Patent Application
20210062595
The present application relates to oil and gas drilling. More particularly, the present application relates to cuttings treatment equipment that processes cuttings produced by a drilling rig.
The background description provided herein is intended to generally present the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
During operation of a drilling rig, the drill bit cuts the formation into small pieces, called cuttings. The unregulated dumping of cuttings produced by drilling rigs is generally regarded as socially and environmentally unacceptable. One acceptable method to manage the disposal of drill cuttings is to transport the cuttings off-site for treatment and thereafter bury the cuttings as landfill or inject the cuttings into an old reservoir. Some conventional systems and methods for dealing with cuttings include using a traditional rock washer positioned perpendicular to the mud cleaning complex such that a narrow side of the traditional rock washer interfaces with the mud complex to collect the cuttings and mud and eventually transport them off-site. Conventional systems and methods can be oversized, cumbersome, inefficient, obtrusive, obstructing, etc.
The following presents a simplified summary of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments, nor delineate the scope of any or all embodiments.
In one or more embodiments, a cuttings processing unit may include a utility interface configured to interface with a mud cleaning complex to receive drill cuttings. The cuttings processing unit may further include a breaker mill module operably positioned to receive the cuttings via the conveyor interface and the breaker mill module may be configured to grind the cuttings into a finer composition. The cuttings processing unit may further include a cuttings tank module operably positioned beneath the breaker mill module, and the cuttings tank module may be configured to agitate the finer composition and create a slurry. The cuttings processing unit may further include a pump module operably positioned beneath the cuttings tank module, and the pump module may be configured to pump the slurry.
In one or more other embodiments, a cuttings processing unit may include a breaker mill configured to receive cuttings from a mud cleaning complex and grind the cuttings into a finer composition. The cuttings processing unit may include a cuttings tank positioned beneath the breaker mill. The cuttings tank may be configured to receive the finer composition and may include an auger configured to agitate contents of the cuttings tank. The cuttings tank may be configured to transform the finer composition into a slurry. The cuttings processing unit may further include at least one pump positioned beneath the cuttings tank. The cuttings processing unit may further include piping in fluid connection with the cuttings tank and the at least one pump, such that the at least one pump may be configured to pump the slurry through the piping.
In one or more embodiments, a method of processing cuttings of a drilling rig may include assembling a cuttings process unit. Forming the cuttings processing unit may include positioning a cuttings tank module on top of a pump module, positioning a breaker mill module on top of the cuttings tank module, and configuring a utilities interface to interface with a mud cleaning complex to receive cuttings from the mud cleaning complex. The method may further include receiving the cuttings in the cuttings processing unit via the utilities interface. The method may further include grinding the cuttings with a mill of the breaker mill module to produce a finer composition. The method may further include using the finer composition to produce a slurry in a cuttings tank of the cuttings tank module. The method may further include pumping the slurry through piping using at least one pump of the pumping module.
While multiple embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the various embodiments of the present disclosure are capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:
The present application, in one or more embodiments, includes a cuttings processing unit arranged in a condensed and efficient configuration that minimizes the total area required for a drilling rig and allows for easier access to the rig and other equipment while allowing for onsite refinement and processing of the cuttings. The cuttings processing unit may be a modular system that may be separated into individual modules as needed, assembled to form a single integrated unit, and disassembled for maintenance, replacement of individual modules, removal, or the like. In some embodiments, the cuttings processing unit may include a utility interface module, a breaker mill module, a cuttings tank module, a pump module, and a control center module. One or more of these modules may be stacked vertically so as to reduce the physical footprint of the cuttings processing unit on the rig pad and to allow for easy access to the drilling rig and other equipment as well as to allow room for maneuvering in the courtyard of the rig pad. The cuttings processing unit may include a transporter that allows the unit to be mobile adding flexibility and easing installation. In some embodiments the cuttings processing unit may be modular, be fully mobile, and possess all controls on board, thus avoiding requiring modifications to the equipment receiving installation (such as the mud cleaning complex).
In contrast, the cuttings processing unit 102 extends vertically and is arranged generally parallel to the mud cleaning complex 108 so as to minimize the footprint of the cuttings processing unit 102 and maximize the courtyard 114. In at least one example, a long side of the cuttings processing unit 102 runs generally parallel to the mud cleaning complex 108. In the illustrated embodiment, a machine 116 is shown maneuvering in the courtyard 114 to load or feed drill pipe 117 at the drilling rig substructure 106. The drill pipe 117 is illustrated in dotted lines to indicate different positions of the drill pipe 117 as it is moved and loaded by the machine 116. This illustrates one example of how the cuttings processing unit 102 allows for easier access to the drilling rig substructure 106 as well as allows the courtyard 114 to be better utilized.
The cuttings processing unit 102 may include a control module 310 to control one or more functions of the cuttings processing unit 102. The control module 310 may be in electrical communication 312 with one or more modules 202, 204, 206, 208 of the cuttings processing unit 102. For example, the control module 310 may be electrically coupled to the breaker module 204 to control the grinding of the cuttings 302, the cuttings tank module 206 to control agitation and creation of the slurry 306, and the pump module 208 to control pumping of the slurry 306. The control module 310 may couple to a power supply 314 to power the cuttings processing unit 102. In some examples, the control module 310 may electrically couple to the mud cleaning complex 108, such that the mud cleaning complex 108 is the power supply 314. In the illustrated embodiment, the control module 310 and the pump module 208 are linked to form a single unit. In some examples, the control module 310 may be a separate unit, while in others the control module 310 may be combined with any of the other modules 202, 204, 206, 208. The control module 310 may include a computer or other equipment to facilitate control of the cuttings processing unit 102. The control module 310 can allow the cuttings processing unit 102 to have all controls on board which can facilitate easier installation and control. In some embodiments, one or more of the modules 202, 204, 206, 208, 310 may be combined into a single module.
The utilities interface module 202 includes a utilities interface 404 which may interact with or otherwise interface with a portion of the utilities. For example, in the illustrated embodiment, the utilities interface 404 is a window configured to receive water, steam, air, a combination of these, or the like. In some examples, a conveyor interface 406 is defined by one or both of the utilities interface module 202 and the breaker mill module 204. The conveyor interface 406 is configured to receive a conveyor (such as a screw conveyor) of the mud cleaning complex 108, such that the conveyor will deposit the cuttings 302 within the breaker mill module 204. In at least one example, gravity will cause the cuttings 302 to proceed from the conveyor to the breaker mill module 204. In at least one example, the utilities interface 404 may be part of a different module, for example the breaker mill module 204, and such an embodiment would not include a utilities interface module 202. The utilities interface 404 interfaces with the utilities (for example, the mud cleaning complex 108) such that a long side of the cuttings processing unit 102 extends substantially parallel to the mud cleaning complex 108 so as to maximize the courtyard 114. In different embodiments, the conveyor interface 406 may be positioned in different portions of the cuttings processing unit 102, for example, the utilities interface module 202, the breaker mill module 204, or both.
The breaker mill module 204 includes a mill 408 configured to break or grind the cuttings 302 into a finer composition 304. The finer composition 304 may generally include more uniformly smaller pieces than the cuttings 302. In some embodiments, the mill 408 is a ball mill. In at least one example, gravity will cause the finer composition 304 to proceed from the breaker mill module 204 to the cuttings tank module 206. In at least one embodiment, the finer composition 304 proceeds through an opening 410 defined by the breaker mill module and the cuttings tank module 206.
The cuttings tank module 206 may include a tank 412 housing an auger 414. The tank 412 contains fluids 416, which are agitated by the auger 414. The auger 414 may further refine the finer composition 304 through agitation or grinding. In some embodiments, the auger 414 may be a solids auger. In some embodiments, the auger 414 may be positioned at the bottom of the tank 412 to avoid accumulation of the finer composition 304 at the bottom of the tank 412. The auger 414 may generally keep solids in fluid suspension. The auger 414, through agitation of the fluids 416, may cause the fluids and the finer composition 304 to form a slurry 306.
The slurry 306 may be pulled through suction piping 418, 419 to one or more pumps 420, 422 in the pump module 208. The one or more pumps 420, 422 may recirculate the slurry 306 or expel the slurry 306 from the cuttings processing unit 102. In some examples, the one or more pumps 420, 422 may be centrifugal pumps. In at least one example, the one or more pumps 420, 422 are industrial slurry pumps. The control module 310 may include controls 424 to facilitate controlling one or more functions of the cuttings processing unit 102. For example, the controls 424 may include a computer, a user interface, a motor control center (MCC), one or more physical actuators, a combination of these, or the like. In at least one example, the pump module includes a hydraulic pumping unit (HPU) 423 that provides power to hydraulic systems, for example one or more features of the transporter 402. In at least one example, the HPU 423 may provide power to skid feet, cylinders for walking the cuttings processing unit 102, a hydraulic motor to turn the auger, or other components that may be powered by hydraulics.
The transporter 402 may include a lift and roll system 426. The lift and roll system 426 may include for example, feet with hydraulics and rollers such that the lift and roll system 426 may allow the cuttings processing unit 102 to lift, rotate, and translate in any direction. In some embodiments, the transporter 402 is a wheeled transporter including wheels 428. The transporter 402 allows for easier installation, since the cuttings processing unit 102 may be moved to accommodate existing equipment, such as the mud cleaning complex 108. The transporter 402 allows for easier transportation since it does not require that it be loaded on a trailer or otherwise require further vehicles to accommodate movement.
The cuttings processing unit 102 is configured such that in the event of a pump breakdown, either pump 420, 422 may be isolated so operations may proceed. In the illustrated embodiment, this is facilitated by two separate pumps 420, 422 and two separate piping circuits 508, 510. First piping circuit 508 serves first pump 420 and allows the pump 420 to move the slurry 306 along a variety of paths. Similarly, second piping circuit 510 serves second pump 422 and allows the pump 422 to move the slurry 306 along a variety of paths. For example, the piping circuits 508, 510 may allow the pumps 420, 422 to move the slurry 306 to a vacuum truck, such as a Guzzler truck via vacuum truck connections 512, 514, back to the tank 412, to a disposal option via cuttings disposal connections 516, 518, and to receive additives at the additives connections 520, 522.
An operator may close valve 524 to have the slurry 306 pass through the first pump 420. An operator may close valves 528, 532 and open valve 524 to facilitate movement of the slurry 306 toward the vacuum truck connection 512. An operator may close valves 524, 536, 544, 548 and open valves 528, 540 to recirculate the slurry 306 back into the tank 412 through pump 420 via the secondary discharge piping spool 550. An operator may close valves 540, 548 and open valves 528, 536 to direct the slurry 306 toward the cuttings disposal connection 516 through pump 420 via the primary discharge piping spool 554. If additives, for example chemicals such as viscosity agents or corrosion inhibitors, are to be added to the slurry 306, then an operator may close valves 532, 540 and open valve 544 to direct the slurry 306 from additives connection 522 toward the tank 412.
An operator may close valve 524 to have the slurry 306 pass through the second pump 422. An operator may close valves 530, 534 and open valve 526 to facilitate movement of the slurry 306 toward the vacuum truck connection 514. An operator may close valves 524, 538, 546, 548 and open valves 530, 542 to recirculate the slurry 306 back into the tank 412 through pump 422 via the secondary discharge piping spool 552. An operator may close valves 542, 548 and open valves 530, 538 to direct the slurry 306 toward the cuttings disposal connection 518 through pump 422 via the primary discharge piping spool 556. If additives, for example chemicals such as viscosity agents or corrosion inhibitors, are to be added to the slurry 306, then an operator may close valves 534, 542 and open valve 546 to direct the slurry 306 from the additives connection 522 to the tank 412.
Since piping circuits 508, 510 are connected by valve 548, the direction of the slurry 306 in this manifold assembly may be directed by manipulation of the various valves and several configurations are possible. Each of pumps 420, 422 may be provided with a pressure gauge 558, 560 and a flow meter, 562, 564 located on the primary discharge spools 554, 556. In some embodiments, secondary suction piping spools 566, 568 may be provided to accommodate vac truck connections 570, 572, 574, 576 when additional suction is required from the cuttings tank 412. In the illustrated embodiment secondary suction piping spool 566 has the capability to service up to two vac trucks via vac truck connections 570, 572 and can be controlled using valves 578, 580. In the illustrated embodiment secondary suction piping spool 568 has the capability to service up to two vac trucks via vac truck connections 574, 576 and can be controlled using valves 582, 584. While the illustrated embodiment includes two pumps and two piping circuits, other embodiments may include more or less pumps and piping circuits. In some embodiments, the pumps 420, 422 are connected in parallel.
At block 804, the cuttings processing unit 102 interfaces with one or more utilities, such as the mud cleaning complex 108. The cuttings processing unit 102, is configured such that a long side of the cuttings processing unit 102 faces the mud cleaning complex 108, and a small side extends perpendicular to the mud cleaning complex 108. As such, the cuttings processing unit 102 is able to interface with the mud cleaning complex 108 while minimizing its interference with the courtyard 114. The utilities interface 404 may be coupled to or otherwise may engage the mud cleaning complex 108. In at least one embodiment, the conveyor interface 406 includes a window to receive a conveyor 502 of the mud cleaning complex 108. At block 806 the cuttings processing unit 102 receives the cuttings 302, for example via the utilities interface 404. In at least one embodiment, gravity may cause the cuttings processing unit 102 to receive the cuttings 302. In some embodiments, the breaker mill module 204 may receive the cuttings 302 via the utilities interface module 202.
At block 808, the mill 408 grinds the cuttings 302 into a finer composition 304. The mill 408 may comprise a ball mill. The mill 408 may be selected based on the desired qualities of the finer composition 304. The finer composition 304 may then pass to the cuttings tank module 206. In some embodiments, gravity may cause the finer composition 304 to move from the breaker mill module 204 to the cuttings tank module 206. At block 810, the auger 414 agitates fluid 416 and the finer composition 304 to create a slurry 306 in the cuttings tank module 206. In some embodiments, the auger 414 may further refine or break down the finer composition 304. The auger 414 may further prevent the finer composition 304 from clogging piping 418, 419.
At block 812 the at least one pump 420, 422 may move the slurry 306 along any of a variety of paths for any of a variety of purposes. For example, in some embodiments the at least one pump 420422 may recirculate the slurry 306 back to the cuttings tank 412. In some embodiments, the at least one pump 420, 422 may move the slurry 306 toward a disposal connection 516, 518 such that the slurry can be disposed of. The piping 418, 419 facilitates movement of the slurry 306. In some embodiments the piping 418, 419 may facilitate additives (such as chemicals) being introduced to the slurry 306 via the additives connection 520, 522. In some embodiments, the piping 418, 419 may facilitate movement of the slurry 306 toward a vacuum truck connection 512, 514, such that a vacuum truck can suck the slurry 306 out of the piping 418, 419. The controller 424 may control the at least one pump 420, 422 and the valves throughout the piping circuits 508, 510, 566, 568, to control the flow of the slurry 306.
In some embodiments, at any point in the method 800, the cuttings processing unit 102 may be moved by the transporter 402. In some embodiments, a lift and roll system 426 may allow the cuttings processing unit 102 to be raised, lowered, moved a direction, tilted, rotated, a combination of these, or the like. In some embodiments, the lift and roll system 426 allows the cuttings processing unit 102 to be moved forward, backward, left, or right. In at least one embodiment, the lift and roll system 426 allows the cuttings processing unit 102 to be moved in any direction. In some embodiments, the transporter 402 may be a wheeled transporter to allow the cuttings processing unit 102 to be moved faster or over greater distances. In some embodiments, the cuttings processing unit 102 may be assembled and then moved into a better position for interfacing with the mud cleaning complex 108. In some embodiments, the cuttings processing unit 102 may be moved to accommodate other equipment or machinery. When the cuttings processing unit 102 is moved to (or back to) its operable position, the method 800 returns to block 804 such that the cuttings processing unit may interface with the mud cleaning complex 108 to start (or resume) processing drill cuttings 302. In at least one embodiment, the cuttings processing unit 102 is substantially empty of cuttings 302 or slurry 306 before the cuttings processing unit 102 is moved.
Alternatively, after moving the cuttings processing unit 102, the method 800 may proceed to block 816, and the cuttings processing unit 102 may be disassembled. In some embodiments, the cuttings processing unit 102 may be disassembled at a number of different points in method 800. In at least one embodiment, the cuttings processing unit 102 is substantially empty of cuttings 302 or slurry 306 before the cuttings processing unit 102 is disassembled. The cuttings processing unit 102 may be disassembled into two or more modules 202, 204, 206, 208, 310. In at least one example, disassembly may involve the reverse procedure of assembly. In at least one embodiment, the cuttings processing unit 102 may be fully or partially disassembled to replace one or more module 202, 204, 206, 208, 310 or to move the cuttings processing unit 102. Following disassembly, the method 800 may proceed to block 802 and the cuttings processing unit 102 may be assembled as needed.
In some embodiments, various portions of the method 800 may be repeated or may be performed simultaneously. For example, one or more of blocks 806, 808, 810, and 812 may be repeated or performed simultaneously. That is, in some embodiments, the cuttings processing unit 102 may receive cuttings, grind cuttings, produce slurry, and move slurry simultaneously and repeatedly. In some embodiments, a subset of those may be repeated or performed simultaneously. For example, the cuttings processing unit 102 may receive cuttings, grind cuttings and produce slurry continuously, but only move slurry intermittently.
The cuttings processing unit 102 allows the cuttings 302 to be processed onsite into a better composition for disposal (slurry 306). Further, the cuttings processing unit 102 is modular and mobile allowing for ease of installation, adjustment, and removal. Finally, the cuttings processing unit 102 has a minimal and efficient footprint on the drill pad 100, allowing for more room in the courtyard 114 than traditional systems and methods and allowing for easier access to other equipment surrounding the courtyard 114, while providing more functionality. In contrast, traditional rock washers are not mobile (they have to be loaded onto a truck to be transported), cannot grind cuttings or produce a slurry, and have a large footprint extending into the courtyard 114.
Various embodiments of the present disclosure may be described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and control systems. Although a flowchart or block diagram may illustrate a method as comprising sequential steps or a process as having a particular order of operations, many of the steps or operations in the flowchart(s) or block diagram(s) illustrated herein can be performed in parallel or concurrently, and the flowchart(s) or block diagram(s) should be read in the context of the various embodiments of the present disclosure. In addition, the order of the method steps or process operations illustrated in a flowchart or block diagram may be rearranged for some embodiments. Similarly, a method or process illustrated in a flow chart or block diagram could have additional steps or operations not included therein or fewer steps or operations than those shown. Moreover, a method step may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc.
As used herein, the terms “substantially” or “generally” refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” or “generally” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of “substantially” or “generally” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is “substantially free of” or “generally free of” an element may still actually contain such element as long as there is generally no significant effect thereof.
To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke 35 U.S.C. § 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.
In the foregoing description various embodiments of the present disclosure have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The various embodiments were chosen and described to provide the best illustration of the principals of the disclosure and their practical application, and to enable one of ordinary skill in the art to utilize the various embodiments with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present disclosure as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled.
