,000 PSI (68.9 MPa), 15,000 PSI (103 MPa), 20,000 PSI (138 MPa), or any value therebetween. For example, the release pressure differential may be greater than 50 PSI (345 KPa). In another example, the release pressure differential may be less than 20,000 PSI (138 MPa). In yet another example, the release pressure differential may be any value within the range between 50 PSI (345 KPa) and 20,000 PSI (138 MPa). In some embodiments, a maximum pressure differential value below 5,000 PSI may be critical to allow the movable member 222 to move when the downhole tool 212 is actuated. In some embodiments, the release pressure differential may be the same or approximately the same as the maximum pressure differential. In some embodiments, the release pressure differential may be less than the maximum pressure differential and greater than the operating pressure differential of the downhole tool 212. In this way, when the downhole tool 212 is lowered into the wellbore, the pressure differential may be kept low enough so that the downhole tool 212 can be actuated despite the presence of large hydrostatic pressures, or a large pressure differential between a starting location (e.g., surface) and an operating location (e.g., downhole).

[0056] In at least one embodiment, the regulator housing 228 can be positioned outside of the partition 218. For example, the regulator housing 228 can be attached to the end of the partition 218 that is away from the housing 214. In other words, the pressure regulator 226 can be independent of the housing 214 and / or the partition 218. This means that the pressure regulator 226 can be positioned in its own structure, namely in the regulator housing 228. In order to allow fluid to travel between the housing port 213 and the fluid chamber 220, one or more branch conduits 242 can be placed in the regulator housing 228 to direct the fluid between the housing port 213 and the fluid chamber 220.

[0057] exist Figure 2-1In the illustrated embodiment, the pressure regulator 226 is one-way, or operates to relieve pressure from the housing chamber 216 having a higher pressure than the fluid chamber 220. Such a pressure differential may occur, for example, when the downhole tool 212 is lowered deeper into a wellbore.

[0058] Figure 2-2 An embodiment of a downhole tool 212 is shown in which a pressure regulator 226 operates to release pressure from a housing chamber having a higher pressure than the fluid chamber. In this embodiment, a flow restrictor 232 may be provided relative to Figure 2-1 The restrictor 232 is shown flipped so that it seals against a seat 236 positioned near the housing 214. The resilient member 234 can push the restrictor 232 against the seat 236 to seal the flow path 230 with a relief pressure differential. When the pressure in the housing chamber 216 increases, the pressure can push the restrictor away from the seat 236, allowing some fluid to escape into the fluid chamber 220. In this way, the housing chamber 216 can be the high pressure side and the fluid chamber 220 can be the low pressure side. For example, such a pressure differential may occur when the downhole tool is tripped toward the surface.

[0059] In some embodiments, the downhole tool 212 may include two pressure regulators 226, including Figure 2-1 and Figure 2-2 Each of the pressure regulators shown. In this way, the downhole tool 212 can maintain a relief pressure differential when drilling uphole and downhole. In some embodiments, a single pressure regulator can be a two-way valve that maintains a relief pressure differential when drilling uphole and downhole.

[0060] Figure 3-1 312 is a representation of a downhole tool 312 according to at least one embodiment of the present disclosure. The downhole tool 312 may include a housing 314 and a housing chamber 316 inside the housing 314. A partition 318 in the housing 314 may seal the housing chamber 316 from the fluid chamber 320. In at least one embodiment, the partition 318 may include a bearing surface 319. The bearing surface 319 may be made of PCD. The movable member 322 may be made of PCD. The bearing surface 319 may be directly adjacent to the movable member 322 so that when the movable member moves relative to the housing 314, the movable member 322 slides against the bearing surface 319. Since the bearing surface 319 and the movable member 322 are made of PCD, the movable member 322 can be inserted into the housing 314 with a tight gap against the bearing surface 319. The tight gap between the bearing surface 319 and the movable member 322 may form a complete or partial seal between the fluid chamber 320 and the housing chamber 316.

[0061] The flow path 330 can be positioned in the divider 318 to provide hydraulic communication between the housing chamber 316 and the fluid chamber 320. The pressure regulator 326 can be positioned in the flow path 330. The pressure regulator can include a restrictor 332 positioned in a regulator chamber 344, which is positioned in the flow path 330. The resilient member 334 can push the restrictor 332 against a seat 336 in the regulator chamber 344 with sufficient force to seal the flow path 330 with a relief pressure differential. In the illustrated embodiment, the resilient member 334 is a spherical ball that can be seated on a circular seat 336. In other embodiments, the resilient member 334 can be a cylindrical piston (e.g., Figure 2-1 and Figure 2-2 as shown), or any other shape that can form a seal with the seat 336.

[0062] When the pressure differential between the fluid chamber 320 and the housing chamber 316 is greater than the release pressure differential, the restrictor 332 may be pushed away from the seat 336. Fluid may then pass through or around the restrictor 332 and into the housing chamber 316. This may reduce the pressure differential to below the release pressure differential, causing the resilient member 334 to push the restrictor 332 back against the seat. Figure 3-1 In the illustrated embodiment, pressure regulator 326 is configured to regulate pressure from high pressure fluid chamber 320 to low pressure housing chamber 316. In at least one embodiment, including pressure regulator 326 in partition 318 can reduce the length of downhole tool 312 and / or reduce the complexity of manufacturing downhole tool 312.

[0063] In some embodiments, the downhole tool 312 may include multiple pressure regulators 326. For example, two or more pressure regulators 326 may be installed in series in the flow path 330. In other words, the same flow path 330 may include two or more pressure regulators 326 installed in series. Several pressure regulators 326 in series can provide more precise regulation of the relief pressure difference and / or the maximum pressure difference. In addition, if the fluid chamber 320 experiences a rapid increase in hydrostatic pressure or other pressure, the pressure regulators 326 in series can suppress the pressure increase experienced by the housing chamber 316.

[0064] In other examples, two or more pressure regulators 326 may be installed in parallel. In other words, the partition 318 may include two or more flow paths 330, wherein each flow path 330 includes a pressure regulator 326. This may allow a larger volume of fluid to pass between the fluid chamber 320 and the housing chamber 316. This may allow the pressure differential to quickly reach a maximum pressure differential if the fluid chamber 320 experiences a rapid increase in hydrostatic or hydraulic pressure.

[0065] In at least one example, the downhole tool may include pressure regulators 326 connected in series and in parallel. In some examples, at least one of the pressure regulators 326 may be connected in series or in parallel with another pressure regulator 326. Figure 2-1 and / or Figure 2-2 Pressure regulator shown.

[0066] Figure 3-2 312 according to at least one embodiment of the present disclosure. In the illustrated embodiment, the pressure regulator 326 may include an elastic member 334 that pushes the flow restrictor 332 toward a seat 336 near the housing chamber 316. In this way, the pressure regulator releases pressure from the housing chamber 316 to the fluid chamber 320.

[0067] In some embodiments, the downhole tool 312 may include multiple pressure regulators 326. For example, two or more pressure regulators 326 may be installed in series in the flow path 330. In other words, the same flow path 330 may include two or more pressure regulators 326 installed in succession. Several pressure regulators 326 in series can provide more precise regulation of the relief pressure difference and / or the maximum pressure difference. In addition, if the fluid chamber 320 experiences a rapid decrease in the hydrostatic pressure or hydraulic pressure, the pressure regulators 326 in series can suppress the pressure drop in the housing chamber 316.

[0068] In other examples, two or more pressure regulators 326 may be installed in parallel. In other words, the partition 318 may include two or more flow paths 330, wherein each flow path 330 includes a pressure regulator 326. This may allow a larger volume of fluid to pass between the fluid chamber 320 and the housing chamber 316. This may allow the pressure differential to quickly reach a maximum pressure differential if the fluid chamber 320 experiences a rapid decrease in fluid static pressure or hydraulic pressure.

[0069] Figure 4 is a representation of a downhole tool 412 according to at least one embodiment of the present disclosure. The downhole tool 412 may include Figure 2-1 to Figure 3-2 At least some of the features and characteristics of the downhole tool described herein. The downhole tool 412 may include two pressure regulators 426-1, 426-2. The first pressure regulator 426-1 may be configured to regulate the pressure difference from the high pressure fluid chamber 420 to the low pressure housing chamber 416 (similar to Figure 2-1 The pressure regulator 226 and Figure 3-1The first pressure regulator 426-1 or the second pressure regulator 426-2 may be configured to adjust the pressure difference from the high pressure housing chamber 416 to the low pressure fluid chamber 420. Thus, the downhole tool 412 may maintain a maximum pressure difference regardless of whether the housing chamber 416 or the fluid chamber 420 has a higher pressure. In some embodiments, the first pressure regulator 426-1 or the second pressure regulator 426-2 or both may have multiple pressure regulators connected in series or in parallel.

[0070] Figure 5 5 is a representation of an embodiment of a downhole tool 512 according to at least one embodiment of the present disclosure. The downhole tool 512 may include a flow path 530 through a partition 518 in a housing 514. The flow path 530 may place a housing chamber 516 and a fluid chamber 520 in fluid communication. The flow path 530 may include a pressure regulator 526. The pressure regulator 526 may include a regulator chamber 544. The regulator chamber may include a diaphragm 546. The diaphragm 546 may be made of any elastic material, such as an elastomer, rubber, spring steel, plastic, or any other elastic material. The diaphragm 546 may have an elastic modulus so that it bends in the presence of a pressure differential. The diaphragm 546 may include an orifice 548. When the diaphragm 546 bends in response to the pressure differential, the diaphragm 546 may open the orifice 548. When the orifice 548 is open, fluid may travel between the fluid chamber 520 and the housing chamber 516. The elastic modulus of the diaphragm 546 may therefore be selected to open the orifice when the pressure differential is released. Thus, diaphragm 546 may be a pressure relief valve.

[0071] Since diaphragm 546 is flexible from fluid chamber 520 to housing chamber 516 and from housing chamber 516 to fluid chamber 520, diaphragm 546 may allow bidirectional communication of fluid between fluid chamber 520 and housing chamber 516. In this way, pressure regulator 526 may be bidirectional.

[0072] Figure 6 is a representation of an embodiment of a downhole tool 612 according to at least one embodiment of the present disclosure. The downhole tool 612 may include Figure 2-1 to Figure 5 At least some of the features and characteristics of the downhole tool described herein. In some embodiments, the downhole tool 612 may include a pressure regulator 626 at any location that allows a flow path 630 to transfer fluid between the fluid chamber 620 and the housing chamber 616. For example, in the illustrated embodiment, the pressure regulator 626 may be positioned in the housing 614. In this embodiment, the pressure regulator 626 and the flow path 630 may be transverse to the movable member 622 and / or the housing passage 615. In other embodiments, the pressure regulator 626 may be positioned at any other location between the fluid chamber 620 and the housing chamber 616 where a flow path 630 may be formed.

[0073] Figure 7is an embodiment of a downhole tool 712 according to at least one embodiment of the present disclosure. The downhole tool 712 may include Figure 2-1 to Figure 6 At least some of the features and characteristics of the downhole tool described herein. The downhole tool 712 may include a pressure regulator 726. The piston 750 may be connected to the pressure regulator 726. The piston may include an inner bore 752. A sealing member 754 may be positioned in the inner bore 752. The sealing member 754 may divide the inner bore 752 into two parts, namely a fluid reservoir 756 near the pressure regulator 726 on a first side of the inner bore 752 and a pressurized fluid 758 near a fluid chamber (not shown) of the downhole tool 712 on a second side of the inner bore 752. The sealing member 754 may seal the fluid reservoir 756 from the pressurized fluid 758.

[0074] As the pressure of the pressurized fluid 758 increases, the pressurized fluid 758 may push the sealing member 754 toward the pressure regulator 726. This may increase the pressure of the fluid in the fluid reservoir 756. When the pressure in the fluid reservoir 756 exceeds the relief pressure differential of the pressure regulator 726, fluid from the fluid reservoir 756 may enter the housing chamber 716, thereby reducing the pressure differential.

[0075] The fluid reservoir 756 may include any fluid. In some embodiments, the fluid in the fluid reservoir 756 may be an oil-based fluid, such as hydraulic oil or an oil-based drilling fluid. In other embodiments, the fluid in the fluid reservoir 756 may be a water-based fluid, such as a water-based drilling fluid. In other embodiments, the fluid reservoir 756 may include a lubricant, such as a grease. Since the fluid from the fluid reservoir 756 is the only fluid inserted into the housing chamber 716 during pressure regulation, including the piston 750 with the pressure regulator 726 may allow control of the fluid entering the housing chamber 716 when the pressure regulator 726 regulates the pressure. This helps keep the downhole tool 712 clean and ensures that it operates correctly.

[0076] In some embodiments, the piston 750 can be a single stroke piston. In other words, when the sealing member 754 reaches the pressure regulator 726, no more fluid from the fluid reservoir 756 can enter the housing chamber 716. In some embodiments, the piston 750 can expand in the cross-sectional area near the pressure regulator 726. In this way, when the sealing member 754 reaches the pressure regulator 726, the fluid from the pressurized fluid 758 can travel around the sealing member 754 to reach the pressure regulator. In other embodiments, the sealing member 754 may include a pressure relief valve, a bursting disc or other mechanism to allow fluid to flow through the sealing member 754.

[0077] Figure 8-1 is a representation of a downhole tool 812 according to at least one embodiment of the present disclosure. The downhole tool 812 may include Figure 2-1 to Figure 7 At least some of the features and characteristics of the downhole tool described herein. The downhole tool 812 may include a flow path 830 connecting the housing chamber 816 to the fluid chamber 820. The pressure regulator 826 may be positioned in a regulator chamber 844 in the flow path 830. The pressure regulator 826 may include a sealing member 854. The sealing member 854 may seal the flow path 830 to prevent fluid from flowing between the fluid chamber 820 and the housing chamber 816.

[0078] When the pressure difference between the fluid chamber 820 and the housing chamber 816 increases, the pressure difference may act on the sealing member 854. The pressure difference may cause the sealing member 854 to move in the regulator chamber 844. This may force the fluid to enter or leave the housing chamber 816, which may adjust the pressure difference. The flow path 830 may lead to both the housing chamber 816 and the fluid chamber 820. Therefore, when the fluid chamber 820 has a higher pressure than the housing chamber 816, the sealing member 854 may move toward the housing chamber 816, thereby increasing the pressure in the housing chamber 816. When the housing chamber 816 has a higher pressure than the fluid chamber 820, the sealing member 854 may move toward the fluid chamber 820, thereby reducing the pressure in the housing chamber 816. In this way, the pressure regulator 826 may be a piston or a compensating piston. Since the sealing member 854 may move toward both the housing chamber 816 and the fluid chamber 820, the pressure regulator 826 may be bidirectional.

[0079] In some embodiments, the sealing member 854 can be a spherical ball. In other embodiments, the sealing member 854 can be cylindrical. In other embodiments, the sealing member 854 can be any shape that can move in the regulator chamber 844 and seal the regulator chamber. In some embodiments, the sealing member 854 can be a flexible diaphragm that expands toward both the housing chamber 816 and the fluid chamber 820. In other embodiments, the sealing member 854 can be a bellows or other expandable and contractible member to seal the flow path 830.

[0080] Figure 8-2 is a representation of a downhole tool 812 according to at least one embodiment of the present disclosure. The downhole tool 812 may include Figure 2-1 to Figure 8-1 At least some of the features and characteristics of the downhole tool described herein. In at least one embodiment, the sealing member 854 of the pressure regulator 826 may shift toward the housing chamber 816 or the fluid chamber 820. In other words, the sealing member 854 moves toward the housing chamber 816 or the fluid chamber 820 beyond the extent that the increased pressure differential can be explained. This may occur due to vibrations of the downhole tool 812, defects in the regulator chamber 844, pulsations in the pressure differential, or any other reason.

[0081] To maintain the sealing member 854 in the neutral position, the relative positioning spring 860 can push the seal 854 back to the neutral position. The relative positioning spring 860 can push the sealing member 854 with a force that reaches the release pressure difference. In some embodiments, the relative positioning spring 860 can move the sealing member 854 to the neutral position using the same or other mechanism (such as, vibration, defect, pressure pulse, etc.) that first caused the sealing member to shift. Maintaining the sealing member 854 in the neutral position can extend the service life of the pressure regulator 826 through a single stroke of the sealing member 854 in either direction.

[0082] Fig. 9 is a representation of a downhole tool 912 according to at least one embodiment of the present disclosure. The downhole tool 912 may include Figure 2-1 to Figure 8-2 At least some of the features and characteristics of the downhole tool described. Downhole tool 912 may include a flow path 930 connecting housing chamber 916 to fluid chamber 920. Pressure regulator 926 may be positioned in flow path 930. Pressure regulator 926 may include one or more flow restrictors 932 in regulator chamber 944.

[0083] The restrictor 932 may have a restrictor cross-sectional area that is smaller than the cross-sectional area of ​​the regulator chamber. In this way, when there is a pressure differential between the housing chamber 916 and the fluid chamber 920, the fluid may flow through the fluid path 930. At high pressure differentials, the fluid flow through the flow path 930 may be sufficient to prevent sediment and other suspended particles from settling in the regulator chamber 944 and blocking the flow path. Therefore, the restrictor 932 may help balance the pressure differential between the housing chamber 916 and the fluid chamber 920. At lower pressure differentials, sediment and other suspended particles may accumulate in the regulator chamber 944 and may block the flow path. Therefore, when the downhole tool 912 reaches the operating depth, a lower pressure differential may be experienced, and the flow path 930 may be blocked. This may allow the operating pressure differential to be maintained during operation without fluid leaking through the flow path 930.

[0084] The restrictor 932 may have a radial gap 945 between the restrictor 932 and the regulator chamber 944. In some embodiments, the radial gap 945 may be within a range having an upper limit value, a lower limit value, or an upper limit value and a lower limit value including any one of 5 μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, or any value therebetween. For example, the radial gap 945 may be greater than 5 μm. In another example, the radial gap 945 may be less than 500 μm. In yet another example, the radial gap 945 may be any value within a range between 5 μm and 500 μm. In some embodiments, a radial gap of 50 μm or less may be critical for the movable member 922 to reliably move when actuated.

[0085] The area percentage of the restrictor 932 can be a percentage of the restrictor cross-sectional area relative to the cross-sectional area of ​​the regulator chamber. In some embodiments, the area percentage can be within a range having an upper limit value, a lower limit value, or an upper limit value and a lower limit value including any one of 85%, 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98%, 99%, or any value therebetween. For example, the area percentage can be greater than 85%. In another example, the area percentage can be less than 99%. In yet another example, the area percentage can be any value within a range between 85% and 99%. In some embodiments, an area percentage greater than 85% may be critical for the movable member 922 to reliably move when actuated.

[0086] Fig.10 is a representation of an embodiment of a downhole tool 1012 according to at least one embodiment of the present disclosure. The downhole tool 1012 may include Figure 2-1 to Figure 9 At least some of the features and characteristics of the downhole tool described herein. The downhole tool 1012 may include a flow path 1030 connecting the fluid chamber 1020 to the housing chamber 1016. The pressure regulator 1026 may be positioned in the flow path 1030. The pressure regulator 1026 may include a sealing member 1054 in the regulator chamber 1044. The pressure regulator 1026 may include a first alternative path 1062-1 and a second alternative path 1062-2. The sealing member 1054 may seal the regulator chamber 1044 to prevent fluid from passing between the fluid chamber 1020 and the housing chamber 1016.

[0087] The relative positioning spring 1060 can act on the sealing member 1054 to maintain the sealing member 1054 in a neutral position. In the neutral position, the sealing member 1054 can block the openings of both the first alternative path 1062-1 and the second alternative path 1062-2 to the regulator chamber. When the pressure difference between the fluid chamber 1020 and the housing chamber 1016 increases, the pressure difference can push against the sealing member 1054. Under the release of the pressure difference, the sealing member 1054 can expose one of the first alternative path 1062-1 or the second alternative path 1062-2 in the regulator chamber 1044.

[0088] For example, when the pressure of the fluid chamber 1020 is greater than the pressure of the housing chamber 1016, the sealing member 1054 can move toward the housing chamber 1016. When the pressure differential becomes greater than the release pressure differential, the first alternative path 1062-1 can be exposed. This can allow the fluid to travel through the first alternative path 1062-1 and into the housing chamber 1016. When the pressure differential decreases below the release pressure differential, the sealing member 1054 can return to the neutral position by the relative positioning spring 1060.

[0089] Similarly, when the pressure of the housing chamber 1016 is greater than the pressure of the fluid chamber 1020, the sealing member 1054 can move toward the fluid chamber 1020. When the pressure differential exceeds the release pressure differential, the second alternative path 1062-2 can be exposed. This can allow fluid to travel through the second alternative path 1062-2 to the fluid chamber. When the pressure differential decreases below the release pressure, the sealing member 1054 can return to the neutral position by the relative positioning spring 1060. In this way, the pressure regulator 1026 can be bidirectional.

[0090] Fig.11 is a representation of a downhole tool 1112 according to at least one embodiment of the present disclosure. The downhole tool 1112 may include Figure 2-1 to Figure 10 At least some of the features and characteristics of the downhole tool described herein. The downhole tool 1112 may include a movable member 1122. The housing 1114 may include a support 1165 at a first end 1117 of the housing. The movable member 1122 may rotate within the support with a tight gap. In some embodiments, the gap may be between 10 μm and 100 μm, as described above with respect to Figure 2-1 When the pressure difference between the housing chamber 1116 and the fluid chamber (not shown) in the housing 1114 increases, solids may accumulate at the bearings and the torque required to rotate the movable member may increase.

[0091] The housing chamber 1116 may include a bearing surface 1168 at the housing second end 1166. The movable member 1122 may include a central support 1170. The movable member 1122 may be supported by the central support 1170 at the bearing surface 1168. Since the movable member 1122 is supported by the central support 1170, the only friction overcome by the torque during operation is the friction of the central support 1170 against the bearing surface 1168. By reducing the bearing area of ​​the central support 1170, the torque required to rotate the movable member 1122 may be reduced.

[0092] The central support 1170 engages the support surface 1168 at a certain support radius. In some embodiments, the central support 1170 may have a sharp point that engages the support surface 1168. Therefore, the support radius can be small, which can reduce the torque required to rotate the movable member 1122. In some embodiments, the support radius can be within a range having an upper limit, a lower limit, or an upper and lower limit including any one of 1 μm, 10 μm, 25 μm, 50 μm, 75 μm, 100 μm, 250 μm, 500 μm, 750 μm, 1.0 millimeter (mm), 2.5 mm, 5.0 mm, 7.5 mm, 10 mm, 25 mm, 50 mm, or any value therebetween. For example, the support radius may be greater than 1 μm. In another example, the support radius may be less than 50 mm. In yet another example, the support radius may be any value in the range between 1 μm and 50 mm. In some embodiments, a radial clearance of 1 mm or less may be critical for the movable member 1122 to move reliably upon actuation. In another embodiment, a radial clearance of 5 mm or less may be critical for the movable member 1122 to move reliably upon actuation. In still other embodiments, a radial clearance between 1 mm and 5 mm may permit the movable member 1122 to move reliably upon actuation.

[0093] The support area of ​​central support 1170 can be a support percentage, or a percentage of the support area relative to the cross-sectional area of ​​the movable member. In some embodiments, the support percentage can be within the range of an upper limit, a lower limit, or an upper and lower limit including any one of 25%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1% or any value therebetween. For example, the support percentage may be greater than 1%. In another example, the support percentage may be less than 25%. In yet another example, the support percentage may be any value within the range between 1% and 25%. In some embodiments, a support percentage lower than 10% may be critical for the movable member 1122 to rotate under high pressure difference.

[0094] Due to the high rotation rates that movable member 1122 may be subjected to, both central support 1170 and bearing surface 1168 may be made of superhard materials. For example, one or both of central support 1170 and bearing surface 1168 may be made of PCD, tungsten carbide (WC), cubic boron nitride, or any other superhard material. In other embodiments, generally hard materials such as ceramics or metals may be used. In some embodiments, downhole tool 1112 may include central support 1170 and bearing surface 1168 that rotate on bearing surface 1168. Figure 2-1 to Figure 10 A combination of one or more of the pressure regulators discussed herein. In some embodiments, the central support 1170 and the bearing surface 1168 can rotate on a bearing, such as a ball bearing. For example, the central support 1170 can include a ball at a contact point between the central support 1170 and the bearing surface 1168. The ball can contact the bearing surface 1168 and rotate relative to both the bearing surface 1168 and the central support 1170. The ball bearing can rotate in response to a lower torque on the movable member 1122.

[0095] Fig.12 is a method diagram of a method 1272 for operating a downhole tool according to at least one embodiment of the present disclosure. The method 1272 may include sealing a housing chamber in a housing at 1274. A movable member may be inserted into the housing chamber and may rotate relative to the housing chamber. The movable member may rotate against a support with a tight gap, the gap forming a seal. The method 1272 may also include generating a pressure differential across a seal between the fluid chamber and the housing chamber at 1276. The pressure differential may be generated due to an increase in hydrostatic pressure in the fluid chamber or an increase in pressure in the housing chamber. Generating the pressure differential may include plugging the seal with particles suspended in the fluid.

[0096] The method 1272 may also include reducing the pressure differential with the pressure regulator at 1278. Reducing the pressure differential may include overcoming a relief pressure differential in the pressure regulator. Reducing the pressure differential may also include moving a sealing member or restrictor along the regulator chamber in response to the pressure differential.

[0097] Embodiments of the pressure regulator have been primarily described with reference to wellbore drilling operations; the pressure regulators described herein may be used in applications other than wellbore drilling. In other embodiments, a pressure regulator according to the present disclosure may be used outside of a wellbore or other downhole environment used to explore or produce natural resources. For example, a pressure regulator of the present disclosure may be used in a borehole used to place a utility line. Therefore, the terms "wellbore," "borehole," and the like should not be construed to limit the tools, systems, assemblies, or methods of the present disclosure to any particular industry, field, or environment.

[0098] One or more specific embodiments of the present disclosure are described herein. These described embodiments are examples of the currently disclosed technology. In addition, in order to provide a brief description of these embodiments, all features of the actual embodiments may not be described in the specification. It should be understood that, as in any engineering or design project, when developing any such actual implementation, numerous decisions related to the specific implementation must be made to achieve the specific goals of the developers, such as complying with system-related and business-related constraints, which may vary from implementation to implementation. In addition, it should be understood that such development work may be complex and time-consuming, but for ordinary technicians who benefit from the present disclosure, this will still be a routine task in design, fabrication, and production.

[0099] The articles "one", "an" and "said" are intended to indicate the presence of one or more features in the preceding description. In addition, it should be understood that reference to "one embodiment" or "embodiment" of the present disclosure is not intended to be interpreted as excluding the presence of other embodiments that also incorporate the features. For example, any element described with respect to the embodiments herein may be combined with any element of any other embodiment described herein. As will be understood by a person of ordinary skill in the art encompassed by the embodiments of the present disclosure, the numerals, percentages, ratios or other values ​​stated herein are intended to include the value, as well as other values ​​that are "about" or "approximately" the value. Therefore, the value should be interpreted broadly enough to include at least sufficiently close to the value to perform the desired function or achieve the desired result. The value includes at least the variation expected in a suitable manufacturing or production process, and may include values ​​within 5%, within 1%, within 0.1%, or within 0.01% of the value.

[0100] In view of the present disclosure, those of ordinary skill in the art should recognize that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and modifications may be made to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional "means plus function" clauses, are intended to cover structures described herein that perform the functions, including structural equivalents that operate in the same manner and equivalent structures that provide the same functions. It is the express intent of the applicant not to invoke means plus function or other functional requirements for any claim, except for the requirement that the words "means for..." appear together with the associated function. Each addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims will be covered by the claims.

[0101] As used herein, the terms "approximately," "about," and "substantially" refer to an amount that is close to a stated amount and still performs a desired function or achieves a desired result. For example, the terms "approximately," "about," and "substantially" may refer to an amount that is within a range of less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount. Furthermore, it should be understood that any directions or reference frames in the foregoing description are merely relative directions or movements. For example, any references to "up" and "down," or "above," or "below," merely describe the relative positions or movements of the associated elements.

[0102] The present disclosure may be embodied in other specific forms without departing from its spirit or features. The described embodiments should be considered as illustrative only and not restrictive. Therefore, the scope of the present disclosure is indicated by the appended claims rather than by the foregoing description. Changes in the meaning and scope of the equivalents of the claims will be included within the scope of the claims.

Claims

1. A downhole tool comprising: case; a housing chamber disposed within the housing; a fluid chamber located outside the housing; a partition connected to the housing, the partition separating the housing chamber from the fluid chamber, the partition preventing particles from passing between the housing chamber and the fluid chamber; a movable member disposed within the housing, the movable member being configured to move relative to the housing through the partition; as well as a pressure regulator separate and distinct from the movable member, the pressure regulator being disposed between the housing chamber and the fluid chamber, and the pressure regulator being configured to maintain a pressure difference between the housing chamber and the fluid chamber below a maximum pressure difference set by the pressure regulator; wherein the shell includes a first flow path passing through the partition, and the movable member is inserted into the first flow path between the shell chamber and the fluid chamber; the pressure regulator includes a second flow path between the shell chamber and the fluid chamber, and the second flow path is separate and different from the first flow path.

2. The downhole tool of claim 1, wherein: The movable member is configured to rotate relative to the divider.

3. The downhole tool of claim 1, wherein: The movable member is a turbine in a generator.

4. The downhole tool of claim 1, wherein: The movable member is a rotor of a rotary valve.

5. The downhole tool of claim 1, wherein: The pressure regulator comprises: a regulator chamber in fluid communication with the housing chamber and the fluid chamber; a seat located on a high pressure side of the regulator chamber; and A flow restrictor is located in the regulator chamber.

6. The downhole tool of claim 5, wherein: The pressure regulator also includes a resilient member that urges the restrictor against the seat with a force sufficient to maintain the maximum pressure differential.

7. The downhole tool of claim 6, wherein: The restrictor is configured to move within the regulator chamber in response to a pressure differential between the housing chamber and the fluid chamber.

8. The downhole tool of claim 5, wherein: The pressure regulator also includes a relative positioning spring that maintains the flow restrictor in a neutral position.

9. The downhole tool of claim 1, wherein the pressure regulator comprises: a regulator chamber in fluid communication with the housing chamber and the fluid chamber; a seat, the seat being located on a high pressure side of the regulator chamber; a sealing member located in the regulator chamber; as well as An opposing positioning spring maintains the sealing member in a neutral position in which the sealing member blocks openings to the first alternate path and the second alternate path.

10. The downhole tool of claim 1, wherein: The pressure regulator includes a first pressure regulator that regulates pressure from the fluid chamber to the housing and a second pressure regulator that regulates pressure from the housing to the fluid chamber.

11. The downhole tool of claim 1, wherein: The pressure regulator includes a diaphragm that opens an orifice between the housing and the fluid chamber in response to a pressure differential between the housing chamber and the fluid chamber.

12. The downhole tool of claim 1, wherein: The partition and the movable member are connected with a gap of 500 μm or less.

13. The downhole tool of claim 1, wherein: The partition includes a support disposed between the movable member and the housing.

14. The downhole tool of claim 1, wherein: The pressure regulator is disposed within the partition.

15. The downhole tool of claim 1, wherein: The pressure regulator includes a regulator chamber, and a flow restrictor in the regulator chamber includes a radial gap of less than 500 μm.

16. The downhole tool of claim 1, wherein: The housing has a first end and a second end; The movable member is connected to the housing at the first end by a bearing, the bearing having a gap of less than 500 μm between the bearing and the movable member, the movable member being rotatable relative to the housing, the movable member comprising a central support; as well as The support surface is disposed at the second end inside the housing, the support surface supporting the central support.

17. The downhole tool of claim 16, wherein: The central support is configured to engage the bearing surface with a bearing radius of 1 mm or less.

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