Patent Application
20160108688
The present disclosure relates in general to mud circulating equipment, and in particular, to a master shaker module for a drilling rig.
Some underground drilling processes require that operators circulate drilling fluid, known as mud, to a bottom hole assembly cutting through subterranean formations. The mud, along with cuttings from the drilling process, flow back up the wellbore to the surface. A mud circulation system is generally required, which includes a mud pump system that circulates the mud down the drill string and up an annulus formed between the drill string and the wellbore. The mud is cleaned, and cuttings are removed before recirculating the mud back down into the wellbore. In order to clean the mud, the mud is passed through a shaker and a mud cleaner of the mud circulation system, where the cuttings are removed and discarded.
In offshore drilling, cranes are generally required to load the drilling equipment onto a drilling platform during assembly of the drilling platform. Generally, smaller cranes are more cost efficient than larger cranes. Therefore, it is desirable for the drilling equipment to have a light weight, which allows a smaller crane to load the drilling equipment onto the drilling platform. Moreover, due to the cost associated with a large footprint of a drilling platform, drilling equipment that has a small footprint is desirous. As such, the arrangement, weight, and footprint of all mud circulation system components are important.
The present disclosure is directed to a master shaker module for drilling rigs and methods that overcome one or more of the shortcomings in the prior art.
The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.
It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact.
Referring to
As set forth in more detail below, the master shaker module 100 supports mud circulation system components. However, unlike conventional mud circulation systems, the master shaker module 100 “stacks” at least a portion of the mud circulation system components, such as shale shakers, in a vertical direction using the upper master skid 110 that is selectively detachable from the lower master skid 105. Stacking the upper and lower master skids 105, 110 may reduce the footprint of the mud circulation system. Embodiments described herein are separable to permit the lower and upper master skids 105, 110 to be separated for weight reduction resulting in reduced handling loads. The lower and upper master skids 105, 110 may also be attached to one another for pick-up in one piece for easier and faster rig assembly. Additionally, and due to the configuration of the master shaker module 100, a portion of the shale shakers may be easily isolated from the mud circulation system. This may reduce costs by only operating a portion of the shale shakers when a fluid, or mud, that is circulated down a drill string and up an annulus formed between the drill string and a wellbore may be adequately cleaned using less than all of the shale shakers.
In one or more exemplary embodiments, the lower master skid 105 has a length extending in the direction indicated by the numeral 120 illustrated in
In an exemplary embodiment, the lower master skid 105 also includes a floor 105c that supports the plurality of shale shakers 135 and a subfloor 105d that is located below the floor 105c. In one or more exemplary embodiments, the lower master skid 105 has a first end 105e and an opposing second end 105f. In one or more exemplary embodiments, a master control panel 105g (
In one or more exemplary embodiments, the lower master skid 105 includes a support structure 105h that includes a plurality of vertically extending supports 105i extending from the floor 105c or the subfloor 105d or both. In one or more exemplary embodiments, the vertically extending supports 105i have a height within the range of 5 feet to 10 feet. However, a variety of heights are contemplated here. In an exemplary embodiment, and as illustrated in
In one or more exemplary embodiments and as illustrated in
In an exemplary embodiment and as illustrated in
In one or more exemplary embodiments and referring back to
In an exemplary embodiment and as illustrated in
In one or more exemplary embodiments and referring back to
In one or more exemplary embodiments and referring back to
In one or more exemplary embodiments, a plurality of fasteners 110o are located on a bottom portion of the upper master skid 110, such as the floor 110e or the subfloor 110f or both. In one or more exemplary embodiments, at least one fastener from the plurality of fasteners 110o corresponds with at least one fastener from the plurality of fasteners 105j. In one or more exemplary embodiments, the plurality of fasteners 110o may include a receiving sleeve 110oa that receives the vertical support 105i and a pin system 110ob that extends through the fastener 105j, a slot, bolts, screws, or any other type(s) of adequate fastener.
In one or more exemplary embodiments and referring back to
As illustrated in
In an exemplary embodiment, the upper master skid 110 is coupled to the lower master skid 105 at the step 205. In an exemplary embodiment, the upper master skid 110 is aligned over the lower master skid 105 such that at least one of the fasteners from the plurality of fasteners 110o align with at least one of the fasteners from the plurality of fasteners 105j. In one or more exemplary embodiments, at least one of the fasteners from the plurality of fasteners 110o is then coupled to at least one of the fasteners from the plurality of fasteners 105j.
In an exemplary embodiment, the pipe 110a is fluidically coupled to the pipe 105a at the step 210. In an exemplary embodiment, the pipe 110a is fluidically coupled to the pipe 105a using traditional pipe connections. In an exemplary embodiment, the pipe 105a is coupled to the pipe 110a such that the valve 110d may fluidically isolate the pipe 105a from the pipe 110a.
In an exemplary embodiment, the storage structure 110g of the upper master skid 110 is fluidically connected to the mud cleaner 140 at the step 215. In one or more exemplary embodiments, the storage structure 110g is coupled to the mud cleaner 140 such that the fluid or mud accommodated within the storage structure 110g may be transferred, via gravity or otherwise, to the mud cleaner 140 for cleaning.
In an exemplary embodiment, the DMS 110i is fluidically coupled to the flow path 105l of the lower master skid 105 at the step 220. In one or more exemplary embodiments, aligning at least one of the fasteners from the plurality of fasteners 110o of the upper master skid 110 to at least one of the fasteners from the plurality of fasteners 105j of the lower master skid 105 also aligns the flow path 105l of the lower master skid 105 with the opening 110l of the DMS 110i of the upper master skid 110.
In an exemplary embodiment, the opening 105n of the lower master skid 105 is aligned with a second debris moving system 230 at the step 225. In an exemplary embodiment, the master shaker 100 is located on a supporting surface on a platform. In an exemplary embodiment, the second debris moving system 230 is at least partially located below the supporting surface. Generally, the second debris moving system 230 is substantially identical to the DMS 110i and therefore will not be described here. Generally, the second debris moving system 230 includes a screw conveyor 235 that moves the debris to another location. Thus, aligning the opening 105n with an opening (not shown) to the second debris moving system 230 allows for the debris that exits the plurality of shale shakers 145 to enter the opening of the second debris moving system and be moved away from the master shaker 100, using the screw conveyor 235. In an exemplary embodiment, the screw conveyor 235 is a 20 inch auger. However, some embodiments employ an auger in the range of 12 to 24 inches depending on the flow requirements. Larger and smaller augers may be utilized depending on the flow requirements. In an exemplary embodiment, aligning the opening 105n with the second debris moving system 230 also aligns the exits of the plurality of shale shakers 135 with openings (not shown) of the second debris moving system 230 (
In an exemplary embodiment, the method 200 is used to provide a master shaker 100 that has a reduced footprint and weight. In an exemplary embodiment, the method 200 is used to provide a master shaker 100 that can be moved using a crane have a 140,000 lb. at 30 ft. capacity. Other sizes may also be used. In an exemplary embodiment, the method 200 results in a vertically stacked mud cleaning system. In an exemplary embodiment, the method 200 results in the plurality of shale shakers 135 positioned under the plurality of shale shakers 140. In one or more exemplary embodiments, the method 200 results in a selectively detachable master shaker module 100, as the upper master skid 110 may be detached and attached to the lower master skid 105. In an exemplary embodiment, the method 200 results in mud circulation system having the plurality of shale shakers 135 that may be fluidically isolated from the mud circulation system. In an exemplary embodiment, the method 200 results in a mud circulation system having a plurality of shale shakers 145 that may be fluidically isolated from the mud circulation system.
As illustrated in
In an exemplary embodiment, the valve 110c and the valve 110d are opened at the step 305. In an exemplary embodiment, opening the valves 110c and 110d allows the fluid to flow through the upper pipe 110a to the manifold 110b and through the lower pipe 105a to the lower manifold 105b at step 305.
In an exemplary embodiment, the mud circulation system is activated at the step 310. In one or more exemplary embodiments, operation of the mud circulation system forces the fluid through the upper pipe 110a and into the manifold 110b and forces the fluid through the lower pipe 105a and into the manifold 105b when the valves 110c and 110d are in an open or partially open position. After entering the manifolds 105b and 110b, the fluid passes through one of the plurality of shale shakers 135 and 145 for processing. In one or more exemplary embodiments, the manifold 110b encourages equal distribution of the fluid to the plurality of shale shakers 145. Similarly, the manifold 105b may encourage equal distribution of the fluid to the plurality of shale shakers 135.
In an exemplary embodiment, it is determined whether operation of the plurality of shale shakers 135 are required to adequately clean the mud at the step 315. In an exemplary embodiment, during certain drilling and/or completion operations, only a small amount of debris will be present in the mud. Thus, there are often situations in which only a portion of the shale shakers within the plurality of shale shakers 135 and 145 are required. For example, during circulation of the mud downhole (no drilling), the plurality of shale shakers 145 may adequately clean the mud. While, when drilling operations are performed, both the plurality of shale shakers 135 and 145 may be required to adequately clean the mud. In an exemplary embodiment, it is determined whether operation of the plurality of shale shakers 135 is required. If not, the valve 110d is shut at the step 320 and the step 315 is the next step. Otherwise, and if the operation of the plurality of shale shakers is required, the next step is 325.
In an exemplary embodiment, and if the operation of the plurality of shale shakers 135 is not required at the step 315, the valve 110d is shut at the step 320. In an exemplary embodiment, shutting the valve 110d fluidically isolates the plurality of shale shakers 135 from the pipe 110a and from the flow of the fluid. In an exemplary embodiment, shutting the valve 110d isolates the plurality of shale shakers 135 from the mud circulation system.
In an exemplary embodiment, and if the operation of the plurality of shale shakers 135 is required at the step 315, the valve 110d is opened or remains open at the step 325. In an exemplary embodiment, opening the valve 325 fluidically connects the plurality of shale shakers 135 to the pipe 105a.
In an exemplary embodiment, the method 300 is used to process the fluid using a minimal amount of shale shakers. In one or more exemplary embodiments, the method 300 may extend the life of mud cleaning equipment, as the mud cleaning equipment is only operated when required. In an exemplary embodiment, the method 300 is used to process the fluid using only a portion of the shale shakers, therefore the master shaker module 100 is a segmentable master shaker, as a portion of the shale shakers may be isolated from the mud circulation system. In an exemplary embodiment, the master shaker module 100 unitizes flow paths to reduce redundant weight.
In an exemplary embodiment, the method 300 may be altered in a variety of ways. For example, instead of determining whether the plurality of shale shakers 135 is required, the method 300 may include determining whether the plurality of shale shakers 145 is required. Additionally, instead of opening and closing the valve 110d in the step 320 and 325, the method 300 may include opening and closing the valve 110c in the steps 320 and 325. That is, instead of isolating the plurality of shale shakers 135 from the mud circulating system, the plurality of shale shakers 145 may be isolated from the mud circulating system.
In an exemplary embodiment, any number of shale shakers may be aligned along the length of the upper master skid 110 and the lower master skid 105. Alternatively, additional mud circulation equipment, such as a centrifuge, may be aligned along the length of the upper master skid 110 or the lower master skid 105 or both. In an exemplary embodiment, each of the valves 110c and 110d has an actuator that controls the opening and the closing of the valves 110c and 110d. In an exemplary embodiment, the actuator may be coupled to a controller that is also is in communication with the controls of each of the shale shakers in the plurality of shale shakers 135 and 145. Thus, upon determining that either the plurality of shale shakers 135 or the plurality of shale shakers 145 may be isolated from the mud circulation system, the controller may power off the plurality of shale shakers 135 and control the actuator to close the valve 110d or may power off the plurality of shale shakers 145 and control the actuator to close the valve 110c.
In an exemplary embodiment, the floors 105c, 105d, 110e, and 110f may be a solid surface, a grate, a cross-support or other support structure.
The present disclosure also introduces an apparatus that includes an upper master skid that includes a first floor configured to support a first plurality of mud circulation system components; a first storage structure at least partially disposed below the first floor and structurally configured to receive a fluid exiting the first plurality of mud circulation system components; a debris moving system at least partially disposed below the first floor and structurally configured to receive debris exiting the first plurality of mud circulation system components; and a first plurality of fasteners carried on the upper master skid; and a lower master skid that includes a second floor configured to support a second plurality of mud circulation system components; a second storage structure at least partially disposed below the second floor and structurally configured to receive a fluid exiting the first plurality of mud circulation system components; and a second plurality of fasteners carried on the lower master skid and configured to correspond to the first plurality of fasteners to couple the upper master skid over the lower master skid. In one exemplary embodiment, the upper master skid and the lower master skid are selectively detachable. In another exemplary embodiment, the apparatus also includes a support structure extending between the upper master skid and the lower master skid and configured to support the upper master skid such that the first plurality of mud circulation system components are located above the second plurality of mud circulation system components. In one exemplary embodiment, the lower master skid further includes a chute extending in the vertical direction and configured to couple to the debris moving system. In yet another exemplary embodiment, the debris moving system includes a trough configured to receive debris that exits from at least one of the mud circulation system components from the first plurality of mud circulation system components; and a conveyor accommodated within the trough that is structurally configured to move the debris in a first direction along the trough to the chute. In another exemplary embodiment, the upper master skid further includes a first pipe that is fluidically coupled to the first plurality of mud circulation system components and configured to allow the fluid to flow into the first plurality of mud circulation system components; and the lower master skid further includes a second pipe that is fluidically coupled to the second plurality of mud circulation system components and configured to allow the fluid to flow into the second plurality of mud circulation system components. In yet another exemplary embodiment, the upper master skid further includes a first valve that is structurally configured to fluidically isolate the first plurality of mud circulation system components from other mud circulation system components; and a second valve that is structurally configured to fluidically isolate the second plurality of mud circulation system components from the other mud circulation system components. In yet another exemplary embodiment, the upper master skid further includes a first manifold that fluidically connects the first pipe to the first plurality of mud circulation system components; and the lower master skid further includes a second manifold that fluidically connects the second pipe to the second plurality of mud circulation system components. In another exemplary embodiment, the first manifold encourages equal distribution of the fluid to each of the mud circulation system components in the first plurality of mud circulation system components; and the second manifold encourages equal distribution of the fluid to each of the mud circulation system components in the second plurality of mud circulation system components. In one or more exemplary embodiments, the second floor is configured to support a mud cleaner; and the first floor forms an opening configured to accommodate a portion of the mud cleaner. In another exemplary embodiment, at least one mud circulation system component of the first plurality of mud circulation system components is a shale shaker; and at least one mud circulation system component of the second plurality of mud circulation system components is a shale shaker.
The present disclosure also introduces a method that includes coupling an upper master skid structurally configured to support a first plurality of mud circulation system components over and to a lower master skid structurally configured to support a second plurality of mud circulation system components; fluidically connecting a first pipe of the upper master skid to a second pipe of the lower master skid; fluidically connecting a first storage structure of the upper master skid to a mud cleaner accommodated on the lower master skid, the first storage structure being configured to receive a fluid that exits from the first plurality of mud circulation system components; and fluidically connecting a first debris moving system of the upper master skid to a chute that vertically extends along the lower master skid, the first debris moving system being structurally configured to move debris that exits from the first plurality of mud circulation system components; the first pipe is arranged to fluidly communicate with the first plurality of mud circulation system components; and the second pipe is arranged to fluidly communicate with the second plurality of mud circulation system components. In an exemplary embodiment, the upper master skid further includes a first floor configured to support the first plurality of mud circulation system components; and a first plurality of fasteners carried on the upper master skid; and wherein the lower master skid includes: a second floor configured to support the second plurality of mud circulation system components; a second storage structure at least partially disposed below the second floor and structurally configured to receive the fluid exiting from at least one mud circulation system components from the first plurality of mud circulation system components; a support structure extending in the vertical direction from the second floor; a second plurality of fasteners located on the support structure and configured to correspond to the first plurality of fasteners to couple the upper master skid to the lower master skid. In an exemplary embodiment, coupling the upper master skid to the lower master skid includes: positioning the upper master skid at a location above the lower maser skid; aligning at least one fastener from the first plurality of fasteners with at least one fastener from the second plurality of fasteners; and coupling at least one fastener from the first plurality of fasteners with at least one fastener from the second plurality of fasteners. In yet another exemplary embodiment, the method also includes aligning the chute of the lower master skid with a second debris moving system that is at least partially located below a support surface upon which the lower master skid rests. In an exemplary embodiment, the first debris moving system includes: a trough configured to receive the debris that exits from at least one of the mud circulation system components from the first plurality of mud circulation system components; and a conveyor accommodated within the trough and structurally configured to move the debris that exits from the at least one mud circulation system component from the first plurality of mud circulation system components in a first direction along the trough and to the chute. In an exemplary embodiment, at least one mud circulation system component from the first plurality of mud circulation system components is a shale shaker; and at least one mud circulation system component from the second plurality of mud circulation system components is a shale shaker. In an exemplary embodiment, the upper master skid and the lower master skid are selectively detachable.
The present disclosure also introduces a method that includes flowing a fluid through a first pipe to a first plurality of mud circulation system components accommodated on an upper master skid; flowing the fluid through a second pipe to a second plurality of mud circulation system components accommodated on a lower master skid that is located below the upper master skid; determining whether operation of both the first and second pluralities of mud circulation system components is required to clean the fluid; and closing a valve to prevent the flow of the fluid through one of the first and second pipes after determining that operation of both the first and second pluralities of mud circulation system components is not required. In an exemplary embodiment, at least one mud circulation system component from the first plurality of mud circulation system components includes a shale shaker; and wherein at least one mud circulation system component from the second plurality of mud circulation system components includes a shale shaker. In yet another exemplary embodiment, the method also includes accommodating the fluid that exits from at least one of the mud circulation system components from the first plurality of mud circulation system components within a first storage structure at least partially disposed below a first floor of the upper master skid; and accommodating the fluid that exits from at least one of the mud circulation system components from the second plurality of mud circulation system components within a second storage structure at least partially disposed below a second floor of the lower master skid. In another exemplary embodiment, the method also includes receiving debris that exits from at least one of the mud circulation system components from the first plurality of mud circulation system components through a trough formed below a first floor of the upper master skid, the first floor supporting the first plurality of mud circulation system components; moving the debris using a screw conveyor that is accommodated within the trough. In an exemplary embodiment, the upper master skid and the lower master skid are selectively detachable.
In several exemplary embodiments, the elements and teachings of the various illustrative exemplary embodiments may be combined in whole or in part in some or all of the illustrative exemplary embodiments. In addition, one or more of the elements and teachings of the various illustrative exemplary embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
Any spatial references such as, for example, “upper,” “lower,” “above,” “below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,” “upwards,” “downwards,” “side-to-side,” “left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described herein.
In several exemplary embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In several exemplary embodiments, the steps, processes and/or procedures may be merged into one or more steps, processes and/or procedures.
In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.
Although several exemplary embodiments have been described in detail above, the embodiments described are exemplary only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure.
The Abstract at the end of this disclosure is provided to comply with 37 C.F.R. §1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. §112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.
