Modified torque generator and methods of use

Abstract

An apparatus for controlling tool face and methods of use with a torque generator connected to a drill string for drilling linear and nonlinear subterranean bore segments. In some embodiments, the apparatus and methodologies of use comprise a tool controller having an outer housing independently rotatable from and extension conduit extending therethrough and forming an annulus therebetween. The tool controller may provide for a first fluid pathway for allowing a bypass portion of fluids to flow through the torque generator, and a second fluid pathway through the annulus for allowing a torque generator portion of fluids to flow through the annulus. In some embodiments, at least one fluid flow restrictor may be provided within the annulus to controllable cause a cascading reduction in torque generator fluid pressure as it flows through the annulus, allowing high resolution tool face control over a larger (and tunable) range of drill string speed (rpm) set points.

1 . (canceled) 
     
     
         2 . An apparatus usable with a torque generator connected to a drill string for drilling subterranean bore segments, the torque generator having a housing independently rotatable from an inner pump and the drill string, the rotor forming a rotor bore extending therethrough for the passage of a bypass fluid stream, the apparatus comprising:
 an outer tubular housing rotationally coupled to the torque generator housing, the outer tubular housing forming an inner housing bore;   an extension conduit extending through the inner housing bore and forming a first annulus therebetween; and   one or more piston assemblies positioned in the inner bore, each respective piston assembly having:
 a piston housing fixedly attached to the outer tubular housing, 
 a piston concentrically received within and extending through the piston housing and forming a piston annulus therebetween, the piston annulus in fluid communication with the first annulus for receiving a torque generator fluid stream, the piston slidably movable axially within the piston housing relative to the outer tubular housing and the extension conduit, 
 wherein at least a portion of the extension conduit extends through a bearing housing positioned within the inner bore of the housing, the bearing housing containing a plurality of bearings allowing for the outer tubular housing to rotate independently from the extension conduit. 
   
     
     
         3 . The apparatus of  claim 2 , wherein the bearing housing comprises a mud lube bearing assembly. 
     
     
         4 . The apparatus of  claim 3 , wherein the mud lube bearing assembly comprises at least a bushing sleeve and a thrust bearing. 
     
     
         5 . The apparatus of  claim 2 , wherein the cross-sectional area of the piston annulus varies depending upon the axial position of the piston within the piston housing. 
     
     
         6 . The apparatus of  claim 2 , wherein the apparatus may further comprise a fluid flow distributor positioned in the inner housing bore, the flow distributor forming a plurality of apertures for constricting the bypass fluid stream flowing through the annulus. 
     
     
         7 . The apparatus of  claim 6 , wherein the fluid flow distributor may be positioned above the one or more piston assemblies. 
     
     
         8 . The apparatus of  claim 6 , wherein the apparatus is operably coupled to a bent sub and drilling motor. 
     
     
         9 . A method of controlling tool face using a torque generator operably coupled to a drill string for drilling subterranean bore segments, the torque generator having a housing independently rotatable from an inner pump and the drill string, and having a tubular extension conduit received within the housing and forming an annulus therebetween, the method comprising:
 pumping fluids into the torque generator, a first portion of the fluids passing through the torque generator as a bypass fluid flow;   providing at least one fluid flow distributor for directing a second portion of the fluids into the annulus as a torque generator fluid stream; and   providing at least one fluid flow restriction in the annulus for increasing fluid pressure of the torque generator fluid flow above the restriction, creating a reduction in fluid pressure of the torque generator fluid stream.   
     
     
         10 . The method of  claim 9 , wherein the at least one fluid flow restriction positioned in the annulus comprises at least one piston assembly forming a restricted fluid flow pathway. 
     
     
         11 . The method of  claim 9 , wherein the at least one piston assembly forms at least two fluid flow restrictions. 
     
     
         12 . The method of  claim 9 , wherein the at least piston assemblies create a cascading reduction in pressure of the torque generator fluid stream to dynamically reduce tool face sensitivity in response to the changes in the drill string speed (rpm).