This technical disclosure relates to a pit pump that can be used to pump drilling fluid in a drilling fluid recycling system for recycling of the drilling fluid. The recycled drilling fluid can then be re-used during a drilling operation performed by a drilling system. The drilling fluid can be used in a drilling operation performed by a horizontal directional drill (HDD) or in other drilling systems that use drilling fluid during drilling.
Drilling fluid (often called drilling mud) is used by various drilling systems to aid in the drilling of boreholes into the earth. One example of a drilling system that uses drilling fluid is a HDD. In a HDD, used drilling fluid is pumped by a pit pump in a recycling system which recycles the drilling fluid for re-use. The pit pump can be disposed in either the exit pit or the entry pit (or there can be a pump in each pit) where the used drilling fluid collects. During operation the pit pump is typically submerged within the drilling fluid.
During a drilling process, a conventional pit pump often needs to be lifted from the pit for servicing of the pit pump. For example, the drilling fluid typically cakes on the exterior of the pump creating an insulating shell that can prevent dissipation of heat from the pump motor. In addition, the inlet of the pit pump can often become blocked by rocks and other particulate material that is carried by the drilling fluid from the borehole. However, servicing of the pit pump is time consuming and results in down time of the drilling operation.
A pit pump is described herein that is configured to permit the pit pump to remain disposed within the pit and submerged in the drilling fluid for long periods of time, thereby reducing or eliminating the need to remove the pit pump from the pit for servicing. The pit pump can be used in any drilling fluid recycling system. A drilling fluid recycling system can be used with many types of drilling systems that use drilling fluid while drilling boreholes in the earth. For example, the drilling fluid recycling system can be used with a HDD.
In one embodiment, the pit pump is driven by a liquid cooled electric drive motor. In this embodiment, a liquid is in direct contact with the electric drive motor to cool the electric drive motor, and the cooling liquid is circulated to an external heat exchanger located outside of the pit to cool the cooling liquid before being returned back to the electric drive motor. The pit pump can stay submerged in the drilling fluid within the pit indefinitely since the pit pump does not require removal of caked-on drilling fluid to prevent overheating of the electric drive motor since the cooling liquid cools the electric drive motor. Further, the liquid cools the electric drive motor even if the pump is stalled.
The electric drive motor can be any electric drive motor that is liquid cooled. In one embodiment, the electric drive motor can be a bi-directional permanent magnet motor. Because the motor is bi-directional, the rotation direction of the pump impeller can be reversed. Reversal of the rotation direction can be useful to help clear away material that may be blocking or impeding flow through the pump inlet. In particular, the discharge hose of the pump normally holds a certain amount of head volume and pressure while pumping. If the pump impeller is reversed, the head volume and pressure is released back out of the inlet of the pump thereby dislodging any material that may be lodged in the inlet.
In another embodiment, the pit pump can be configured to permit remote, electronic monitoring of the pit pump. For example, one or more of the motor temperature, temperature of the cooling liquid, motor torque, revolutions per minute of the electric motor and/or of the impeller, horsepower, and vibrations of the electric motor and/or of the pump impeller, and other variables can be monitored. Non-pump variables such as the weight of the drilling fluid, viscosity, head pressure, and the length of the hose connected to the outlet of the pit pump can also be measured. The operation of the pit pump can also be remotely controlled, either wirelessly or via a physical connection via a tether or a wire. The pit pump can include a controller thereon that receives readings from one or more sensors.
In one embodiment, readings concerning the motor torque, the revolutions per minute of the electric drive motor, the horsepower being provided by the electric drive motor, the drilling fluid weight and the hose length can be used together to determine or calculate the volume of the drilling fluid being pumped. This permits the operator to calculate the volume without using a mechanical flow meter or ultrasonic sensor. In some embodiments, one or more sensors can be provided, for example at or near the outlet of the pump, to sense an actual volume being output which can then be used to validate the determined/calculated volume. In addition, the weight of the drilling fluid in the pump output can be calculated based on the torque on the electric drive motor.
Referring to
The pit pump 12 is part of a drilling fluid recycling system that is used to recycle used drilling fluid for re-use during a borehole drilling operation. Used drilling fluid from the drilling operation, mixed together with solids from the borehole, can collect in a pit 14, which can be an exit pit or an entry pit, with the used drilling fluid mixed with solids then being pumped by the pit pump 12 to a drilling fluid recycler where the used drilling fluid is processed to remove the solids and to make the drilling fluid otherwise suitable for reintroduction back into the borehole. The construction and operation of a drilling fluid recycling system is well known in the art. The pit 14 is illustrated as having used drilling fluid 16 therein, and the pit pump 12 is disposed in the pit 14 so that the pit pump 12 is at least partially submerged in the used drilling fluid 16. Typically, the pit pump 12 will be completely submerged in the used drilling fluid 16 as is illustrated in
As will be discussed in further detail below, the pit pump 12 can be driven by an electric drive motor, and a cooling liquid is used to cool the electric drive motor. The cooling liquid is circulated between the pit pump 12 and an external heat exchanger 18 by a cooling liquid supply pipe (or hose) 20 and a cooling liquid return pipe (or hose) 22. One or more pumps 23 can be provided for circulating the cooling liquid in the closed coolant loop. For example, the pump 23 can be provided in the supply pipe (or hose) 20 within or outside the drilling fluid 16, in the return pipe (or hose) 22 within or outside the drilling fluid 16, in the heat exchanger 18 or in the pit pump 12 itself. The heat exchanger 18 is located outside the pit 14, and is configured to cool the cooling liquid before the cooling liquid is returned back to the pit pump 12 to cool the electric drive motor. The heat exchanger 18 can be configured as, for example, a liquid-to-air heat exchanger or a liquid-to-liquid heat exchanger.
In addition, electrical energy for powering the electric drive motor of the pit pump 12 can be provided via a power line 24 from a controller 26 that is configured to control operation of the pit pump 12 and the heat exchanger 18. In addition, various data signals can be transmitted over a data line 28 between the pit pump 12 and the controller 26. Electrical energy for powering operation of the various mechanisms described herein can be supplied from a suitable electric power supply 30. Data and power lines 34 can also be provided between the controller 26 and the heat exchanger 18 to direct electrical power to the heat exchanger 18, to control operation of the heat exchanger 18, and to send data signals from the heat exchanger 18 to the controller 26.
The electric power supply 30 can be any supply that is suitable for providing electrical power to the pit pump 12. In one embodiment, the power supply 30 can be an electrical generator. In another embodiment, the power supply 30 can be line power obtained from an available electrical power line. In addition, two power supply sources can be provided with one power supply acting as a back-up in case of failure of the first or primary power supply.
The system 10 can further include a HDD rig 32 that is separate from the drilling fluid recycling system. The HDD rig 32 can have any configuration that is suitable for performing horizontal directional drilling.
One embodiment of the pit pump 12 is illustrated in
The pump portion 40 can have any configuration that is suitable for pumping the used drilling fluid 16 mixed with solids. The pump portion 40 will have an inlet, generically designated as 44, through which the used drilling fluid enters the pump portion 40 and an outlet, generically designated as 46, through which the used drilling fluid exits the pump portion 40. The pump portion 40 also includes a pump impeller 48 or other motive device for pumping the used drilling fluid from the inlet 44 to the outlet 46. One example of a suitable pump configuration includes, but is not limited to, a centrifugal pump with the inlet 44 being an axial inlet, the outlet 46 being a radial or tangential outlet, and the pump impeller 48 being rotatably mounted in the pump portion 40. However, other pump configurations can be used.
With continued reference to
The electric drive motor 82 can be any drive motor that can be reversed in rotation direction. In one embodiment, the electric drive motor 82 can include a bi-directional permanent magnet drive motor which permits reversal of the rotation direction. However, other electric drive motors are possible. In addition, as discussed in further detail below, the electric drive motor 82 is configured to be cooled by a suitable cooling liquid, such as, but not limited to, a 50/50 water/ethylene glycol mix, that is circulated through the electric drive motor 82. Liquid-cooled electric drive motors are known in the art.
Referring to
In one embodiment best seen in
The drive motor 82 includes a drive shaft 100 (shown in dashed lines in
Referring to
For example, one or more of the following parameters can be monitored by suitable sensors: temperature of the drive motor 82, temperature of the cooling liquid used to cool the drive motor 82, torque of the drive motor 82, revolutions per minute of the drive motor 82 and/or of the impeller 48 (and/or the shaft 100), horsepower, and vibrations of the drive motor 82 and/or of the pump impeller 48. Non-pump variables such as the weight of the used drilling fluid 16, viscosity, head pressure, and the length of the hose connected to the outlet 46 of the pump portion 40 can also be measured. Moisture in the housing 80 (if present) may also be monitored using one or more sensors. The types of sensors necessary to monitor these parameters are well known in the art. Data from the sensors is routed to the controller 26 (and/or routed to an internal controller of the pump described further below) which can monitor the parameters to determine the health of the individual components and how the pit pump 12 is operating. This permits the performance parameters of various elements of the pit pump 12 to be monitored, and if the monitoring determines that an element is not operating correctly, maintenance can be scheduled to replace or repair the element and/or the sensors. Additional sensors can also be added as needed in order to monitor other parameters.
With reference to
In still another embodiment, a power converter 99, such as a DC to AC inverter that converts DC power to AC power or an AC to DC inverter that converts AC power to DC power, can be incorporated onto the pump 12. For example, the power converter 99 can be located on or within the housing 80 or located on the drive motor 82 itself. If present, the power converter 99 can be connected to the power line 24 to convert incoming electrical power into the appropriate form for use by the pump 12.
In one embodiment, the volume of the used drilling fluid mixed with solids pumped by the pit pump 12 and the volume of the cleaned drilling fluid pumped back into the borehole 52 can be determined. The difference between these two volumes provides a determination as to the amount of solids being removed from the borehole 52. A significant difference in the volumes of the used and cleaned drilling fluids can provide an indication of possible leakage of the drilling fluid, for example within the borehole 52, in the pit 14, or elsewhere in the path of the drilling fluid. In addition, the amount of solids being removed provides an indication of the drilling operation and whether the borehole 52 is clean enough.
The volume of the used drilling fluid mixed with solids pumped by the pit pump 12 and the volume of the cleaned drilling fluid pumped into the borehole 52 can be determined using any suitable techniques. For example, mechanical flow meters can be provided at suitable locations at or near the output of the pit pump 12 and at or near the output of the downhole pump. In another embodiment, one or more of the volumes can be determined mathematically using variables and parameters measured from various components of the system. In an embodiment, one or more sensors 85 (seen in
Additional embodiments that can be implemented include:
A horizontal directional drilling system including:
A pit pump to be used within a pit containing drilling fluid for use with drilling operations performed by a horizontal directional drilling rig, the pit pump including:
A drilling fluid reclamation method that includes:
A pit pump operation method comprising:
The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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Entry |
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International Search Report and Written Opinion issue in PCT/US2020/022699, dated Jul. 2, 2020. |
Number | Date | Country | |
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20200318445 A1 | Oct 2020 | US |
Number | Date | Country | |
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62819109 | Mar 2019 | US |