System and method for monitoring motion of downhole tool components of a drilling system

Abstract

A drilling system tool including at least one sensor configured to detect movement of one or more components of the drilling system tool. The sensor is configured to operate at high pressures and temperatures typical in the drilling environment downhole. The sensors are suitable for vibration damping tools, rotary steerable motors systems, downhole motors, drill bits, or other similar downhole drilling equipment that includes a movable component.

What is claimed: 
     
         1 . A rotary steerable system configured to control directional orientation of a drill bit along a drill string drilling into an earthen formation, the rotary steering tool comprising:
 a guidance module having a housing that extends along a central axis, a recess defined by the housing, a moveable member selectively movable from a retracted position, where the movable arm is disposed toward a central axis, to an extended position, where the movable member is disposed outwardly from the retracted position away from the central axis;   a proximity sensor configured to detect information indicative of movement of the moveable member; and   a computer processor in electronic communication with the proximity sensor, the computer processor configured to, in response to the information indicative of the movement of the movable member, and determine a position of the movable member relative to the housing,   wherein the computer processor is configured to compensate a measured distance between the proximity sensor and the movable member based on an offset, a measured pressure, and a measured temperature proximate to the proximity sensor to provide a compensated distance between the proximity sensor and the movable member, thereby improving accuracy of the determined position of the movable member relative to the housing.   
     
     
         2 . The rotary steerable system of  claim 1 , further comprising a temperature sensor configured to measure temperature proximate the proximate sensor. 
     
     
         3 . The rotary steerable system of  claim 1 , further comprising a pressure sensor configured to measure the pressure proximate the proximity sensor. 
     
     
         4 . The rotary steerable system of  claim 1 , wherein the proximity sensor is operable when exposed to a temperature range between approximately 0 degrees centigrade and approximately 200 degrees centigrade. 
     
     
         5 . The rotary steerable system of  claim 1 , wherein the proximity sensor is operable when exposed to 175 degrees centigrade. 
     
     
         6 . The rotary steerable system of  claim 1 , wherein the proximity sensor is pressure rated up to 1700 BAR. 
     
     
         7 . The rotary steerable system of  claim 1 , wherein the proximity sensor is pressure rated up to 1000 BAR. 
     
     
         8 . The rotary steerable system of  claim 1 , wherein the proximity sensor is operable when subject to pressure between approximately 1000 BAR and approximately 1700 BAR. 
     
     
         9 . The rotary steerable system of  claim 1 , wherein a frequency response of the proximity sensor is at least 1 Khz. 
     
     
         10 . The rotary steerable system of  claim 1 , wherein the proximity sensor is an eddy current sensor. 
     
     
         11 . The rotary steerable system of  claim 1 , wherein the recess is a first recess, the movable member is a first movable member and the proximity sensor is a first proximity sensor, and further comprising a second proximity sensor at or near a second recess that includes a second movable member, and a third proximity sensor that is at or near a third recess that includes a third movable member. 
     
     
         12 . A rotary steerable system for a drill string that is configured to define a borehole in an earthen formation during a drilling operation, the rotary steerable system comprising:
 a housing that defines a recess;   a movable member at least partially disposed on the recess, and each moveable member is operable to move between a first position and a second position relative to the housing;   a proximity sensor supported by the housing and adjacent to the recess, the proximity sensor having a detection range that extends into the recess, wherein each sensor is configured to detect the presence of the movable member within the detection range;   a temperature sensor configured to measure temperature proximate the proximity sensor;   a pressure sensor configured to measure the pressure at or near the proximity sensor; and   a computer processor configured to determine the amount the moveable member moves based on information that is indicative of the presence of the moveable member within the detection range of the proximity sensor, the measurement of the temperature, and the measurement of the pressure.   
     
     
         13 . The rotary steerable system of  claim 12 , wherein the computer processor is configured to compensate for the measured temperature and pressure proximate the proximity sensor. 
     
     
         14 . The rotary steerable system of  claim 12 , wherein the recess is a first recess, the movable member is a first movable member and the proximity sensor is a first proximity sensor, and further comprising a second proximity sensor at or near a second recess that includes a second movable member, and a third proximity sensor that is at or near a third recess that includes a third movable member. 
     
     
         15 . The rotary steerable system of  claim 12 , wherein the proximity sensor is operable when subject to pressure between approximately 1000 BAR and approximately 1700 BAR. 
     
     
         16 . The rotary steerable system of  claim 12 , wherein the proximity sensor is an eddy current sensor.