Mud pulse driven actuator

Abstract

A wellbore drilling system includes a drill string and an auxiliary device, such as a steering arm or rib, a reamer blade, or a bent sub assembly. The auxiliary device is powered with reactive forces generated while imbedding mud pulse signals in drilling mud flowing through the drill string. The reactive forces are transmitted to the auxiliary device either mechanically or hydraulically. The mud pulse signals are imbedded into the drilling mud with a valve assembly in the drill string, which includes an orifice placed in a path of the flow of drilling mud. The mud pulses are generated by reciprocating a plug member in the drilling mud flow at a location adjacent to and downstream of the orifice. The reactive forces are harvested from the reciprocating movement itself or from pressure differences caused by the reciprocating movement.

Description

Attorney Docket No.: 0005355.000251 (65TEL-510957-WO-2)PCT PATENT APPLICATIONMUD PULSE DRIVEN ACTUATORInventors: Thomas WETTMARSHAUSENBastian SAUTHOFFCROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and the benefit of co-pending U.S. Provisional Application Serial No. 63 / 736,214, filed December 19, 2024.BACKGROUND OF THE INVENTION1. Field of Invention

[0002] The present disclosure relates to an actuator for use in a downhole drilling tool that is driven by mud pulses.2. Description of Prior Art

[0003] Production of hydrocarbons from subterranean formations typically involves forming a wellbore into the formation that intersects a reservoir where the hydrocarbons are trapped. Drilling systems are commonly used for forming the wellbores, which are generally made up of a drill string with a drill bit on its lower end for excavating through the formation. Drill strings are usually formed by end to end connection of a number of pipe joints, and are rotated by a top drive or rotary table on surface, which in turn rotates the drill bit. In some drilling systems the drill bit is rotated by a mud motor that is disposed in the drill string. The bottom end of the drill bit usually includes a type of cutting element to scrape against the formation and break away rock fragments or cuttings to deepen the wellbore. The rotation along with adding weight onto the bit, provides the excavating force necessary to fracture the rock and form the cuttings. Pressurized drilling fluid is directed to a bore inside the drill string, where it is directed to the drill bit. The fluid exits the drill bit through-1-IM -#10886784.5nozzles on its lower surface and then flows back to surface in an annulus between the drill string and walls of the wellbore. The cuttings become entrained in the drilling fluid circulating uphole and are removed from within the wellbore.

[0004] The drill strings of most drilling systems include auxiliary devices for completing tasks in addition to or associated with drilling the wellbore. Some of the typical auxiliary devices include reamer blades, tools for handling coiled tubing, and directional steering, all of which require an applied force or torque for their operation. Often, the power for operating these devices is generated downhole for a defined period and magnitude, such as with a generator or hydraulic power unit. These devices usually require additional support equipment for their operation, such as, an electrical power source, a motor, a hydraulic pump, a gearbox, and a control unit, which adds expense and complicates drill string design and operation. A need exists for downhole actuation that is less costly and complicated.SUMMARY OF THE INVENTION

[0005] Disclosed herein is an example of a method of wellbore operations that includes generating a reactive force in the wellbore by forming a pressure pulse in fluid flowing through a tubular in the wellbore, and using the reactive force to actuate an auxiliary device coupled with the tubular. Forming a pressure pulse optionally includes reciprocating a pulser in a path of the fluid flowing through the tubular, and in an alternative, generating the reactive force includes pressurizing a hydraulic fluid contained in the tubular with the reciprocating pulser to form a pressurized hydraulic fluid, and where using the reactive force to actuate an auxiliary device includes directing the pressurized hydraulic fluid to the auxiliary device. Further optionally, the hydraulic fluid is contained in a chamber having a volume that correspondingly fluctuates with reciprocation of the pulser. In another alternative, the reactive force is transferred to the auxiliary device via a linkage connected between the pulser and the auxiliary device. In an embodiment, reciprocating the pulser causes a pressure difference between a pressure upstream of the pulser and a pressure downstream of the pulser, and the reactive force is generated by the pressure difference, and optionally, the pressure upstream of the pulser is applied to an upstream side of an annular piston in the tubular, and where the pressure downstream of the pulser is applied to a downstream side of the annular piston, and where the annular piston comprises a cam in abutting contact with the auxiliary device. In another example, the auxiliary device is an attachment to the tubular, such as a reamer, a steering sub, or a steering rib. In an example, the tubular is a drill string, and where the method further forming a wellbore in a subterranean formation, in an alternative, the auxiliary device is a reamer, the method further including widening a diameter of the wellbore with the reamer.

[0006] Also disclosed is a system for use in wellbore operations, which includes a tubular having an axial bore, a valve assembly in the bore, the valve assembly having a valve actuator selectively changeable into different operating modes and a valve member that is moveable to different locations within the bore when the valve actuator is in different operating modes. The system also includes an auxiliary device coupled with the tubular, the auxiliary device changeable between a retracted configuration and a deployed configuration and a force transmission assembly having an end coupled to the valve actuator and an opposing end coupled to the auxiliary device, a reactive force being transmitted from the valve actuator to the auxiliary device through the force transmission conduit when the valve actuator is in one of the different operating modes. In an embodiment, the force transmission assembly includes a fluid circuit and hydraulic fluid in thefluid circuit, where the auxiliary device is changed into the deployed configuration when the hydraulic fluid is pressurized. In an example, the fluid circuit includes a chamber and a fluid passage having an end in communication with the chamber and an opposite end in communication with the auxiliary device. The valve actuator optionally includes a housing and an activation portion inside the housing, and an opening in an end of the housing, where the chamber is defined in the housing and adjacent the opening, where the opening receives an end of an anchored piston mounted in the bore, and where when the valve actuator is in the one of the different operating modes the anchored piston projects into the chamber and fluid flows from the chamber through the fluid circuit and to the auxiliary device. Examples of the force transmission assembly include a mechanical linkage. In an example, the valve actuator includes a housing and an activation portion inside the housing, and an opening in an end of the housing, where the chamber is defined in the housing and adjacent the opening, where the opening receives an end of an anchored piston mounted in the bore, and where when the valve actuator is in the one of the different operating modes the valve actuator and mechanical linkage move with response to the anchored piston and the reactive force is exerted onto the auxiliary device by movement of the mechanical linkage. The valve assembly is optionally a mud pulser and the valve member comprises a plug member.

[0007] Another example system for use in wellbore operations is disclosed and that includes a tubular having an axial bore, a valve assembly in the bore, which includes a valve actuator selectively changeable into different operating modes, and a valve member that is moveable to different locations within the bore when the valve actuator is in different operating modes. The system also includes an auxiliary device coupled with the tubular, the auxiliary device changeable between a retracted configuration and a deployed configuration and an actuator in the bore comprising an annular piston having an end abutting the auxiliary device, a high pressure side in communication with a portion of the bore upstream of the valve member, and a low pressure side in selective communication with a portion of the bore downstream of the valve member, wherein a pressure in the bore downstream of the valve member is reduced to below a pressure upstream of the valve member by moving the valve member to a designated position in the bore, which urges the annular piston against the auxiliary device to move the auxiliary device into the deployed configuration. The system further optionally includes a passage formed through a sidewall of the tubular, where opposing ends of the passage are in communication with the upstream and downstream of the valve member respectively. The system optionally includes a pressureequalizing circuit that includes a reservoir, a floating piston in the reservoir, an inlet port extending between an end of the reservoir and the low pressure side of the piston, and an exit port between the passage and an end of the reservoir opposite the inlet port.BRIEF DESCRIPTION OF DRAWINGS

[0008] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:

[0009] FIG. 1 is a partial side sectional view of an example of forming a wellbore with a drilling system having a drill string.

[0010] FIG. 2 is a side sectional view of an example of a valve assembly in the drill string of FIG. 1.

[0011] FIGS. 3 and 4 are side sectional views of alternate examples of the valve assembly of FIG. 2.

[0012] FIG. 5A is a side sectional view of another alternate example of the valve assembly of FIG. 2, shown in a retracted configuration.

[0013] FIG. 5B is a side sectional view of the valve assembly of FIG. 5A shown in a deployed configuration.

[0014] FIG. 6 is a side sectional view of an alternate example of the drilling system of FIG. 1 in which the orientation of the valve assembly of FIG. 2 is reversed.

[0015] FIG. 7 is a side sectional view of an alternate example of the valve assembly of FIG. 2.

[0016] While subject matter is described in connection with embodiments disclosed herein, it will be understood that the scope of the present disclosure is not limited to any particular embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents thereof.DETAILED DESCRIPTION OF INVENTION

[0017] The method and system of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments are shown. The method and system of the present disclosure may be in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey its scope to those skilled in the art. Like numbers refer to like elements throughout. In an embodiment, usage of the term “about” includes + / - 5% of a cited magnitude. In an embodiment, the term “substantially” includes + / - 5% of a cited magnitude, comparison, or description. In an embodiment, usage of the term “generally” includes + / - 10% of a cited magnitude.

[0018] It is to be further understood that the scope of the present disclosure is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation.

[0019] . An example of using a drilling assembly 10 to form a wellbore 12 is shown in a side partial section view in FIG. 1, and in which wellbore 12 extends into a subterranean formation 14 from surface 16. Included with drilling assembly 10 is a drill string 18 made up of multiple joints of drill pipe 20 that fit end to end. Integrally within the drill string 18 is a valve assembly 22, which as described in more detail below selectively restricts a flow of drilling mud DM through the drill string 18 and in alternatives operates as a mud pulser generating mud pulses that travel to the surface 16. In FIG. 1 drilling mud DM flows within an inner bore 24 of the drill string 18 to a drill bit 26 coupled to a lower terminal end of the drill string 18. The drilling mud DM exits drill bit 26 through nozzles (not shown) on its lower end and flows back uphole within an annulus 28 between sidewalls 12A of the wellbore 12 and drill string 18. The drilling mud DM is provided from a mud source 30. such as a mud pit, a suction tank, and / or shaker tank, which are outside the wellbore 12 on surface 16. A line carries drilling mud DM from an outlet of the mud source 30 to a pump 32 that pressurizes the drilling mud DM and directs it through another line to a kelly 34 shown suspended within a derrick 36 shown assembled over an opening of wellbore 12. An upperend of drill string 18 connects to a lower end of kelly 34. Below its connection to the kelly 34, drill string 18 passes through a wellhead assembly 38 mounted on top of an opening of wellbore 12. A pressure transducer 29 is located near the wellhead to detect pressure variations in the drilling mud DM. At the lower end of the drill string 18 is a bottom hole assembly (“BHA”) 35, which in examples includes downhole components for drilling the borehole in addition to the valve assembly 22. Embodiments of the BHA 35 include components to determine the downhole location of the BHA 35 and the drill bit 26 and to determine the properties of the rock formation 14 surrounding the wellbore 12, including detecting hydrocarbon bearing rock formation layers. The BHA 35 optionally includes a mud motor and / or a steering unit (not shown) to control the trajectory of the wellbore 12, and one or more of the following: a formation evaluation device (FE device), such as a resistivity device, a nuclear resonance device, an acoustic device, a density device, or a formation sampling device, a measurement while drilling device (MWD) configured to detect inclination and azimuth of the borehole, an accelerometer, a magnetometer, a power source, such as a downhole generator or a battery, and a telemetry device to communicate with the surface. Examples of the telemetry device include a mud pulser, an electromagnetic telemetry device, or an acoustic telemetry device. In an alternative configuration the BHA 35 and the drill string 18 include a wire (not shown) to the surface (wired pipe). The term uphole in this application refers to a direction closer to the earth surface. The term downhole refers to a direction closer to the bottom end of the drill string 18 in the borehole. The term upstream refers to a direction in relation to the location where the drilling mud DM is pumped into the inner bore of the drill string. An upstream direction is closer to the pump 32 that pumps the drilling mud into the inner bore of the drill string 18. A downstream direction is farther away from the pump 32 in relation to the location where the drilling mud DM leaves the inner bore of the drill string through the nozzles in the drill bit 26. The inner bore of the drill string 18 is also referred to herein as axial bore.

[0020] FIG. 2 is a partial side sectional view of an example of the valve assembly 22 shown having an outer housing 40, also referred to as a tool collar, which is annular, and part of the BHA 35. Valve assembly 22 includes an orifice 42 or flow restrictor mounted within housing 40, which is a generally cylindrical member depicted having a diameter exceeding its length (along longitudinal axis A22). As described in more detail below, orifice 42 is axially moveable along axis A22. An opening 44 is formed axially through orifice 42, which as shown is generally coaxial with axis A22 of the valve assembly 22, and a seal S circumscribing orifice 42 to form a barrier toaxial flow between orifice 42 and housing 40. A plug member 45 is spaced an axial distance downstream of opening 44. A forward end 46 of plug member 45 has a conical or frusto-conical surface and is facing the opening 44, a rearward end 47 of plug member 45 is generally planar. Plug member 45 alternatively has other configurations, such as cylindrical, parabolic, spherical, disc, etc. Downstream of plug member 45 is an actuator 48 for selectively reciprocating plug member 45 within housing 40 and positioning plug member 45 at different distances away from a downhole end 49 of opening 44. The present disclosure includes valve assemblies having any type of valve, such as but not limited to plunger valves, or shear valves (rotating or oscillating). The plug member 45 is also referred to herein as valve member.

[0021] A piston rod 50 is shown having an end connected to the rearward 47 end of plug member 45, an opposite end of piston rod 50 is coupled with actuator 48. In examples, operating actuator 48 reciprocates piston rod 50 and attached plug member 45. which moves plug member 45 to different locations relative to the downhole end 49 of opening 44. In the example of FIG. 2, plug member 45 is reciprocated so that forward end 46 of plug member 45 is moved between first and second set distances Di. D2 from the downhole end 49 of opening 44. The plug member 45 is in a first position Vi when forward end 46 is spaced the first set distance Di downstream from the downhole end 49 and plug member 45 is in a second position V2 when forward end 46 is spaced the second set distance D2 downstream from the downhole end 49. When the plug member 45 is in the first position Vi, plug member 45 interferes with drilling mud DM flowing through the opening 44 (plug member 45 restricts opening 44), whereas when the plug member 45 is in the second position V2 plug member 45 causes little to no interference with drilling mud DM flowing through the opening 44 (plug member does not restrict opening 44), such that by reciprocating the plug member 45 between the first and second positions Vi. V2. pressure pulses are generated in the drilling mud DM. The pressure pulses are detectable at locations distal from the valve assembly 22, such as at surface 16 (FIG. 1) by the pressure transducer 29, so that by strategically reciprocating the plug member 45 data signals are embedded in the flow of drilling mud DM and detectable remotely. Restricting opening 44 by plug member 45 creates a pressure differential between an upstream portion 23A and a downstream portion 23B (low pressure side) of inner bore 24. Upstream portion 23A (high pressure side) is upstream the orifice 42 and the downstream portion 23B is downstream the orifice 42.

[0022] In alternatives, actuator 48 includes an electrical motor (not shown) disposed in an actuation portion 51 of actuator 48. Optionally, the actuator 48 relies on hydraulics as the energy source for selectively moving plug member 45, such as to selected set distances (e.g., Di or D2) from opening 44 and along longitudinal axis A22. In an example, the second set distance is D2 and the first set distance (dashed outline) is Di. The first set distance Di is a given travel AD away from the second set distance D2. In an alternative embodiment the second set distance is Di (dashed outline) and the first set distance is D2. The first set distance D2 is a given travel AD away from the second set distance Di. That is, the given travel is AD=IDi-D2l=ID2-Dll. Consequently, first position Vi is a given travel AD away from the second position V2, and second position V2 is a given travel AD away from the first position Vi, respectively. Set distances Di, D2 are given for the purposes of discussion herein as examples exist in which plug member 45 is moveable to locations such that forward end 46 of plug member 45 is closer to downhole end 49 of opening 44 than the first set distance Di, and moveable to locations such that forward end 46 is farther from downhole end 49 than the second set distance D2

[0023] In FIG. 2, an annular space 52 is formed between actuator 48 and inner surface of housing 40. A collar 54 is shown coupled onto an end of actuator 48 proximate its connection to piston rod 50. Collar 54 has an annular configuration and extends radially into the annular space 52 and adjacent an inner surface of housing 40, webs W extend radially between an outer surface of actuator 48 and an inner surface of the collar 54. The orifice 42 and collar 54 are shown connected by annular sidewalls 55. and in examples, the orifice 42, collar 54, and sidewalls 55 are moveable together with respect to the housing 40. An end of housing 40 downhole of plug member 45 and distal from orifice 42 is closed to define a bulkhead 56 which extends radially between sidewalls of housing 40. Drilling mud DM is shown flowing along a path P through opening 44 across plug member 45 and through passages 58 in collar 54. Passages 58 extend axially between the webs W. Downstream of passages 58 the path P intersects passages 60 shown formed axially through the bulkhead 56. A sliding sleeve 62 is shown on a downhole end of actuator 48, sleeve 62 extends axially a distance downstream from the activation portion 51 and towards bulkhead 56. Inside sliding sleeve 62 is a chamber 63 having a cylindrical shape. An end of sleeve 62 distal from activation portion 51 is open and receives an anchored piston 64 that projects a distance into chamber 63. In the example shown, the interface between chamber 63 and piston 64 is sealed by seal 65 to block fluid communication between chamber 63 and bore 24. Anchored piston 64 isshown as a cylindrical member and having an end opposite chamber 63 mounted onto a mounting 66 that is support on and abuts bulkhead 56. Shown inside chamber 63 is a helical spring 68.

[0024] Still referring to FIG. 2, as described above, mud pulses, also referred to herein as pressure pulses, are created by reciprocating the plug member 45 in path P of fluid flowing through the bore 24 of the valve assembly 22. Creating the pressure pulses (differential pressures) by reciprocating the plug member 45 in path P generates reactive forces causing responsive axial movement of actuator 48, collar 54, sidewalls 55, and orifice 42 with respect to housing 40. The resulting mud / pressure pulses travel from within the valve assembly 22 into the tubular drill string 18 (FIG. 1) and are subsequently monitored by pressure transducer 29 on surface 16 or by a pressure transducer within the wellbore 12. When these components move in a downstream direction (z.e., towards bulkhead 56), spring 68 is compressed between a downstream end of actuator 48 and an upstream end of piston 64. In this example, a fluid 70 is in the chamber 63, examples of fluid 70 include a substantially incompressible fluid, such as hydraulic fluid. In addition to compressing the spring 68, the downstream movement of the actuator 48 with respect to piston 64 pressurizes the fluid 70 and forces the fluid 70 through a fluid passage 72 formed axially through the bulkhead 56. The passage 72 is part of a fluid circuit 74 in the bulkhead 56, which also includes a check valve 76 disposed in the passage 72 and a cylindrically shaped cavity 78 at a terminal end of the passage 72. A schematic depiction of an auxiliary device 80 is provided in FIG. 2, with the device 80 inserted into the cavity 78. A seal 82 are shown on the device 80 to prevent fluid 70 from leaking between device 80 and cavity 78. Examples of the auxiliary device 80 include a reamer blade, a biasing member, such as a steering piston, or a steering rib, an adjustable stabilizer blade, a release mechanism (e.g., for installing casing or production liner), a probe (such as for formation evaluation, sampling, pressure testing, etc.), a device for closing the annulus 28 in an overpressure situation (such as a packer), and any other device for use in a wellbore that is coupled with a downhole tubular (e.g. drill pipe 20) or drill string 18. The fluid circuit 74 further includes a bypass 84 around the check valve 76, in the bypass is a solenoid valve 86 that is selectively changed between open and closed. Operation of the valve assembly is optionally controlled remotely by signals provided from a controller 88 (FIG. 1) on surface, a downhole controller 90 (FIG. 2) included with the valve assembly 22, or both controllers 88, 90. A communication means 92 is schematically shown for providing communication to actuator 48 and valve 86 from one or both controllers 88, 90. Examples of means 92 include wireless, hard wired, fluctuations in mudflowrate and fiberoptic. An optional sensor 94 is included with valve assembly 22 and adjacent or on auxiliary device 80 for monitoring device 80 for determining a position or configuration (i.e., deployed, retracted / stowed. jammed) of device 80. Examples for the optional sensor 94 include distance measurement devices (optical electrical), travel distance measurement devices (optical, electrical). Further shown in FIG. 2 is a key 96 (such as a fitted key) or guide that extends radially from piston 64 into a slot 97 formed axially along an inner surface of sleeve 62. Inserting key 96 into slot 97 interferes with rotation of sleeve 62 (and actuator 48) and prevents rotation of sleeve 62 and with respect to anchor piston 64.

[0025] In an example of operation of the valve assembly 22 of FIG. 2, a signal is transmitted from controller 88, 90 to actuator 48 via communication means 92 having a command causing actuator 48 to reciprocate plug member 45 with respect to orifice 42 to create mud pulses in the fluid inside the valve assembly 22 that propagate into the drill string 18 (FIG. 1). While creating the mud pulses reactive forces are generated due to the differential pressure generated with restricting opening 44 by plug member 45, which are harvested and used to activate the auxiliary device 80. More specifically and as described above, the reactive forces generated when creating the mud pulses urge the actuator 48 downstream towards the bulkhead 56. Moving actuator 48 towards bulkhead 56 reduces the volume of the chamber 63 to displace fluid 70 from within into the fluid circuit 74 and cavity 78 and hydraulically activate the auxiliary device 80, reactive force FR schematically represents the pressure of fluid 70 exerted over a surface area of device 80 in contact with fluid 70. In the configuration of FIG. 2, fluid 70 in the portion of the fluid circuit 74 between valves 76, 86 and cavity 78 is blocked from flowing back towards the chamber 63. This is because the solenoid valve 86 is in a closed configuration and blocks flow of fluid 70 through the bypass line 84 and the check valve 76 is spring loaded and blocks a backflow of fluid 70. When in the configuration of FIG. 2, the auxiliary device 80 is in a deployed or extended configuration and retained in the deployed configuration with the valves 76, 86 that keep fluid 70 in the cavity 78. When in a deployed configuration, the auxiliary device 80 is urged outward from an outside surface 89 of outer housing 42 of valve assembly 22 for its intended use. For example, in examples in which the device 80 is a reamer, it extends radially outward from housing 42 into contact with the sidewalls 12A of wellbore 12 and with the surrounding subterranean formation 14 (FIG. 1 ) so that with rotation of the valve assembly 22 or associated drill string 18, the formation 14 is excavated by the reamer. Similarly, in examples in which the auxiliary device 80 is a steering rib, it is pivotedoutward when in the deployed configuration and into biasing contact with the surrounding subterranean formation for redirecting drill bit 26 within formation 14. To return the auxiliary device 80 to a stowed or retracted configuration, solenoid valve 86 is changed to a bypass configuration (such as by receiving a signal from controller(s) 88, 90 via communication means 92) that allows fluid 70 to flow through bypass line 84 and back to chamber 63. In the schematic example of FIG. 2, the body of valve 86 is reoriented so that the portion having the arrow registers with bypass line 84 to allow fluid 70 to flow upstream and through the valve 86. When in the stowed or retracted configuration, the auxiliary device 80 is within the confines of the valve assembly 22 or drill string 18 so as not to interfere with passage through the wellbore. In an example of a stowed or retracted configuration the auxiliary device 80 is within the cavity 78 in the outer surface 89 of housing 40 so that an exposed portion of auxiliary device 80 that is outside the cavity 78 in retracted configuration is smaller than an exposed portion of auxiliary device 80 in a deployed or extended position. A stowed portion of auxiliary device 80 that is inside the cavity 78 in retracted configuration is larger than a stowed portion of auxiliary device 80 in a deployed or extended position. As previously noted, the auxiliary device 80 is depicted in a simple schematic form in FIG. 2 and for the sake of brevity not shown are some details of actuating an auxiliary device (e.g„ reamer, a steering sub, a steering rib, etc.) that is included with a downhole tubular or drill string 18. However, these details of actuating an auxiliary device are readily apparent to those skilled in the art and achievable without undue experimentation. It should be pointed out that the assembly (fluid circuit) 74 is but one example of using energy harvested from a downhole operation to actuate an auxiliary device, as these details can vary greatly depending on the application.

[0026] Alternate embodiments of the valve assembly 22 of FIG. 2 are shown in side sectional views in FIGS. 3 and 4. The valve assembly 22A of FIG. 3 relies on a piston rod 98 A to transmit reactive forces FR from movement of the actuator 48A for actuating the auxiliary device 80A. An uphole end of piston rod 98A mounts to actuator 48A and extends axially through cavity 63A, anchor piston 64A, and through an opening 100A axially formed in the bulkhead 56A. Uphole movement of the piston rod 98 A is limited by an optional bushing 102A shown anchored in the bulkhead 56A. An end of the piston rod 98A is coupled to auxiliary device 80A with a linkage 104A shown made up of pins and articulated members. The linkage 104A is configured to deploy or retract the auxiliary device 80A in response to axial movement of the piston rod 98A, which iscaused by reactive forces from operation of the actuator 48A and from differential pressures generated by restricting opening 44A by plug member 45 A. A cavity 106A is formed in the bulkhead 56A to provide a space for stowing the auxiliary device 80A when in the retracted configuration. Sensor 94A is disposed in or adjacent cavity 106A. A portion of the linkage 104A is also shown within the cavity 106A.

[0027] The valve assembly 22B of FIG. 4 is similar to that of FIG. 3 by transmitting reactive forces FR generated from creating mud pulses from the actuator 48B through a piston rod 98B to actuate an auxiliary device 80B. Valve assembly 22B also includes a passage 72B for transmitting fluid 70B through bulkhead 56B that is urged from cavity 63B in response to reciprocating motion of the actuator 48B as described above. As shown, passage 72B extends past cavity 106B to transmit fluid 70B pressurized by an application of reactive forces. In examples, the fluid 70B is used to actuate another device (not shown) downhole of auxiliary device 80B.

[0028] Another embodiment of a valve assembly 22C is shown in a side sectional view in FIGS. 5A and 5B. In this example a pressure difference or gradient is created between different axial locations in the bore 24C, and a reactive force from the pressure gradient (differential pressure) is applied to actuate the auxiliary device 80C. In this example, the assembly 22C includes a housing 40C in which the actuator 48C, orifice 42C, plug member 45C are disposed. Upstream of orifice 42C an annular cavity 106C circumscribing axis A22C is shown formed in a sidewall of housing 40C. An annular piston 108C inserts into cavity 106C. A radial thickness of piston 108C proximate orifice 42C transitions to form a rim HOC shown facing away from orifice 42C. A spring 112C circumscribes a portion of piston 108C uphole of rim HOC, an end of spring 112C abuts a radial surface of rim HOC. An end of spring 112C opposite rim HOC abuts a transition 114C created by an abrupt diameter change of bore 24C. A hydraulic fluid 116C is in a portion of cavity 106C between annular piston 108C and inner sidewalls of housing 40C. A pressure equalizing circuit 118C is also formed in the sidewalls of housing 40C, which includes a reservoir 120C. a separating piston 122C (or floating piston) in the reservoir 120C, and a manifold 124C providing communication between reservoir 120C and annular cavity 106C. In one leg of the manifold is a check valve 126C that allows flow from the annular cavity 106C into reservoir 120C and blocks reverse flow. Other legs of the manifold include a nozzle 128C for regulating a rate of fluid flow between cavity 106C and reservoir 120C and a selector valve 130C that is opened and closed remotely. An end of piston 108C distal from rim HOC projects radially outward to form acam 132C, shown abutting auxiliary device 80C. In the example of FIGS. 5 A and 5B, the auxiliary device 80C is a reamer, and which is pivotable about a pin 134C that couples it to housing 40C. Sensor 94C is shown coupled with auxiliary device 80C, which optionally monitors a configuration of device 80C. An optional pressure sensor 136C is coupled to housing 40C and is in pressure communication with a portion of bore 24C in annular space 52C and between collar 54C and bulkhead 56C. Communication means 92C connects to and provides communication between sensor 136C, sensor 94C, selector valve 130C, actuator 48C, controller 88 (FIG. 1), and controller 90C. Further in this example is a passage 138C shown formed axially through the sidewall of housing 40C, passage 138C has an uphole end in communication with a downhole port 1 IOC of reservoir 120C. An opposite end of passage 138C terminates at a port 140C that extends radially inward through inner circumference of housing 40C and intersects with downstream portion 23B of bore 24C, passage 138C is in communication with bore 24C through port 140C.

[0029] In an example of operation of the valve assembly 22C of FIGS. 5 A and 5B, auxiliary device 80C is shown in a stowed configuration in FIG. 5A and actuated into a deployed or extended configuration in FIG. 5B. Further shown in FIG. 5B is that by operation of actuator 48C, plug member 45C is moved along axis A22C in a direction away from collar 54C towards and proximate to downhole end 49C of opening 44C of orifice 42C. Positioning plug member 45C proximate to opening 44C of orifice 42C that interferes with a flow of drilling mud through opening 44C (orifice 42C is restricted) creates a pressure drop in the fluid in a downstream portion 23B of bore 24C and a pressure increase in an upstream portion 23A of bore 24C. A differential pressure is created between upstream portion 23A and downstream portion 23B of inner bore C. Due to the pressure drop in downstream portion 23B the pressure at port 140C is reduced to below that of the cavity 106C and a pressure differential is created across separating piston 122C. The pressure differential biases separating piston 122C towards the downhole port 119C of reservoir 120C, reducing pressure of fluid 116C in the cavity 106C. Due to the pressure increase in upstream portion 23A a pressure differential is created between the pressure in cavity 106C and the pressure in upstream portion 23A with the greater pressure in upstream portion 23A, resulting in a reactive force FR shown exerted against piston 108C and urging piston 108C uphole to impinge cam 132C against auxiliary device 80C. Cam 132C is configured so that upon impingement, auxiliary device 80C rotates (AR) about pin 134C and is deployed radially outward into contact with formation 14 and positioned for excavating formation 14. Check valve 126C blocks fluid 116C from returning tocavity 106C to retain the piston 108C in its urged position of FIG. 5B and keep the auxiliary device 80C deployed. The auxiliary device 80C is selectively deactivated and returned to the retracted or stowed configuration of FIG. 5A by actuating selector valve 130C (such as by transmitting a command signal via communication means 92C) and allowing fluid from reservoir 120C to flow through manifold 124C back to cavity 106C. O-rings 142C, 144C are shown respectively on the inner and outer surfaces of piston 108C. which are strategically located to block fluid communication between cavity 106C and upstream portion 23 A of bore 24C and between cavity 106C and borehole annulus 28 of the wellbore 12. Examples exist in which different duration mud pulses are generated for actuating the different types of auxiliary devices, such as, the frequency and duration of a mud pulse for actuating a reamer is different from a frequency and duration for actuating a steering rib. It is within the capabilities of those skilled in the art to identify a frequency and duration of a mud pulse suitable for actuating a particular type of auxiliary device. In one embodiment the frequency of the mud pulses correlates with the rotational speed (revolutions per minute. RPM) of the drill string 18. This is particularly important in a steering device application in which the auxiliary device 80C is supposed to be extended at a specific rotational position of the drill string in order to push the drill string 18 into a specific direction (e.g. east, west, north, south direction). In the embodiments shown in FIGS. 5A and 5B the orifice 42C, the collar 54C, and sidewalls 55C do not have to be movable relative to housing 40C. In an alternative embodiment housing 40C and orifice 42C, collar 54C, and / or annular sidewalls may be manufactured integrally or may be fixedly connected.

[0030] Shown in FIG. 6 is an alternate example of operation in which the valve assembly 22 orientation is reversed from that of FIG. 2, so that the plug member 45 is located downhole of the actuator 48, so that the components of the valve assembly 22 in the upstream and downstream portions 23A, 23B differ from that in the orientation of FIG. 2. In this orientation, the drilling mud DM exits the passages 60 in the bulkhead 56 before entering the annular space 52. The drilling mud DM passes through the passages 58 in the collar 54, over the plug member 45, and through the opening 44 in the orifice 42. Different to that described above with regard to the example of FIG. 2, the plug member 45 is reciprocated between different locations with respect to the uphole end 43 of opening 44 of the orifice 42 to generate mud pulses in the flow of drilling mud DM. In this embodiment the pressure pulses created by reciprocating the plug member 45 in path P generates a reactive force FR causing responsive movement of actuator 48, collar 54, sidewalls 55,and orifice 42 with respect to housing 40. When these components move in a downstream direction (i.e., away from bulkhead 56), spring 68 is decompressed or is pulled apart between an upstream end of actuator 48 and a downstream end of piston 64. The decompression of spring 68 can be used to drive auxiliary device 80.

[0031] Another alternate example of a valve assembly 22D is shown in a partial side sectional view in FIG. 7. which creates mud pulses in the drilling mud DM with a rotor 146D made up of a disc-like hub 148D and blades 150D that project radially from the hub 148D. In this example, the rotor 146D is downstream of the bulkhead 56D, so that drilling mud DM flowing through a drill string (FIG. 1) enters the valve assembly 22D via passages 60D in the bulkhead 56D. After exiting the passages 60D, the drilling mud DM follows path P through the annular space 52D between the actuator 48D and housing 40D before entering the passages 58D in the collar 54D. The rotor 146D is in a plane generally transverse to axis A22D and mounted adjacent to and downstream of collar 54D, so that in certain angular orientations of rotor 146D, one or more of blades 150D interferes with drilling mud DM exiting passages 58D. As illustrated by arrow A146D, the rotor 146D is rotatable about axis A22D in a clockwise or counterclockwise direction. Rotor 146D is configured to either rotate or oscillate. Actuator 48D of this example provides a rotational force for rotating rotor 146D. Mud pulses are generated by the interference of the blades 150D with the drilling mud DM exiting passages 58D in collar 54D. In this embodiment collar 54D acts as a stator in a shear valve configuration formed by stator 54D and rotor 146D. Patterns or sequences of mud pulses are generated in the drilling mud DM by strategically rotating or oscillating rotor 146D so that blades 150D selectively interfere with the drilling mud DM exiting the passages 58D. In this embodiment the collar 54D acts as an orifice or restrictor, the passages 58D act as an opening and the rotor act as a valve member. In an alternative, the orientation of the valve assembly 22D is reversed so that drilling mud DM contacts the rotor 146D before flowing through passages 58D, and the selective rotation of rotor 146D generates mud pulses in the drilling mud DM. Depending on the configuration the collar 54D and the rotor 246D move in a downstream direction (i.e., away from bulkhead 56D), spring 68D (not shown) is decompressed or is pulled apart between an upstream end of actuator 48D and a downstream end of piston 64D (not shown). The decompression of spring (not shown) can be used to drive auxiliary device (not shown).

[0032] It is to be understood that in all embodiments described in this application through restrictor 42 flows all the fluid flow (100%) that is pumped from the surface 16 through the BHA 35 downto the drill bit 26. In an embodiment there can be a bypass (e.g. in housing 40) allowing some fluid to bypass the restrictor 42. The bypass can allow up to 1%, 5%, 10%, 30%, 50%, or any amount between these stated values of the fluid flow to divert away from restrictor 42.

[0033] The present invention described herein, therefore, is well adapted to carry out the objectives and attain the ends and advantages mentioned, as well as others inherent therein. While one or more embodiments have been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.

Claims

CLAIMSWhat is claimed is.

1. A method of wellbore operations comprising: generating a reactive force in the wellbore by forming a pressure pulse in fluid flowing through a tubular in the wellbore: and using the reactive force to actuate an auxiliary device coupled with the tubular.

2. The method of Claim 1, wherein forming a pressure pulse comprises reciprocating a valve member in a path of the fluid flowing through the tubular.

3. The method of Claim 2, wherein the step of generating the reactive force comprises pressurizing a hydraulic fluid contained in the tubular with the reciprocating valve member to form a pressurized hydraulic fluid, and wherein using the reactive force to actuate an auxiliary device comprises directing the pressurized hydraulic fluid to the auxiliary device.

4. The method of Claim 3, wherein the hydraulic fluid is contained in a chamber having a volume that correspondingly fluctuates with the reciprocating of the valve member.

5. The method of Claim 1 and 2, wherein the reactive force is transferred to the auxiliary device via a linkage connected between the valve member and the auxiliary device.

6. The method of Claim 2, wherein reciprocating the valve member relative to a restrictor causes a pressure differential between a pressure upstream of the restrictor and a pressure downstream of the restrictor, and wherein the reactive force is generated by the pressure differential.

7. The method of Claim 6, wherein the pressure upstream of the restrictor is applied to a downstream side of an annular piston in the tubular, and wherein the pressure downstream of the restrictor is applied to an upstream side of the annular piston, and wherein the annular piston comprises a cam in abutting contact with the auxiliary device.

8. The method of Claim 1-7, wherein the auxiliary device comprises an attachment to the tubular selected from the group consisting of a reamer, a biasing member, and a stabilizer blade.

9. The method of Claim 1-8, wherein the tubular comprises a drill string, and wherein the method further comprises forming a wellbore in a subterranean formation.

10. The method of Claim 1 -9, wherein actuation the auxiliary device comprises using a processor.

11. A system for use in wellbore operations comprising: a tubular having an axial bore; a valve assembly in the axial bore, the valve assembly comprising, a restrictor, a valve member that is moveable to different locations relative to the restrictor ; a valve actuator configured to move the valve member to restrict fluid flow through the restrictor and create a differential pressure; and an auxiliary device coupled with the tubular, the auxiliary device changeable between an undeployed configuration and a deployed configuration; and a force transmission assembly driven by the differential pressure and coupled to the auxiliary device, to transmit a reactive force caused by the differential pressure to the auxiliary device .

12. The system of Claim 11, wherein the force transmission assembly comprises a fluid circuit and hydraulic fluid in the fluid circuit, wherein the auxiliary device is changed into the deployed configuration when the hydraulic fluid is pressurized.

13. The system of Claim 12, wherein the fluid circuit comprises a chamber and a fluid passage having an end in communication with the chamber and an opposite end in communication with the auxiliary device.

14. The system of Claim 13, wherein the valve actuator comprises a housing and an activation portion inside the housing, and an opening in an end of the housing, wherein the chamber is defined in the housing and adjacent the opening, wherein the opening receives an end of an anchored piston mounted in the axial bore, and wherein when the valve actuator moves the valve member to restrict fluid flow through the restrictor the anchored piston projects into the chamber and fluid flows from the chamber through the fluid circuit and to the auxiliary device.

15. The system of Claim 11, wherein the force transmission assembly comprises a mechanical linkage.

16. The system of Claim 15, wherein the valve actuator moves axially in the axial bore driven by the reactive force, and the linkage operatively connected to the valve actuator to apply the reactive force onto the auxiliary device.

17. The system of Claim 11-16, wherein the valve assembly comprises a mud pulser.

18. A system for use in wellbore operations comprising: a tubular having an axial bore; a valve assembly in the axial bore, the valve assembly comprising, a restrictor, a valve member that is moveable to different locations relative to the restrictor; a valve actuator configured to move the valve member to restrict fluid flow through the restrictor, an auxiliary device coupled with the tubular, the auxiliary device changeable between an undeployed configuration and a deployed configuration; and an annular piston having an end abutting the auxiliary device, a high pressure side in communication with a portion of the axial bore upstream of the restrictor, and a low pressure side in selective communication with a portion of the axial bore downstream of the restrictor, wherein a pressure in the axial bore downstream of the restrictor is reduced to below a pressure upstream of the restrictor by moving the valve member to restrict fluid flow through the restrictor to create a pressure differential, and the annular piston is urged against the auxiliary device to move the auxiliary device into the deployed configuration using the differential pressure.

19. The system of Claim 18, further comprising a passage formed through a sidewall of the tubular, wherein opposing ends of the passage are in communication with the axial bore upstream and downstream of the restrictor respectively.

20. The system of Claim 19, further comprising a pressure equalizing circuit comprising a reservoir, a floating piston in the reservoir, an inlet port extending between an end of the reservoir and the low pressure side of the piston, and an exit port between the passage and an end of the reservoir opposite the inlet port.

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