Steering device enhancements, methods, and systems

Abstract

A steering intensifier for a steering device of a drilling tool includes: a body; a first flow channel in the body and configured to convey a fluid supply; a channel at an outer surface of the body, the channel configured to generate a Bernoulli effect in the channel during fluid flow therein; a second flow channel fluidly connecting the first flow channel to the channel; and a valve associated with the second flow passage and configured to allow, prevent, or suppress flow through the second flow passage. A downhole drill bit assembly includes a steering intensifier, a drill bit attached to the steering intensifier. A method for drilling a wellbore in a surface includes delivering a steering device into the wellbore, operating a valve to allow, prevent, or suppress flow through a second flow passage, generating a steering force at a steering enhancer by the generated Bernoulli effect.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of an earlier filing date of U.S. Application Serial No. 63 / 425,798, filed on November 16, 2022, the entire disclosure of which is incorporated herein by reference. Background Art

[0003] In the industry of accessing underground reservoirs through boreholes, it is sometimes desirable to be able to turn a string of pipes that extends in a borehole being drilled or even in a pre - existing borehole to assist the movement of these pipes through deviations in the borehole trajectory. Bending joints are common devices used to cause the turning of pipes formed or extending in a borehole. Although bending joints and other devices for turning have been used quite successfully, there has always been room for improvement in efficiency in the art. Summary of the Invention

[0004] An embodiment of a steering enhancer for a steering device of a drilling tool, the steering enhancer comprising: a body having an inner surface and an outer surface and configured to be attached to a drill bit; a first flow path defined by the inner surface of the body and configured to convey a fluid supply source; a channel located at the outer surface of the body and configured to generate a Bernoulli effect in the channel during fluid flow therein; a second flow path fluidly connecting the first flow path to the channel; and a valve associated with the second flow path and configured to allow, block, or inhibit flow through the second flow path.

[0005] An embodiment of a downhole drill bit assembly, the downhole drill bit assembly comprising a steering enhancer and a drill bit attached to the steering enhancer.

[0006] An embodiment of a method for drilling a borehole in the earth's surface, the method comprising conveying a steering device into the borehole, operating a valve to allow, block, or inhibit flow through the second flow path, and generating a steering force at the steering enhancer through the generated Bernoulli effect. Description of the Drawings

[0007] The following description should not be considered restrictive in any way. Referring to the accompanying drawings, like elements are denoted by like reference numerals:

[0008] Figure 1 is a cross - sectional view of a steering device as disclosed herein;

[0009] Figure 1A is an alternative embodiment of a steering device as disclosed herein;

[0010] Figure 1B is an alternative embodiment of a steering device as disclosed herein;

[0011] Figure 2 shows an embodiment of a flow barrier;

[0012] Figure 3 is similar to Figure 1 but has a view of a single actuator;

[0013] Figure 4 is a cross-sectional view of a steering enhancer;

[0014] Figure 5 is of Figure 3 with different stabilizer positions; and

[0015] Figure 6 is a view of a wellbore system including a steering device as disclosed herein. DETAILED DESCRIPTION

[0016] A detailed description of one or more embodiments of the devices and methods disclosed herein is presented by way of example and not limitation with reference to the accompanying drawings.

[0017] Referring to Figure 1 , a steering device 10 is shown in cross-section. The device includes a drill bit 12 that is configured to cut and / or break down a subterranean formation such as subterranean formation 52 and has a flow passage 14 therein. The flow passage 14 may include one or more sections, such as connected sections, to allow fluid to flow through the sections and from one section to other sections. Figure 1Three sections (14a, 14b, 14c) of the flow path 14 are shown. These provide a fluid path through the flow path 14 from a fluid supply source 18 of the steering device 10 (which may be a conveyance tool or source) to the outer surface 16 of the drill bit 12. Note that the fluid supply source 18 may be defined by the inner diameter (ID) of the steering device 10, which is fluidly connected to the ID of a pipe string 20 (e.g., a drill string 20 or drill pipe 20) that is capable of supplying fluid 56 (e.g., drilling fluid, also known as drilling mud or mud) to the steering device 10, but control lines may also be used to supply the fluid 56 to other devices such as one or more valves 22. Optionally, in addition to the fluid flow through the flow path 14 via the valve 22, one or more additional permanent flow paths 37 also provide a continuous fluid flow through the drill bit. In this context, a permanent flow path 37 means that the flow path 37 is not connected to a valve that selectively or temporarily changes, reduces, or blocks the fluid flow through the permanent flow path 37 even when a pressure differential occurs between the pressure in the fluid supply source 18 and the pressure at the outer surface 16 of the drill bit 12. The additional fluid flow through the additional permanent flow paths 37 allows for cooling and lubricating the drill bit 12 even when all the valves 22 are closed and / or when the fluid flow through the valves 22 is insufficient. The drill bit 12 and the steering device 10 are threadedly connected and rotate at the same speed during operation. The flow path 14 and the valves 22 rotate with the steering device 10. One or more stabilizers 123 may be mounted on the steering device 10 or the pipe string 20 to stabilize and guide the steering device 10 / pipe string 20 within the wellbore 40.

[0018] The valve 22, selectively operated by an actuator 24, is disposed in the fluid path from the fluid supply source 18 to the flow path 14. In an embodiment, the valve 22 may be a rotary valve or a reciprocating valve. The valve 22 has an inlet port 67 connected to the fluid supply source 18. The outlet port 73 of the valve 22 is connected to the flow path 14, which in turn leads to a flow outlet 130 (such as an outlet nozzle) that may be located at the end of section 14b or 14c. At the surface 54 ( Figure 2 )), the fluid 56 may be pumped into the pipe string 20 and thus into the fluid supply source 18 of the steering device 10 (sometimes referred to herein as the borehole fluid passage) to become the fluid supply source 18, which is then used for the steering device 10. Depending on the size of the selected flow path 14, the pressure in the fluid supply source 18 may be significantly higher than the pressure between the outer surface 16 of the drill bit 12 and the inner surface 38 of the wellbore 40.

[0019] The valve 22 can be actuated in a selective manner by an actuator 24 electrically, mechanically, hydraulically, or otherwise, and this selective manner is controlled by a controller 26 operatively connected to the actuator 24. Thus, in the actuated state, the valve connects the high-pressure fluid supply source 18 fluidly with the flow passage 14. Due to the pressure difference between the fluid supply source 18 and the annular space (sometimes referred to herein as the wellbore annulus) between the outer surface 16 of the drill bit 12 and the inner surface 38 of the wellbore 40, the drilling fluid is discharged at a rate that causes a lower fluid pressure and, correspondingly, pulls the drill bit 12 toward the inner surface 38 of the wellbore 40, where the fluid discharges from the passage 14c.

[0020] The controller 26 can be located within or above the steering device 10, and optionally, the actuator 24 and / or the controller 26 can also rotate with the steering device 10. Alternatively, the controller 26 can be located remotely downhole or at the surface 54 (see Figure 6)。The controller 26 can be hardwired to the actuator 24 or wirelessly connected to the actuator 24. It should be understood that in an embodiment, more than one valve 22 can be controlled by one actuator 24, or one controller 26 can operate more than one actuator 24. The controller 26 can be configured to control one or more actuators 24 and / or valves 22 individually. For example, the controller 26 can be configured to control a first actuator and a second actuator 24 and / or a first valve and a second valve 22 to allow a greater flow of fluid through the first valve compared to the second valve. In some operating modes, the controller 26 is configured to actuate the valve 22 in such a way that fluid 56 flows through the flow passage 14 only when the flow passage 14 is at or near a particular azimuthal direction of the steering device 10 about its axis of rotation 28. For example, the controller 26 can be connected to one or more direction sensors 43 (e.g., in the tubular string 20) inside or outside the steering device 10, which provide information about the rotational position of the steering device 10 (e.g., a rotational azimuthal value about the axis of rotation 28 of the steering device 10 or a signal indicating that the rotational azimuthal value of the steering device 10 is at a preselected rotational azimuth or has a preselected rotational azimuth interval). Based on this information, the controller 26 operates one or more valves 22. The controller 26 can, for example, operate the valve 22 to increase fluid flow only when the steering device 10 is in a preselected rotational position interval (i.e., when the rotational azimuth of the steering device 10 about the axis of rotation 28 is within a preselected value range). Alternatively, the direction sensor 43 provides the rotational speed of the steering device 10, and the controller 26 operates the valve 22 in a periodic manner, where the period is related to the rotational speed provided by the direction sensor 43. For example, in some operating modes, such as when the rotational speed of the steering device 10 is constant, the controller 26 is configured to actuate the valve 22 in a periodic manner with a constant period such that fluid 56 flows through the flow passage 14 only when the flow passage 14 is at or near a particular azimuthal direction of the steering device 10 about its axis of rotation 28. By actuating the valve 22 in this way, the fluid 56 flowing in the section 14c will generate a steering force on the steering device 10, which section can be a waste chute or channel formed in the drill bit 12 for conveying the fluid 56. Due to the pressure difference between the hole fluid passage and the annular passage in the wellbore annulus between the steering device 10 and the inner surface 38 of the wellbore 40, this creates a high-speed fluid flow through the section 14c, resulting in a Bernoulli effect, where the lower pressure causes a Bernoulli suction that pulls the steering device 10 in the direction of the fluid flow, thereby serving as a steering force on the steering device 10, which is configured to change the drilling direction of the wellbore 40 to steer the steering device 10 including the drill bit 12 during the drilling process. The valve 22, actuator 24, and / or controller 26 can be operated in such a way that the generated Bernoulli suction remains stationary relative to the ground. In this context, stationary relative to the ground means that the direction of the Bernoulli suction points in the same azimuthal direction relative to a fixed reference (such as the formation, the Earth's magnetic field, and / or the direction of gravity).That is, the Bernoulli suction does not change its azimuthal direction around the axis of rotation 28 over a period of time. In an embodiment, the Bernoulli suction remains stationary relative to the ground when the steering device 10 rotates. In some embodiments, the ground stationary nature of the Bernoulli suction is maintained for a predefined time interval or a predefined number of revolutions. For example, when the steering device 10 rotates at least ten revolutions, such as the steering device 10 rotates at least 20 revolutions or even at least 50 revolutions, the Bernoulli suction will remain stationary relative to the ground.

[0021] In Figure 1 FIG. 2, the valve 22 is shown as a reciprocating valve (e.g., a poppet valve or a mushroom valve), where the actuator 24 causes a reciprocating motion of a blocking member (e.g., a plug) 29 to press it against an opening (e.g., a base) 27 or release it from the opening to regulate the flow of fluid 56 through the flow passage 14. Alternatively, the actuator 24 may also rotate a rotating member (not shown) operatively connected to the blocking member 29 and cause a reciprocating motion of the blocking member 29 (e.g., when the rotating member is a camshaft rotated by the actuator 24 and operatively connected to the blocking member 29, where the rotation of the camshaft causes a reciprocating motion of the blocking member 29). As another example, the valve 22 may be a rotary valve, where the rotation of a passage (e.g., a passage included in a lateral plug) connects or disconnects the fluid supply source 18 from the flow passage 14 to regulate the flow of fluid 56 through the attached flow passage 14. For a rotary valve, the blocking member 29 may rotate relative to the opening 27. The rotation of the blocking member 29 may be at the same rotational speed as the rotation of the steering device 10 or at a different rotational speed to achieve a ground stationary Bernoulli suction.

[0022] A waste chute or channel adjacent to other waste chutes or channels is at least partially hydraulically isolated from the adjacent waste chutes or channels to enhance the fluid flow that generates the Bernoulli effect. This can be managed by structures such as a flow barrier 33 between adjacent waste chutes or channels (e.g., which can be a cutting arm of the drill bit 12 or a dedicated structure), which is within a certain distance from the inner surface 38 of the wellbore 40. This distance is less than the distance from the outer surface of the channel to the surface 38 of the wellbore 40. For example, when the steering device 10 is in use, the distance of the flow barrier 33 to the inner surface 38 of the wellbore 40 can be about 10 mm or less, or even 5 mm or less. That is, the diameter of the flow barrier 33 is 20 mm or less, or even 10 mm or less smaller than the diameter of the outermost cutting structure of the drill bit 12. Additionally, it is contemplated that the flow barrier 33 can be configured with an extendable element 42 that can move towards the inner surface 38 of the wellbore 40 during use to enhance the hydraulic isolation between adjacent waste chutes or channels and then easily collapse so as not to create resistance on the drill bit 12. Note that the extendable element 42 can be advantageous but is not necessary for practicing the present disclosure. Instead, some concepts disclosed herein are adapted to provide a steering device for downhole that does not have an extendable component (e.g., does not have an extendable component that contacts the wellbore wall 120).

[0023] The fluid flow in the flow channel 14 can leave a portion of the flow channel 14 (which can be at the end of section 14b or at the end of section 14c) and reach the outer surface 16 of the drill bit 12, located at the surface 36 of the drill bit 12 or at the radial side of the drill bit 12. In some embodiments (refer to Figure 6 ), at the flow outlet 130 where the fluid flows out of the flow channel 14 (e.g., located at the end of section 14b and / or section 14c), the flow direction is in the upward drilling direction of the drill bit 12, which is also the downstream direction for the flowing fluid 56 (e.g., drilling mud) to return to the surface. For example, a flow outlet 130 on the radial outer surface 16 of the drill bit 12 rather than on the drill bit surface 36 generates a flow with a flow direction along the upward drilling direction of the drill bit 12. When steering is required, flow through the flow channel 14 is allowed mainly or even only near or at selected azimuthal positions (by the actuator 24 and the valve 22). The fluid flow along the outer surface 16 of the drill bit 12 from the flow channel 14 generates a radial Bernoulli suction force (represented by the arrow 39) and a steering force in the same azimuthal direction.

[0024] In the case of including more than one Bernoulli subsystem (flow channels 14, valves 22, and actuators 24), by cycling the sequential valves 22 at appropriate times and at appropriate azimuthal positions of the flow channel sections 14b / 14c, the steering device 10 can generate more than one steering force per revolution, such that each valve provides fluid flow only when its associated flow channel section 14b / 14c is in the desired azimuthal position. When none of the flow channel sections 14b / 14c are in the selected azimuthal position, the valves 22 can be actuated to reduce or prevent fluid flow through their associated flow channel sections 14b / 14c. Figure 1 Two Bernoulli subsystems are shown, but more can be envisioned. In an ideal embodiment, at least three Bernoulli subsystems are envisioned. In each Bernoulli subsystem, the actuator 24 can be individually addressable to cause repositioning of the associated valve 22, thereby allowing control of: 1) when the Bernoulli effect is generated according to fluid flow in the associated flow channel 14; and 2) the magnitude of the fluid flow to generate a greater (greater Bernoulli effect) or smaller (smaller Bernoulli effect) steering force and the radius of curvature of the drilled borehole 40. In an embodiment, the actuator 24 is capable of operating at at least 3 Hz, but faster and slower rates are also envisioned for various requirements. It should also be understood that if all the valves 22 are opened or closed simultaneously, and thus at all azimuthal positions, the steering device 10 will drill in the natural direction without a steering force applied by the Bernoulli subsystems. Closing all the valves 22 can also help eliminate any blockages in the permanent flow channels 37, which may be generated, for example, by solids in the fluid 56 during operation of the steering device 10.

[0025] In one or more embodiments, actuator 24 is also capable of being actuated to position valve 22 at a position other than fully open or fully closed. Valve 22 can in fact be positioned at any position between fully open and fully closed (and including fully open and fully closed), thereby allowing control of the degree of Bernoulli suction and / or steering force generated in steering device 10. Thus, the Bernoulli suction can be adjustable to produce a specific magnitude of steering force that can always vary as needed. Specifically, if a smaller flow of fluid 56 is released through flow passage 14 by only partially opening valve 22, a smaller Bernoulli suction is generated and thus a smaller steering force. The greater the fluid flow through flow passage 14, the greater the Bernoulli effect and thus the greater the steering force caused. In some embodiments, desired steering parameters such as desired steering force, Bernoulli suction, flow rate of fluid 56, radius of curvature of the drilled borehole 40, etc. can be determined and transmitted to controller 26. Transmitting the desired steering parameters to controller 26 can be done before the steering device 10 is operated downhole or during the drilling process and while the steering device 10 is in operation (e.g., in real time). Controller 26 uses the desired steering parameters to adjust one or more valves 22 accordingly.

[0026] In an embodiment, actuator 24 can include a position feedback configuration that can include a sensor 17 operably connected to actuator 24 or valve 22 or flow passage 14. Sensor 17 can provide data on the relative position of valve 22 or data on the fluid flow through flow passage 14 to controller 26 to adjust valve 22 via actuator 24 until the measured data of sensor 17 is close enough to a predetermined value (e.g., until the difference between the measured data of sensor 17 and the predetermined value is less than a predetermined threshold). For example, when the sensor is a flow meter, it can be used to measure the fluid flow rate in flow passage 14, thereby generating fluid flow rate data, and this fluid flow rate data can be used by controller 26 to adjust valve 22 via actuator 24 until sensor 17 measures the desired fluid flow rate. As another example, the position feedback configuration reports the position of the Bernoulli subsystem (e.g., the position of blocking member 29 relative to opening 27) to controller 26, for example, in real time. In other embodiments, actuator 24 can include a resolver motor such that the motor position can be known to the controller.

[0027] Figure 1AAn alternative embodiment is shown that includes one or more channels 145 machined into the steering device 10 (e.g., by milling or by welding, brazing, or screwing additional material onto the OD of the tool body), and a timed threaded connection 165 between the drill bit 12 and the steering device 10. The timed threaded connection 165 ensures alignment of the section 14c (which can be a waste chute or channel in the drill bit 12) with the one or more channels 145 such that fluid flowing through the section 14c will also flow through the channels 145. Advantageously, the one or more channels 145 can be machined into a portion 155 of the steering device 10 that is larger than an adjacent portion 175. For example, the portion 155 can have an outer diameter that is larger than the outer diameter of the adjacent portion 175. The one or more channels 145 provide additional flow paths behind the drill bit 12. The one or more channels 145 increase the effective area of the lower pressure, thereby causing a higher Bernoulli suction and a steering force for the steering device 10 and the drill bit 12.

[0028] Figure 1B Another alternative embodiment is shown in which one or more flow channels 115 are machined into a sleeve 105 mounted on the outer diameter of the steering device 10. The sleeve 105 can be fixed by retention features 125, such as a retaining sleeve, e.g., a threaded retaining sleeve. The sleeve 105 can be aligned with the drill bit 12 such that the section 14c (which can be a waste chute or channel in the drill bit 12) is aligned with the one or more channels 115 in the sleeve 105 such that fluid flowing through the section 14c will also flow through the channels 115. The alignment between the section 14c and the channels 115 can be fixed (e.g., locked) by a rotational locking feature 135 (e.g., a fastener such as a locking key, bolt, screw, or pin) or by the shape of the mating surfaces of the drill bit 12 and the sleeve 105 (such as key teeth, profiles, or serrated structures), thereby allowing the use of a standard, non-timed threaded connection 117 between the drill bit 12 and the steering device 10. The one or more channels 115 provide additional flow paths behind the drill bit 12. The one or more channels 115 increase the effective area of the lower pressure, thereby causing a higher Bernoulli suction and a correspondingly higher steering force for the steering device 10 and the drill bit 12.

[0029] Figure 1A The portion 155 in Figure 1B and the sleeve 105 in can provide additional mounting space for electronics or sensors or one or more flow barriers 33 (such as seals). The one or more flow barriers 33 can be formed by an extensible element 42 ( Figure 1) and / or provided by additional fluid flows introduced other than the fluid flows through section 14c, passage 145, and / or passage 115, and can be directed and configured to reduce or prevent fluid exchange between passage section 14c, passage 145, and / or passage 115. In the case where the distance between the outer surface 16 of the drill bit 12 and / or the steering device 10 and the inner surface 38 of the wellbore 40 is large ( Figure 1 ), the flow barrier 33 can support generating sufficient Bernoulli suction. The flow barrier 33 can thereby ensure that sufficient steering force is available to push the drill bit 12 in the desired direction. In some embodiments, passage 145 above or within portion 155 of the steering device 10 and / or passage 115 above or within sleeve 105 can each be longer than section 14c, such as a waste chute or passage on the drill bit 12.

[0030] In some embodiments, one or more valves 22 can interact to control fluid flow in a particular mud passage 14c (e.g., interact via controller 26). For example, if three or more valves 22 are used, such as a first valve, a second valve, and a third valve, the fluid flow through one of the first valve, the second valve, and the third valve can be adjusted based on the fluid flows through the other two of the first valve, the second valve, and the third valve. For example, in a particular rotational position of the steering device 10, the first valve can allow a first fluid flow, the second valve can allow a second fluid flow, and the third valve can allow a third fluid flow. In this example, one or more of the first fluid flow, the second fluid flow, and the third fluid flow can be zero. The first fluid flow can be adjusted by the first valve based on the second fluid flow and the third fluid flow, the second fluid flow can be adjusted by the second valve based on the first fluid flow and the third fluid flow, and / or the third fluid flow can be adjusted by the third valve based on the first fluid flow and the second fluid flow. Thus, the first fluid flow, the second fluid flow, and the third fluid flow can be different and can vary independently over time. Alternatively or in addition, the fluid flow through one of the one or more valves 22 can be adjusted individually based on downhole pressure and / or the total available fluid flow from the fluid supply source 18 through the steering device 10. Further, one or more valves 22 can be operated to compensate for disturbances in the steering force, such as by system amplification or attenuation of the steering force or Bernoulli suction.

[0031] Now turning to Figure 2 , the flow barrier 33 can include, for example, a tip seal 210 located in a groove 240 (such as an elongate groove) along or between the waste chutes (see Figure 2)。The flow barrier 33, including the top seal 210, can be arranged substantially parallel to the axis of rotation 28 of the steering device axis 10 or can be arranged at an angle relative to the axis of rotation 28 of the steering device 10. Such a top seal 210 can be powered by a biasing member 230 which, in embodiments, can include an active element (such as an actuator) and / or can include a passive element (such as a (weak) spring) (e.g., a spring with a relatively low stiffness that is configured to extend with a relatively low force and engage the borehole wall 220 to keep friction and frictional forces at a relatively low level while still inhibiting fluid flow therethrough. In some cases, the shape of the outer radial surface 16 of the drill bit 12 may not exactly match the shape of the inner surface of the borehole wall 220. In these cases, there may be a fluid-filled space or one or more cavities between the drill bit 12 / steering device 10 and the borehole wall 220, such as a first cavity 250 and / or a second cavity 260. The flow barrier 33 or the top seal 210 serves to limit or reduce the fluid connection between adjacent first and second cavities or waste grooves, thereby limiting or reducing the fluid flow between the first and second cavities, thus increasing the sealing effect between these cavities or waste grooves. Reducing the fluid connection between adjacent first and second cavities or waste grooves further confines the region of relatively high flow rate to a separate azimuthal range defined by the first or second cavity. If Bernoulli suction produces a desired lateral offset in the direction of the low-pressure region towards the borehole, the top seal 210 can be squeezed to retract the spring accordingly. The spring is sized to maintain the extended position of the top seal 210.

[0032] In some embodiments, the valve 22 rotates with the steering device 10, and in other embodiments, the actuator 24 also rotates with the steering device 10. In other embodiments, see Figure 3 , a single actuator 30 is configured to operate more than one valve 22. The single actuator 30 can operate one or more valves 22 and / or all valves 22 in the steering device 10. Figure 3An iteration of the steering device 10 is shown, in which a single actuator 30 operates a plurality of valves 22 and operates the plurality of valves 22 by means of a swashplate 32 attached to a motor 34. The swashplate 32 can be rotated to ensure that the valves 22 will operate periodically, for example to generate a Bernoulli suction force that remains stationary relative to the ground. In this context, remaining stationary relative to the ground means that the direction of the Bernoulli suction force points in the same azimuthal direction relative to a fixed reference (such as the formation, the earth's magnetic field, and / or the direction of gravity). That is, the Bernoulli suction force does not change its azimuthal direction around the axis of rotation 28 of the steering device 10 over a period of time. Then, in an embodiment, when the steering device 10 rotates, the swashplate 32 will remain stationary relative to the ground. In some embodiments, the ground-stationary nature of the Bernoulli suction force is maintained for a predefined time interval or a predefined number of revolutions. For example, when the steering device 10 rotates at least ten revolutions, the steering device 10 rotates at least 20 revolutions, or even rotates at least 50 revolutions, the swashplate 32 will remain stationary relative to the ground. The motor 34 can be an electric motor, a hydraulic motor, etc.

[0033] See Figure 4 and Figure 5 , a steering enhancer 60 is also disclosed. The enhancer 60 can be used as a supplement to the steering device 10 disclosed above, or as a separate entity coupled to other tools that require steering input. When the enhancer 60 is used in combination with the steering device 10, the enhancer will increase the total length of the channels or waste grooves to improve the overall Bernoulli effect. In some embodiments, the enhancer channels can each be longer than section 14c ( Figure 1 ), such as the waste grooves or channels on the drill bit 12. The enhancer 60 includes a body 62 that has a longitudinal extent and defines an inner surface 64 and an outer surface 66. In some embodiments, the body is configured to be attached to the drill bit 12, but it is also contemplated that the body can be configured to be attached to other downhole tools rather than the drill bit, and these other downhole tools will still benefit from the steering input that the enhancer can provide. The inner surface 64 depicts a longitudinally oriented flow channel 68 that is supplied with fluid 56, such as drilling mud, from a tubular string 20 connected thereto. The body 62 also defines a radially oriented flow channel 70 (i.e., a flow channel having a radial direction component) that fluidly connects the longitudinally oriented flow channel 68 to the outer surface 66 of the body 62. In addition, a first channel 72 is formed at the outer surface 66 of the body 62 to generate a Bernoulli effect through the wall of the wellbore 40 during the flow of fluid therethrough. Additional channels 72 can also be used and can be distributed circumferentially around the enhancer 60, for example, evenly distributed if desired. One, two, three, or more channels 72 are contemplated. The number of channels 72 is only limited by the available space around the periphery of the booster 60. A first valve 74 is associated with the radially oriented flow channel 68 such that the valve 74 can be actuated as needed or in response to a controller (e.g., Figure 1the program in the controller 26) to allow, block, or inhibit fluid flow through the radially oriented flow channels 68 so that a Bernoulli effect can be generated at or near a target azimuthal direction relative to the axis 76 of the intensifier 60. The actuator and valve can be any of the above-described actuators and valves and can also include a disk valve as shown in Figure 4 and Figure 5 and identified by the numeral 74. The disk valve can be operated by a single motor 34 having the ability to hold the valve 74 substantially stationary relative to the ground.

[0034] Referring back to the channels 72, it should be understood that such channels can be cut into the body 62 or constructed on its outer surface 66. The barrier 78 between adjacent channels 72 can be any material and, in an embodiment, can be sized to extend from the body 62 by about 10 mm or less, or even 5 mm or less, from the inner surface 38 of the borehole 40. The material for the barrier 78 can be attached to the surface 66 by welding, hard soldering, adhesives, fasteners, etc. The barrier 78 can have only that specific purpose or can be configured to have additional purposes, such as a mounting area for electronics or sensors, a sealing function for reducing or preventing fluid leakage between the channels 72, etc. The sealing function can be provided by a seal on the barrier 78, such as using an extensible element similar to the extensible element 42 described above, or by fluid flow. The sealing function generated by fluid flow can be achieved in several different ways, one of which is to provide additional flow channels between the inner surface 64 and each barrier 78. A portion of the total flow will leave these channels rather than the nozzles or channels 70 in the drill bit 12. The additional sealing channels can preferably be oriented such that the drilling fluid leaves the barrier 78 substantially perpendicular to the inner surface 38 of the borehole 40. Since this additional sealing flow will slow down by colliding with the borehole wall, it will create an increased pressure volume between the outer surface of the barrier 78 and the inner surface 38 of the borehole 40. This increased pressure volume counteracts the pressure balance between adjacent channels 72, providing benefits similar to the extensible element 42 but without moving parts that may be subject to wear and tear during operation.

[0035] The body of the intensifier 60 may be configured with timing threads 80 that ensure that the passageway 72 will be generally aligned with a waste chute or passageway in the drill bit 12 (which constitutes section 14c in some embodiments) when used with the drill bit. In this context, approximate alignment means that the angular difference between the waste chute / passageway of the drill bit 12 and the passageway 72 is in the range of +90° to -90°, such as in the range of +45° to -45° or even in the range of +20° to -20°. For example, aligning the passageway 72 with section 14c will enhance the steering input by extending the length of the flow path in which the Bernoulli effect may be achieved, and thus increase the resulting steering moment. In some embodiments, aligning the passageway 72 approximately 180° away from section 14c (i.e., the angular difference between the waste chute / passageway of the drill bit 12 and the passageway 72 is in the range of 90° to 270°, such as in the range of 135° to 225° or even in the range of 160° to 200°) may also have a steering effect, particularly when the stabilizer 84 is installed between the passageway 72 and the drill bit 12 (see the discussion below with respect to Figure 5 ). Although the timing threads can well align the passageway 72 with section 14c in the drill bit 12 or align the passageway 72 approximately 180° away from section 14c in the drill bit 12, they are cumbersome to manufacture. Thus, it is also contemplated that the body 62 may include a sleeve 82 disposed thereon that is capable of rotating about the body 62 until it is fixed (e.g., locked) in place by a fastener (such as a locking key, bolt, screw, or pin) or by the shape of the mating surfaces of the drill bit 12 and the sleeve 105 (such as key teeth, profiles, or tooth forms, etc.). Thus, the body 62 can be attached to the tool to be steered without timing threads, then the sleeve 82 can be rotated to align the passageway 72 as needed, and the sleeve can be fixed in place. The additional length of the passageway associated with a higher Bernoulli effect can also be achieved by lengthening the drill bit 12, but this increases the cost of the drill bit, while the intensifier 60 provides an advantage without increasing the cost.

[0036] As a further feature of the intensifier 60, the stabilizer 84 may be disposed at the Figure 4 position or at the Figure 5 position. For example, as shown in Figure 4 , in some embodiments, the stabilizer 84 may be located above the passageway 72, which places the passageway 72 between the stabilizer 84 and the drill bit 12. In other embodiments, as shown in Figure 5 , the stabilizer 84 may be located between the passageway 72 and the drill bit 12 (where it is not necessary for the passageway to extend from section 14c ( Figure 1) continuation, where the section can be a passage or a waste chute of the drill bit 12) or other tools located in the upward drilling direction of the passage 72. In other embodiments, more than one stabilizer 84 is installed, and one of the stabilizers 84 is located below the passage 72 and the other stabilizer 84 is located above the passage 72.

[0037] It should also be understood that if the valves 22, 74 are not operated during one or more rotations of the steering device 10 and thus at all azimuthal positions of the steering device 10 (e.g., if the valves 22, 74 are opened or closed or in a fixed position between fully open and fully closed during one or more rotations of the steering device 10), the steering force caused by the fluid 56 leaving the outlet 130 will also rotate with the steering device 10 and will thus be cancelled during one or more rotations of the steering device 10, or become distributed 360 degrees around the steering device 10 and cancelled, and thus no steering effect is provided to the steering device 10 and / or the drill bit 12. Therefore, when the valve 22 is not operated during one or more rotations of the steering device 10, the steering device 10 will drill in a natural direction (such as in a straight or tangential direction), thereby forming a straight or tangential section of the wellbore 40 (such as the straight or tangential section 99 of the wellbore 40, rather than the curved section 93 of the wellbore achieved when a geostationary steering force is formed, see Figure 6 ). In use, the intensifier 60 can be configured such that during drilling with the steering intensifier 60 rotating 5 or more turns in a natural direction (such as in a straight or tangential direction), the total flow rate through the valves 22, 74 (e.g., the first flow rate through the first valve and the second flow rate through the second valve) remains constant within about 20% or less, thereby creating a straight or tangential section of the wellbore 40. A similar effect is achieved when the controller 26 operates one or more valves 22, 74 in a periodic manner, where the period of valve operation is not a multiple of the revolution period of the rotation of the steering device 10. That is, when the controller 26 operates one or more valves 22, 74 in a periodic manner, where the period of valve operation is not a multiple of the revolution period of the rotation of the steering device 10 during one or more rotations of the steering device 10, the steering force caused by the fluid 56 leaving the outlet 130 will be cancelled during one or more rotations of the steering device 10, or become distributed 360 degrees around the steering device 10 and cancelled, and thus no steering effect is provided to the steering device 10 and / or the drill bit 12. Therefore, when the controller 26 operates one or more valves 22, 74 in a periodic manner, where the period of valve operation is not a multiple of the revolution period of the rotation of the steering device 10 during one or more rotations of the steering device 10, the steering device 10 will drill in a natural direction (such as in a straight or tangential direction), thereby forming a straight or tangential section of the wellbore 40 (such as the straight or tangential section 99 of the wellbore 40, see Figure 6)。In one embodiment, valves 22, 74 will operate randomly (e.g., open and close randomly) during one or more rotations of the steering device 10 such that the steering force caused by the fluid 56 exiting the flow outlet 130 will be canceled during one or more rotations of the steering device 10, or become distributed and canceled around 360 degrees of the steering device 10, thereby not providing a steering effect to the steering device 10 and / or the drill bit 12 to drill in a natural direction (such as in a straight or tangential direction), thereby forming a straight or tangential section (such as straight or tangential section 99 of the wellbore 40, see Figure 6 )。

[0038] See Figure 6 , the wellbore system 50 includes a wellbore 40 in a subterranean formation 52. A drilling system or string 20 is disposed in the wellbore 40. The steering device 10 is disposed as part of the string 20.

[0039] In use, the steering device 10 facilitates the successful placement of the drilled wellbore 40 by selectively unevenly distributing fluid toward a selected azimuthal direction relative to the formation, the earth's magnetic field, and / or the direction of gravity, and thereby causing a steering force related to the Bernoulli effect on the steering device 10.

[0040] In addition, relative to any of the above, it is contemplated to associate a direction sensor with a process that serves to ensure that the geographical direction is always known and can thus be used by the controller to control the actuators and valves so that the steering input and direction can be selected or not selected in real time. Additionally, it should be noted that some embodiments will also include a mud passage 37 that extends to the drill bit and is not valve controlled (e.g., see Figure 1 ). Insofar as it is desired to pulse the fluid in these passages, this can be simply achieved by closing all valves or in the case where the disc valve is in a position where the disc valve is misaligned with the outflow opportunity.

[0041] Some embodiments of the foregoing disclosure are shown below:

[0042] Embodiment 1: A steering enhancer for a steering device of a drilling tool, the steering enhancer comprising: a body having an inner surface and an outer surface and configured to be attached to a drill bit; a first flow passage defined by the inner surface of the body and configured to convey a fluid supply source; a passage located at the outer surface of the body and configured to generate a Bernoulli effect in the passage during fluid flow therein; a second flow passage fluidly connecting the first flow passage to the passage; and a valve associated with the second flow passage and configured to allow, block, or inhibit flow through the second flow passage.

[0043] Embodiment 2: The steering enhancer according to any of the foregoing embodiments, wherein the configuration attached to the drill bit is a timed thread.

[0044] Embodiment 3: The steering enhancer according to any of the foregoing embodiments, wherein the azimuthal difference between the waste groove of the drill bit and the channel is in the range of +90° to -90°.

[0045] Embodiment 4: The steering enhancer according to any of the foregoing embodiments, wherein the azimuthal difference between the waste groove of the drill bit and the channel is in the range of 90° to 270°.

[0046] Embodiment 5: The steering enhancer according to any of the foregoing embodiments, wherein the channel is located in the outer surface of the body.

[0047] Embodiment 6: The steering enhancer according to any of the foregoing embodiments, wherein the channel is located in a sleeve that nests with the body and is selectively rotatable on the body and fixable to the body.

[0048] Embodiment 7: The steering enhancer according to any of the foregoing embodiments, wherein the sleeve is selectively fixable by mating surfaces of the drill bit and the sleeve.

[0049] Embodiment 8: The steering enhancer according to any of the foregoing embodiments, further comprising a stabilizer between the channel and the drill bit.

[0050] Embodiment 9: The steering enhancer according to any of the foregoing embodiments, wherein the sleeve is fixable by a fastener.

[0051] Embodiment 10: The steering enhancer according to any of the foregoing embodiments, wherein the steering device is rotatable within the wellbore and the valve rotates with the steering device.

[0052] Embodiment 11: The steering enhancer according to any of the foregoing embodiments, wherein the valve is located between the inner surface and the outer surface of the body.

[0053] Embodiment 12: The steering enhancer according to any of the foregoing embodiments, wherein the valve includes an actuator.

[0054] Embodiment 13: The steering enhancer according to any of the foregoing embodiments, wherein the valve is rotatable independently of the steering enhancer.

[0055] Embodiment 14: A downhole drill bit assembly comprising the steering enhancer according to any of the foregoing embodiments and a drill bit attached to the steering enhancer.

[0056] Embodiment 15: A method for drilling a wellbore in the earth's surface, the method comprising: conveying the steering device as described in any of the foregoing embodiments into the wellbore, operating a valve to allow, block or inhibit the flow through the second flow path, and generating a steering force at the steering enhancer through the generated Bernoulli effect.

[0057] Embodiment 16: The method according to any of the foregoing embodiments, the method further comprising: aligning the passage with the waste chute of the drill bit such that the azimuth difference between the waste chute and the passage is in the range of +90° to -90°.

[0058] Embodiment 17: The method according to any of the foregoing embodiments, the method further comprising: aligning the passage with the waste chute of the drill bit such that the azimuth difference between the waste chute and the passage is in the range of 90° to 270°.

[0059] Embodiment 18: The method according to any of the foregoing embodiments, wherein the passage is located in a sleeve nested with the body, and further comprising: rotating the sleeve to align the passage and fixing the sleeve to the body after alignment.

[0060] Embodiment 19: The method according to any of the foregoing embodiments, the method further comprising: installing a stabilizer between the passage and the drill bit.

[0061] Embodiment 20: The method according to any of the foregoing embodiments, the method further comprising: rotating the steering device within the wellbore and rotating the valve together with the steering device.

[0062] In the context of describing the present invention (especially in the context of the appended claims), the use of the terms "a", "an" and "the" and similar referents should be construed to cover the singular and the plural unless otherwise specified herein or clearly contradicted by the context. In addition, it should be noted that the terms "first", "second", etc. herein do not denote any order, quantity or importance, but are used to distinguish one element from another. The terms "about", "substantially" and "approximately" are intended to include, based on the equipment available at the time of filing the application, the degree of error associated with a particular quantity of measurement. For example, "about" and / or "substantially" and / or "approximately" include a range of ±8% of a given value.

[0063] The teachings of the present disclosure can be used in a variety of well operations. These operations can involve using one or more treatment agents to treat a formation, fluids resident in the formation, a wellbore, and / or equipment in the wellbore, such as production tubing. The treatment agent can be in the form of a liquid, gas, solid, semi-solid, and mixtures thereof. Exemplary treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, preservatives, cements, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, mobility improvers, and the like. Exemplary well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water injection, cementing, and the like.

[0064] Although the invention has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted for its elements without departing from the scope of the invention. Additionally, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from its basic scope. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out the invention, but that the invention will include all embodiments falling within the scope of the claims. Additionally, in the drawings and the detailed description, exemplary embodiments of the invention have been disclosed, and although specific terms have been employed, they have been used only in a general and descriptive sense and not for purposes of limitation, and thus the scope of the invention is not so limited.

Claims

1. A steering intensifier (60) for a steering device (10) of a drilling tool, the steering intensifier (60) being characterized in that: a body (62) having an inner surface (64) and an outer surface (16) and configured to be attached to a drill bit (12); a first flow channel (68) defined by the inner surface (64) of the body (62) and configured to convey a fluid supply source (18); a channel (72) located at the outer surface (66) of the body (62), the channel (72) being configured to generate a Bernoulli effect in the channel during fluid flow therein; a second flow channel (70) fluidly connecting the first flow channel (68) to the channel (72); and a valve (74) associated with the second flow channel (70) and configured to allow, block, or inhibit flow through the second flow channel (70).

2. The steering intensifier (60) according to claim 1, wherein the configuration for attaching to the drill bit (12) is a timing thread (80).

3. The steering intensifier (60) according to claim 1, wherein the azimuthal difference between the waste groove (14c) of the drill bit (12) and the channel (72) is in the range of +90° to -90°.

4. The steering intensifier (60) according to claim 1, wherein the azimuthal difference between the waste groove (14c) of the drill bit (12) and the channel (72) is in the range of 90° to 270°.

5. The steering intensifier (60) according to claim 1, wherein the channel (72) is located in the outer surface (16) of the body (62).

6. The steering intensifier (60) according to claim 1, wherein the channel (72) is located in a sleeve (82) that nests with the body (62) and is selectively rotatable on the body (62) and fixable to the body (62).

7. The steering intensifier (60) according to claim 6, wherein the sleeve (82) is selectively fixable by mating surfaces of the drill bit (12) and the sleeve (82).

8. The steering intensifier (60) according to claim 1, further characterized in that a stabilizer (84) located between the channel (72) and the drill bit (12).

9. The steering intensifier (60) according to claim 6, wherein the sleeve (82) is fixable by a fastener (135).

10. The steering intensifier (60) according to claim 1, wherein the steering device (10) is rotatable within a wellbore (40), and the valve (74) rotates with the steering device (10).

11. The steering intensifier (60) according to claim 1, wherein the valve (74) is located between the inner surface (64) and the outer surface (66) of the body (62).

12. The steering intensifier (60) according to claim 10, wherein the valve (74) includes an actuator (34).

13. The steering intensifier (60) according to claim 1, wherein the valve (74) is rotatable independently of the steering intensifier (60).

14. A downhole bit assembly characterized in that: the steering intensifier (60) according to claim 1; a bit (12), the bit being attached to the steering intensifier (60).

15. A method for drilling a borehole (40) in a surface (54), the method being characterized in that: conveying the steering device (10) according to claim 1 into the borehole (40); operating the valve (74) to allow, prevent or inhibit flow through the second flow path (70); generating a steering force at the steering intensifier (60) by the Bernoulli effect generated.

16. The method according to claim 15, further characterized in that aligning the passage (72) with the waste groove (14c) of the bit (12) such that the azimuth difference between the waste groove (14c) and the passage (72) is in the range of +90° to -90°.

17. The method according to claim 15, further characterized in that aligning the passage (72) with the waste groove (14c) of the bit (12) such that the azimuth difference between the waste groove (14c) and the passage (72) is in the range of 90° to 270°.

18. The method according to claim 15, wherein the passage (72) is located in a sleeve (82) nested with the body (62), and further characterized in that rotating the sleeve (82) to align the passage (72) and fixing the sleeve (82) to the body (62) after alignment.

19. The method according to claim 15, further characterized in that installing a stabilizer (84) between the passage (72) and the bit (12).

20. The method according to claim 15, further characterized in that rotating the steering device (10) within the borehole (40) and rotating the valve (74) together with the steering device (10).

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