Patent Application
20160220929
The invention is for use in the field of oil and gas drilling operations and provides a device for use in recovering used drilling fluids from drill cuttings,
The loss of drilling fluids presents several technological and cost challenges to the energy exploration industry. These challenges generally include the seepage losses of drilling fluids to the formation, the recovery of drilling fluids at surface and/or the disposal of drilling detritus or cuttings that are contaminated with drilling fluid. In the context of this description, “drilling fluid” is both fluid prepared at surface used in an unaltered state for drilling as well as all fluids recovered from a well that may include various contaminants from the well including water and hydrocarbons (both liquid and gas).
During the excavation or drilling process, drilling fluid losses can reach levels approaching 300 cubic meters of lost drilling fluid over the course of a drilling program. With some drilling fluids having values in excess of $1600 per cubic meter, the loss of such volumes of fluids represents a substantial cost to drill operators.
Drilling fluids are generally characterized as either “water-based” or “oil-based” drilling fluids that may include many expensive and specialized chemicals as known to those skilled in the art. As a result, it is desirable that minimal quantities of drilling fluids are lost during a drilling program such that many technologies have been considered and/or employed to minimize drilling fluid losses both downhole and at surface.
Additionally, in some areas the delivery of oil or water for the formulation of drilling fluids can present several costly challenges for some operations; specifically desert, offshore and even some districts where communities will not allow allocation of water for this use.
As noted above, one particular problem is the separation of drilling fluid and any hydrocarbons from the formation that may be adhered to the drill cuttings (collectively “fluids”) at the surface. The effective separation of various fluids from drill cuttings has been achieved by various technologies including but not limited to; hydrocyclones, mud cleaners, linear motion shakers, scroll centrifuges, vertical basket centrifuges (VBC), vacuum devices, and vortex separators. As known to those skilled in the art, these devices are typically rented by operators at costs ranging from $1000 to $2000 per day and, as a result, can also represent a significant cost to operators. Thus, the recovery of fluids necessary to recover these costs generally requires that the recovered fluid value is greater than the equipment rental cost in order for the recovery technology to be economically justified. On excavation projects where large amounts of high-cost drilling fluid are being lost (for example in excess of 3 cubic meters per day), daily rental charges for specialized separation equipment can provide favorable economics. In addition, an operator will likely also factor in the environmental effects and/or costs of disposal of drilling fluid contaminated drill cuttings in designing their drilling fluids/drill cutting separation/recovery systems.
Past techniques for separating drilling fluid from drill cuttings have also used liquid spraying systems to deliver “washing” liquids to drill cuttings as they are processed over shaker equipment. Such washing liquids and associated fluid supply systems are used to deliver various washing fluids as the cuttings are processed over a shaker and can include a wide variety of designs to deliver different washing fluids depending on the type of drilling fluid being processed. For example, washing liquids may be comprised of oil, water, or glycol depending on the drilling fluid and drill cuttings being processed over the shaker. Generally, these washing fluids are applied to reduce the viscosity and/or surface tension of the fluids adhered to the cuttings and allow for more fluids to be recovered. However, these techniques have generally not been cost effective for many drilling fluids as the use of diluting fluids often produces unacceptable increases in drilling fluid volume and/or changes in chemical consistency and rheological properties of the drilling fluid.
Thus, while various separation systems are often effective and/or efficient in achieving a certain level of fluids/cuttings separations, each form of separation technology can generally only be efficiently operated within a certain range of conditions or parameters and at particular price points. For example, standard shakers utilizing screens are relatively efficient and consistent in removing a certain amount of drilling fluid from cuttings where, during the typical operation of a shaker, an operator will generally be able to effect drilling fluid/cuttings separation to a level of about 12-40% by weight of fluids relative to the drill cuttings (i.e. 12-40% of the total mass of recovered cuttings is drilling fluid). The range of fluids/cuttings wt % is generally controlled by screen size wherein an operator can effect a higher degree of fluids/cuttings separation by using a larger screen opening (such as 50-75 mesh) and a lower degree of fluids/cuttings separation with a smaller screen opening (such as up to 325 mesh). The trade-off between using a large mesh screen vs. a small mesh screen is the effect of mesh screen size on the quantity of solids passing through the screen and the time required to effect that separation. That is, while an operator may be able to lower the fluids retained on cuttings coming off the shaker with a larger mesh screen (50-75 mesh), the problem with a larger mesh screen is that substantially greater quantities of solids will pass through the screen, that then significantly affect the rheology and density of the recovered fluids and/or require the use of an additional and potentially less efficient separation technology to remove those solids from the recovered drilling fluids. Conversely, using a small mesh screen, while potentially minimizing the need for further downstream separation techniques to remove solids from recovered drilling fluids, results in substantially larger volumes of drilling fluids not being recovered, as they are more likely to pass over the screens hence leading to increased drilling fluids losses and/or require subsequent processing.
Accordingly, in many operations, an operator will condition fluid recovered from a shaker to additional processing with a centrifugal force type device in order to reduce the fluid density and remove as much of the fine solids as possible before re-cycling or reclaiming the drilling fluid. However, such conditioning requires more expensive equipment such as centrifuges, scrolling centrifuges, and hydrocyclones which then contribute to the overall cost of recovery. These processing techniques are also directly affected by the quality of the fluid they are processing, so fluids pre-processed by shakers using a coarse screen will not be as optimized as those received from finer screens.
Furthermore, the performance of centrifuges, hydrocyclones and other equipment are directly affected by the viscosity and density of the feed fluid. As a result, drilling fluid recovery techniques that send heavy, solids-laden fluids to secondary processing equipment require more aggressive techniques such as increased g-forces and/or vacuum to effect separation which will typically cause degradation in the drill cuttings.
Further still, such secondary processing equipment typically cannot process drill cuttings and drilling fluids at the same throughput values of a shaker with the result being that additional separation equipment may be required or storage tanks may be required to temporarily hold accumulated drilling fluid.
Thus, the operator will try to balance the cost of drilling fluid losses with the quality of the fluid that is recovered together with other considerations. While operators will typically have little choice in the quality of the cuttings processing and fluid recovery techniques available, many operators will operate separation equipment to provide recovered drilling fluid density about 200-300 kg/m3 heavier than the density of the circulating fluid in the system. This heavier fluid which would contain significant quantities of fine solids and that, when left in the drilling fluid, will either immediately or over time impair the performance of the drilling fluid or any other type of fluid.
As a result, there continues to be a need for systems that economically increase the volume of fluids recovered from a shaker without negatively impacting the rheological properties of the recovered drilling fluid.
In addition, there has been a need to develop low-cost retrofit technologies that can enhance fluid recovery and do so at a fractional cost level to mechanisms and technologies currently employed. Further, there has been a need for retro-fit technologies that can be utilized on a variety of shakers from different manufactures and that can be used to enhance the operation of existing shakers.
The use of vacuum technology has been one solution to improving the separation of drilling fluids. However, vacuum technologies may also present dust and mist problems in the workplace. With past vacuum techniques there is a need to regularly clean clogged screens with high pressure washes. High pressure washing of screens creates airborne dust and mist hazards to operators. Thus, there continues to be a need for technologies that minimize the requirement for screen washing.
Further still, there has been a need for improved fluid separation systems on the underside of a vacuum screen that allows relatively large volumes of air to be drawn through a vacuum screen to be effectively and efficiently separated from the relatively low volume of drilling fluid being drawn through a vacuum screen. That is, there has been a need for improved fluid/air separation systems.
Further still, there has been a need for retrofit systems that can be adapted to standard shakers without substantial modification to the existing shaking and that allow for quick and easy installation at a job site. In addition, there has been a need for retrofit systems that also allow for ready disassembly of the system for transport and/or maintenance.
As a result, there has also been a need for systems that improve the ability of shaker systems to improve fluid separation at a shaker. Currently used systems typically include a vacuum conduit running from the shaker screen connection to a large recovery tank which is in line with a powerful vacuum system. According to normal operations, the vacuum systems run continuously until the large tanks become filled with recovered drilling fluid, at which point the recovered drilling fluid is pumped out of the recovery tank and conveyed to the main drilling fluid supply vessels which are known as “mud tanks.” Improved systems which reduce the complexity of fluid transfer and related energy requirements are desirable.
Various technologies including vacuum technologies have been used in the past for separating drilling fluids from drill cuttings including vibratory shakers.
For example, U.S. Pat. No. 4,350,591 describes a drilling mud cleaning apparatus having an inclined travelling belt screen and degassing apparatus including a hood and blower. U.S. Patent Publication No, 2008/0078700 discloses a self-cleaning vibratory shaker having retro-fit spray nozzles for cleaning the screens. Canadian Patent Application No. 2,664,173 describes a shaker with a pressure differential system that applies a non-continuous pressure across the screen. U.S. Pat. No. 4,639,258 and U.S. Patent Publication Nos. 2014/0110357, 2014/0091028 and 2013/0074360 describe vacuum-assisted shale shakers. U.S. Pat. No. 8,691,097 describes a separating tower with a top vacuum discharge port and a bottom solids discharge port. Other references including U.S. Pat. No. 6,092,390, U.S. Pat. No. 6,170,580, U.S. Patent Publication No. 2006/0113220 and POT Publication No. 2005/054623 describe various other separation technologies. Each of the above-noted references is incorporated herein by reference in entirety.
Vacuum technologies based on shakers are described in U.S. Patent Publication Nos. 2014/0091028, 2013/0092637, 2013/0074360, 2012/0279932 and 2011/0284481, each of which is incorporated herein by reference in entirety.
Thus, while past technologies may be effective to a certain degree in enabling drilling fluid/cuttings separation, it remains desirable to improve aspects of the design and operation of alternative separation devices that enable expedient conveyance of the collected drilling fluid in a convenient and cost-effective manner with minimal equipment requirements.
One aspect of the present invention is a screened vacuum enclosure for use in separating drilling fluid from drill cuttings in a vacuum-based shaker system, the screened vacuum enclosure comprising:
In some embodiments, the vacuum ports extend through the outside front surface of the downstream longitudinal frame member to the interior of the frame.
In some embodiments, the one or more inner frame support members include longitudinal and transverse inner frame members dividing the inside of the rectangular frame into a plurality of interior sections and wherein vacuum pipes are placed in at least some of the vacuum ports, the vacuum pipes having open ends located in at least some of the interior sections.
In some embodiments, the inner frame support members comprise two longitudinal inner frame members and two transverse inner frame members dividing the interior of the rectangular frame into a grid with nine interior sections, and defining three interior longitudinal areas and three interior transverse areas.
In some embodiments, the screened vacuum enclosure includes nine substantially equi-spaced vacuum ports.
In some embodiments, the vacuum ports are round and have interior threaded sidewalls for installation of one or more threaded plugs.
In some embodiments, the screened vacuum enclosure includes nine vacuum pipes with one vacuum pipe placed in each one of the nine vacuum ports.
In some embodiments, one pipe of the nine vacuum pipes terminates in each one of the nine interior sections.
In some embodiments, each of the three transverse areas includes three vacuum pipes of the nine vacuum pipes with one of the three vacuum pipes terminating in each of the three interior sections included in each of the three transverse areas.
In some embodiments, the screened vacuum enclosure includes four vacuum pipes installed in the second, fourth, sixth and eighth vacuum ports of the nine vacuum ports and wherein the plugs are installed in the first, third, fifth, seventh and ninth vacuum ports of the nine vacuum ports.
In some embodiments, each one of the four vacuum pipes extends across the three longitudinal areas and terminates in the longitudinal area adjacent the longitudinal outer frame member opposing the longitudinal outer frame member with the vacuum ports.
In some embodiments, each of the two inner longitudinal frame members includes three equi-spaced channels adjacent the floor to allow vacuum suction to extend to longitudinal sections that do not include the open ends of the vacuum pipes.
In some embodiments, at least some of the outer frame members are at least partially hollow and are joined to form a continuous hollow space within the rectangular frame, and wherein the vacuum ports join the hollow space and communicate vacuum suction to the interior of the screened vacuum enclosure via one or more additional openings in the rectangular frame.
In some embodiments, the additional openings are provided by one or more slots located in one or more of the longitudinal or transverse outer frame members.
In some embodiments, the one or more slots is eight slots substantially equi-spaced across the length of the interior side of the upstream longitudinal outer frame member, and wherein the downstream outer frame member includes six substantially equi-spaced vacuum ports.
In some embodiments, the eight slots have substantially identical lengths and different widths, with widest slots located at the center of the upstream longitudinal member, and with narrowest slots located adjacent to the ends of the upstream longitudinal member.
In some embodiments, the slots each have radiused corners.
In some embodiments, the slots have a total open area greater than the total open area of the plurality of vacuum ports.
In some embodiments, the outer frame has mitered corners and each end of the downstream longitudinal frame member has a vacuum port extending into a corresponding mitered corner of the mitered corners.
In some embodiments, the one or more inner frame support members is seven transverse inner frame support members.
In some embodiments, the screened vacuum enclosure further comprises seven spacer elements located between corresponding transverse inner frame support members and the floor, the spacer elements having a length less than the length of the transverse inner frame support members, thereby providing upstream and downstream spaces between the transverse inner frame support members and the floor.
In some embodiments, the floor covers between about one quarter to about three quarters of the interior area of the rectangular frame and is bounded by the entire length of the downstream longitudinal member, the entire length of an opposing inner longitudinal support member and opposing portions of the transverse outer frame members.
In some embodiments, the floor covers about half of the interior area.
In some embodiments, the one or more slots is provided by a pair of opposing slots located in the portions of the transverse outer frame members, and wherein the transverse outer frame members each have an interior boundary limiting the interior hollow space.
In some embodiments, the interior boundary in each transverse outer frame member is located adjacent to the upstream end of each of the opposing slots.
In some embodiments, the floor has two sloped portions increasing in height from the opposing portions of the transverse outer frame members to a substantially central apex.
In some embodiments, the floor is supported by a central reinforcing member attached to the underside of the floor and the upstream interior area of the rectangular frame not covered by the floor includes one or more transverse inner frame members.
In some embodiments, the one or more vacuum ports is provided by a single vacuum port located in an adapter inserted in a slot in the downstream outer frame member which is open to the interior of the frame.
In some embodiments, the adapter includes (i) an elongated base with a plug portion configured to fit into the slot and (ii) an outward extending funnel-shaped portion terminating with the vacuum port.
In some embodiments, the elongated base is defined by having one or more bolt or screw holes for connection of the adapter to the downstream outer frame member.
In some embodiments, the floor covers between about one quarter to about three quarters of the interior area of the rectangular frame and is bounded by the entire length of the downstream longitudinal member, the entire length of an opposing inner longitudinal support member and opposing portions of the transverse outer frame members.
In some embodiments, the floor covers about half of the interior area.
In some embodiments, the floor has three sloped sections with first and second triangular sections sloping downward from downstream corners of the rectangular frame and a central trapezoidal section sloping downward from the inner longitudinal support member to the downstream longitudinal frame member.
In some embodiments, the downstream longitudinal outer frame member includes a vacuum pressure gauge for displaying vacuum pressure in the hollow space.
Another aspect of the invention is a vacuum shaker system for separation of drilling fluid from drill cuttings, the system comprising:
In some embodiments, the system further comprises at least one additional upstream screened vacuum enclosure as recited herein which is substantially identical to the downstream screened vacuum enclosure with the proviso that, in the upstream screened vacuum enclosure, all vacuum pipes or adapters are removed and all vacuum ports are sealed to restrict the function of the upstream screened vacuum enclosure to that of a screen frame only, thereby providing a means to shake drill cuttings at a similar level from the upstream screened vacuum enclosure to the downstream screened vacuum enclosure.
In some embodiments, each one of the upstream screen beds of the shaker holds a separate upstream screened vacuum enclosure having features as defined for the upstream screened vacuum enclosure described herein.
In some embodiments, the system further comprises a wash module connected to two or more of the vacuum ports for pumping of wash fluid into the screened vacuum enclosure to expel obstructions from the hollow space of the screened vacuum enclosure.
Another aspect of the invention is a kit for assembly of a screened vacuum enclosure for use in separating drilling fluid from drill cuttings on a shaker, the kit comprising:
In some embodiments, the kit further comprises a plurality of vacuum pipes dimensioned to enter the vacuum ports and fit through the second set of openings.
In some embodiments, the kit further comprises a second set of inner longitudinal frame members, each containing a set of regularly spaced channels, such that, when the screened vacuum enclosure is assembled and in use in conjunction with a vacuum source and a shaker, vacuum pressure is transmissible through all sections of a grid formed by the inner frame members.
In some embodiments, the kit further comprises a set of plugs for closure of selected vacuum ports among the series of vacuum ports.
In some embodiments, the interior sidewalls of the vacuum ports are threaded and the plugs are threaded for corresponding installation into the vacuum ports.
In some embodiments, the kit further comprises instructions for assembly of a screened vacuum enclosure with a commercially-obtained screen and either nine vacuum pipes or four vacuum pipes, wherein the assembly of the screened vacuum enclosure with nine vacuum pipes uses longitudinal inner frame members without channels and the screened vacuum enclosure with four vacuum pipes uses longitudinal inner frame members with channels.
In some embodiments, the kit further comprises an adhesive for fixing the covering floor structure to one side of the frame and for fixing a screen to the other side of the frame.
Various objects, features and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of various embodiments of the invention. Similar reference numerals indicate similar components.
This system is provides a means for flushing out blockages inside the hollow body of the screened vacuum enclosure 210. The remaining adapters are connected to the vacuum distributor 40.
Existing vacuum screen fluid recovery systems, such as the systems described in U.S. Patent Publication Nos. 2014/0091028, 2013/0092637, 2013/0074360, 2012/0279932 and 2011/0284481 (each incorporated herein by reference in entirety), use a vacuum device attached to the underside of the frame of a screen on a shaker (see for example, FIG. 1E of U.S Patent Publication No. 2013/0074360, which is attached to about one third of the underside of the screen frame). This vacuum system operates by suction of the drilling fluid from the drill cuttings as they vibrate on a downstream shaker screen after having vibrated without vacuum suction across one or more upstream shaker screens. The recovered drilling fluid is then conveyed under vacuum pressure to a storage tank and then circulated to mud tanks for re-use.
While this system represents a valuable advancement in the art which has met with significant commercial success, improvements continue to be sought after in efforts to address certain disadvantages. For example, the existing vacuum attachment arrangement adds weight disproportionately to one portion of the downstream screen and interferes with the manufacturers intended harmonics profile for the screen during the shaking process, thereby impacting the efficiency of separation. Commercially available shakers, screens and screen frames are not designed to handle such asymmetric stress. It would be advantageous to provide alternatives that address these issues as well as providing additional advantages. Such advantages are provided by various embodiments of the present invention.
The present invention has been made to address a number of shortcomings of existing vacuum-based liquid recovery systems. One such example is the issue of the extra weight placed on the screen by an external vacuum attachment connected to the underside of the screen as noted above. Therefore, the present invention allows the external vacuum manifold attachment and screen system to be replaced with a structure formed from a rectangular frame to which is fixed a top screen and an opposing floor. The rectangular frame is configured for installation of a series of vacuum pipes or adapters which may adopt various configurations and which are provided for connection to a vacuum system. This inventive structure is herein designated the “screened vacuum enclosure.”
One of the long sides of the frame (a longitudinal frame member) of the screened vacuum enclosure is provided with a series of vacuum ports for provision of vacuum suction extending from the screen surface, down into the interior of the structure and the outward via the vacuum ports to the vacuum source. Advantageously, all connections of the parts of the device are sealed to preserve vacuum flow of air down from the screen and outward to the vacuum source. As such, the entire interior of the structure which is bounded by the outer frame members, the top screen and the floor, or a portion thereof, can be subjected to vacuum suction in a manner similar to the vacuum suction provided by the vacuum manifold structure of the vacuum systems described in U.S. Patent Publication Nos. 2014/0091028, 2013/0092637, 2013/0074360, 2012/0279932 and 2011/0284481 (each incorporated herein by reference in entirety). The screened vacuum enclosure is more compact and lighter than the state-of-the-art vacuum screen system currently in use. It is expected that significant mitigation of the mechanical stress-related problems caused by direct connection of large vacuum attachments to the underside of the screen will be confirmed.
In certain embodiments, the weight of the screened enclosure is substantially similar to as that of a framed screen unit itself, as supplied by manufacturers. Furthermore, replacement of the external vacuum attachment system with the screened vacuum enclosure is expected to provide more space near the downstream end of the shaker. Certain embodiments of the screened enclosure are customizable by adding or removing vacuum conduit pipes to and from the frame as described hereinbelow. Thus the system can be adapted to provide optimal vacuum pressure for removal of various types of drilling fluids from various consistencies of drill cuttings.
As used herein, the term “screened vacuum enclosure” is a general term which encompasses all embodiments of the present invention which include a support frame with vacuum ports, a top screen and a bottom floor, as well as any pipes, adapters and/or plugs which may be connected to the vacuum ports.
As used herein, the term “frame” refers to a three dimensional support structure in the sense of a building frame rather than a two-dimensional surrounding support structure in the sense of a picture frame, and is used in context of describing a support structure for the screened vacuum enclosure.
As used herein, the terms “shaker” and the alternative art-accepted term “shale shaker” are synonymous and refer to an apparatus designed to support and vibrate screen frames in a process for recovering drilling fluid from drill cuttings. Used drilling fluid flows directly to the shale shakers for processing. Once processed by the shale shakers, the drilling fluid is deposited into containers known as “mud tanks.”
As used herein, the terms “screen basket” and “screen bed” are synonymous and refer to a platform on the shaker which is responsible for transferring the shaking intensity of the machine to the screen frames as they are held securely in place. It is to be understood that all embodiments of the screened vacuum enclosure are dimensioned for placement on screen beds. Different shakers produced by different manufacturers may have screen beds with different dimensions, therefore requiring screen frames and/or screened vacuum enclosures with different dimensions.
As used herein, the term “drilling fluid” is synonymous with the term “mud” used in the art of drilling for hydrocarbons. Drilling fluids are integral to the drilling process and, in addition to providing other functions, serve to lubricate and cool the drill bit as well as convey the drilled cuttings away from the bore hole. These fluids are composed of a mixture of various chemicals in water or oil based solutions and can be very expensive. For both environmental reasons and to reduce the cost of drilling operations, drilling fluid losses are minimized by removing them from the drilled cuttings before the cuttings are disposed of.
As used herein, the term “drill cuttings” refers to any material conveyed upwards to the surface by the drilling process as a result of a drilling operation and may include soil, mud, and pieces/particles of various classes of rocks. When drill cuttings emerge from a drilling operation, they are typically covered with drilling fluid.
As used herein, the term “conduit” is used to describe any means for transmission of a vacuum pressure and/or liquids. Examples include, but are not limited to tubes, pipes or hoses of various compatible diameters which may be coupled to conveyance means driven by various types of liquid pumps or vacuum sources for conveyance of liquids.
As used herein, the terms “downstream” and “upstream” are relative terms used to identify locations in a process with respect to one or more other locations. A downstream location with respect to another location is a position closer to the end of the process than the other location. An upstream location with respect to another location is a position closer to the beginning of the process than the other location. These terms are in common usage in the arts relating to process engineering and are well understood by those skilled in the art.
As used herein, the terms “longitudinal” and “transverse” are used to distinguish between different frame members and specific interior areas of the screened vacuum enclosure. Longitudinal members and areas are greater in length than transverse members and areas.
As used herein, the term “screen” refers to any screen or mesh structure appropriate for separation of drilling fluid from drill cuttings on a shaker bed.
As used herein, the term “vacuum distributor” refers to an enclosed structure for distributing vacuum pressure or suction from a vacuum source to a plurality of vacuum lines extending to the screened vacuum enclosure of the present invention. The vacuum distributor may have any structure compatible with the function of splitting vacuum pressure to a plurality of vacuum lines extending to a screened vacuum enclosure.
Various aspects of the invention will now be described with reference to the figures. For the purposes of illustration, components depicted in the figures are not necessarily drawn to scale. Instead, emphasis is placed on highlighting the various contributions of the components to the functionality of various aspects of the invention. A number of possible alternative features are introduced during the course of this description. It is to be understood that, according to the knowledge and judgment of persons skilled in the art, such alternative features may be substituted in various combinations to arrive at different embodiments of the present invention. For example, the ensuing description illustrates embodiments that include screened vacuum enclosures configured for connection of the vacuum ports to various numbers of vacuum conduits in specific arrangements. Other arrangements with more than nine vacuum conduits as well as more or less than six or four vacuum conduits are possible and may be assembled by making routine modifications to the basic structure of the screened vacuum enclosure, or by simply connecting more or fewer vacuum conduits to alternative vacuum ports. Modifications required to arrive at such alternative embodiments can be effected by the skilled person without undue experimentation and are within the scope of the invention as defined by the claims.
Any terms which have not been explicitly defined herein, are to be considered as having meanings as they would be understood by persons skilled in the art. Such terms may also be reasonably inferable from the drawings and description and the combination thereof with the knowledge of the skilled person.
With reference to
Referring now to
The structure of the screened vacuum enclosure 10 includes a top screen 32 which may be any type of screen known in the art and used for separating drill cuttings from drilling fluids. Such screens are well known to those skilled in the art. The screen is attached to the top surfaces of the frame 12 in certain embodiments may also be at least partially supported by the upper surfaces of the interior support members 16a, 16b, 18a and 18b. The screened vacuum enclosure 10 also includes a floor 30 attached to the bottom surfaces of the frame 12. An appropriate manner of attaching the screen 32 and floor 30 to the top and bottom surfaces of the frame 12 may be readily developed by one with ordinary skill in the art and may include the use of an adhesive such as an epoxy resin or cement, or other equivalent attachment means. Advantageously, the attachments provide a sealing arrangement such as a fitted gasket, for example, which prevents loss of vacuum pressure when the screened vacuum enclosure is in operation. Such attachment and sealing features are compatible with all embodiments of the invention and can be produced by the skilled person without undue experimentation.
More detail regarding the interior connections between the frame members 14a-14d, the interior support members 16a, 16b, 18a and 18b and the vacuum pipes 28a-28i will now be described with reference to
As noted above, this particular embodiment of the screened frame enclosure 10 includes a rectangular frame structure 12 formed of four exterior frame members 14a, 14b, 14c and 14d in a rectangular shape. There are two longitudinal support members 16a and 16b and two transverse support members 18a and 18b. In this particular embodiment, the longitudinal support members 16a and 16b are wider than the transverse support members 18a and 18b and this enables assembly of the frame 12 to be facilitated by providing rectangular shaped lateral openings 20s, 20t in longitudinal support member 16b and rectangular shaped lateral openings 20u and 20v in longitudinal support member 16a. The rectangular transverse support members 18a and 18b are dimensioned to extend through and seal each of these rectangular lateral openings 20s, 20t, 20u and 20v to fix the transverse support members 18a and 18b in place within the frame 12. Likewise, rectangular notches 22w and 22x are provided in frame member 14d and rectangular notches 22y and 22z are provided in frame member 14c. The ends of longitudinal members 16a and 16b fit into these rectangular notches 22w, 22x, 22y, and 22z to fix the longitudinal members 16a and 16b to the frame 12.
In this particular embodiment, each of the longitudinal support members 16a and 16b is provided with a series of round openings for passage of vacuum conduit pipes. The skilled person will recognize that alternative embodiments will employ vacuum conduit pipes with square or rectangular cross sections and that the openings in longitudinal support members 16a and 16b will also be square or rectangular to allow passage of square vacuum pipes.
In the present embodiment, longitudinal support member 16b is provided with six round openings 24j, 24k, 24l, 24m, 24n and 24o. In a similar manner, longitudinal support member 16a is provided with three round openings 24p, 24q and 24r. Each of these nine openings 24j-24r is aligned with a corresponding port from among the nine vacuum ports 26a-26i in outer frame member 14a to allow passage of one of the vacuum pipes 28a-28i. Therefore, vacuum pipe 28a is of intermediate length and extends through opening 24j in longitudinal member 16b, terminating in the middle section of the rightmost transverse interior area; vacuum pipe 28b is a short pipe which terminates before reaching longitudinal member 16b, terminating in the right section of the rightmost transverse interior area; and vacuum pipe 28c is a long pipe which extends through opening 24k in longitudinal member 16b as well as opening 24p in longitudinal member 16a, terminating in the left section of the rightmost transverse interior area.
The arrangement of pipes 28a to 28c with respect to the frame 12 and the inner support members 16a, 16b, 18a and 18b has just been described for the three rightmost inner rectangles of the grid in
The outer ends of the pipes 28a-28i are each configured for attachment to a corresponding vacuum conduit line which extends to a central vacuum distribution unit (shown in
Turning now to
It is seen in the bottom perspective view of
The skilled person will recognize that the present arrangement of vacuum pipes 128b, 128d, 128f and 128h, which each terminate near frame member 114b would have the effect of providing the vacuum suction to only the leftmost rectangles of the grid (with reference to
The skilled person will recognize that the two different arrangements for providing suction via vacuum pipes according to the two embodiments described hereinabove, will provide different relative vacuum pressures at different locations of the screens. This differential vacuum suction may be characterized without undue experimentation and applied advantageously to separation of drilling fluids from drill cuttings with different characteristics in order to achieve an optimal balance between recovery of optimal volumes of drilling fluid with minimal generation of undesired fine particles of drill cuttings.
Turning now to
As described in the previous embodiments, a series of vacuum ports 226a, 226b, 226c, 226d, 226e and 226f are provided in the forward facing (downstream) frame member 214a. However, these vacuum ports do not extend through the opposite side of frame member 214a but instead join the hollow interior space within frame member 214a. As noted above, all of the outer frame members 214a-d are hollow. These members are arranged such that their individual hollow spaces meet each other at the corners of the frame 212 to form a continuous hollow space that functions as a vacuum conduit when vacuum pressure is applied at one or more of the vacuum ports. While it is not necessary for the transverse support members 218a-g to be hollow and to join the hollow interior space of the frame, the skilled person will recognize that such an embodiment can be constructed if an analysis of air flow under vacuum pressure through the structure indicates that such a structure will enhance the removal of fluid from drill cuttings vibrating on the screen. Such an analysis and an interpretation thereof may be performed by the skilled person without undue experimentation.
The vacuum ports 226a-f are provided with a means for connecting adapters or plugs, such as interior threading. Adapters and plugs are then provided with corresponding outer threading and will be described in more detail hereinbelow.
Frame member 214b which opposes the front frame member 214a is provided with a series of slots on its side facing the interior of the screened vacuum enclosure 210. In this particular embodiment, there is one slot in each of the interior sections of the enclosure defined by the transverse support members 218a-g. Other embodiments may include fewer or additional slots. In this particular embodiment, slots 244a, 244b, 244c and 244d have similar dimensions, slots 246a and 246b have similar dimensions and are wider than slots 244a-d while having essentially the same length, and slots 248a and 248b have similar dimensions and are wider than slots 244a-d and 246a-b while having essentially the same length. These features are seen most clearly in
Turning now to
Turning now to
Turning now to
Shown in
The skilled person will recognize that this action may be performed simultaneously with vacuum pressure provided on the adapters 250b-e (as shown in
The provision of a hollow space within the frame of this embodiment allows installation of a pressure gauge for measurement of vacuum pressure within the hollow space. Advantageously, the pressure gauge is installed in the downstream longitudinal member where it can be easily viewed by an operator at the front of the shaker.
Turning now to
This particular embodiment of the screened vacuum enclosure 310 includes a frame 312 formed of exterior frame members 314a, 314b, 314c and 314d, interior transverse support frame members 318a, 318b, 318c and 318d and a single longitudinal inner support member 316 which forms the dividing line between the vacuum portion and the non-vacuum portion as described in more detail below.
Frame member 314a has vacuum ports 326a, 326b, 326c and 326d and as such is oriented at the front of the shaker during operation. As for previous embodiments, the vacuum ports 326a, 326b, 326c and 326d are configured for installation of corresponding hollow-body adapters 350a, 350b, 350c and 350d to facilitate connection of vacuum lines. In some embodiments, the vacuum ports 326a-d have sidewalls with threading to facilitate threading installation of the adapters 350a-d.
This embodiment also has a bottom floor 330 and a top screen 332 as similarly described for the previous embodiments. While the top screen 332 is generally similar to the top screens of the other embodiments, the floor 330 covers only about half of the interior area of the screened vacuum enclosure 310, with boundaries formed by the front halves of the transverse frame members 314c and 314d, the longitudinal support member 316 and the front longitudinal support member 314a. In addition, the floor 330 is generally sloped upwards from each transverse side toward a mid-point apex 331. As such the floor 330 has two sloped portions 330a and 330b which meet at the apex 331.
The purpose of structuring the floor 330 with the apex 331 is to reduce the total volume of space inside the screened vacuum enclosure below the screen 332 to make the vacuum pressure more effective and also to provide some gravity drainage of fluid collected in the screened vacuum enclosure 310.
The remaining half of the interior area of the frame 312 (the back half as shown in
As noted above and described in the previous embodiments, the vacuum ports 326a, 326b, 326c and 326d are provided in the forward facing exterior frame member 314a. However, as described above for embodiment 3, these vacuum ports do not extend through the opposite side of frame member 314a but instead join a hollow interior space within frame member 314a. In addition, frame members 314c and 314d are each provided with a single corresponding slot 349a and 349b opening into the floor area and the frame members 314c and 314d are continuously hollow at least as far as the back end of the slots 349a and 349b (slot 349a is visible in
The hollow portions of members 314c and 314d each join the hollow interior of member 314a for the purpose of providing a continuous hollow vacuum conduit extending from the vacuum ports 326a, 326b, 326c and 326d at least as far as the back of the slots 349a and 349b. In this particular embodiment, all exterior frame members 314a, 314b, 314c and 314d are hollow and interior walls are either installed within the hollow spaces of frame members 314c and 314d or formed integrally therewithin. In this particular example embodiment an interior wall 351a is shown inside the hollow space of member 314c is shown in the magnified perspective view of
The general pattern of air flow under vacuum is now described with reference to
The skilled person will recognize that pumping of wash fluid into the front hollow portion of the frame 312 may be performed in a similar manner as described for embodiment 3, in order to dislodge obstructions. Such obstructions are dislodged through the slots 349a and 349b into the interior of the screened vacuum enclosure 310.
As for embodiment 3, the provision of a hollow space within the frame of this embodiment allows installation of a pressure gauge for measurement of vacuum pressure within the hollow space. Advantageously, in certain embodiments, the pressure gauge is installed in the downstream longitudinal member where it can be easily viewed by an operator at the front of the shaker.
As described for embodiment 3, the present embodiment may be configured for washing to remove obstructions by pumping of washing fluid into the device.
Turning now to
This particular embodiment of the screened vacuum enclosure 410 includes a frame 412 formed of exterior frame members 414a, 414b, 414c and 414d, interior transverse support frame members 418a, 418b, 418c and 418d and a single longitudinal support member 416 which forms the dividing line between the vacuum portion and the non-vacuum portion as described in more detail below.
Frame member 414a has a generally centered slot 447 for installation of an adapter 460 whose structure is shown in detail in three different views in
Advantageously, the interior sidewall of the port 461 is provided with threads to allow threading connection of a nozzle 462 to facilitate connection of a single vacuum line.
This embodiment also has a bottom floor 430 and a top screen 432 as similarly described for the previous embodiments. While the top screen 432 is generally similar to the top screens of the other embodiments, the floor 430 covers only about half of the interior area of the screened vacuum enclosure 410, as for embodiment 4, with boundaries formed by the front halves of the transverse frame members 414c and 414d, the longitudinal support member 416 and the front longitudinal support member 414a.
The three dimensional structure of the floor differs from the floor 330 of embodiment 4 by having three separately sloped portions 430a, 430b and 430c. Sloped floor portions 430a and 430b are triangular and diagonally sloped downwards from their respective front corners to promote flow of drilling fluid towards the center of the floor at portion 430b. As such, the highest point of floor portion 430a is at the front left corner of the screened vacuum enclosure 410 where the front longitudinal frame member 414a meets the left transverse frame member 413c. Likewise, the highest point of the of floor portion 430c is at the front right corner of the screened vacuum enclosure 410 where the front longitudinal frame member 414a meets the left transverse frame member 413d. As noted above, floor portion 430b, which is a trapezoidal shape, is also sloped. The slope of floor portion 430b is downward from a plane near the top edge of the inner longitudinal support member 416 to a plane near the bottom edge of the front longitudinal frame member 414a below the slot 447. The purpose of structuring the floor 430 with the sloped portions 430a-c is to reduce the total volume of space inside the screened vacuum enclosure below the screen 432 to make the vacuum pressure more effective and to promote gravity flow of fluid toward the slot.
The remaining half of the interior area of the frame 412 (the back half as shown in
One notable difference between embodiment 4 and the present embodiment is that it is not a requirement for any of the frame members 414a-d or portions thereof to be hollow, although they may be hollow if desired, provided that boundaries such as walls or vacuum impervious filler are provided on each side of the slot 447, to prevent vacuum from being pulled through the frame 412 (as this would decrease the efficiency of the system. As such, the vacuum suction is concentrated above the floor 430 of the screened vacuum enclosure 410.
The general pattern of air flow under vacuum is now described with reference to
The skilled person will recognize that pumping of wash fluid into the screened vacuum enclosure 410 may be performed in a similar manner as described for embodiments 3 and 4, in order to dislodge obstructions within the funnel portion 465 of the adapter 460. Such obstructions are dislodged through the slot 447 into the interior of the screened vacuum enclosure 410.
One advantage of this embodiment relative to the other embodiments described hereinabove is that because there is only one vacuum port 461, there is no need to provide a vacuum distributor when the screened vacuum enclosure 410 is incorporated into a vacuum-based shaker system (see
As for embodiments 3 and 4, the provision of a hollow space within the frame of this embodiment allows installation of a pressure gauge for measurement of vacuum pressure within the hollow space. Advantageously, in certain embodiments, the pressure gauge is installed in the downstream longitudinal member where it can be easily viewed by an operator at the front of the shaker.
As described for embodiments 3 and 4, the present embodiment may be configured for washing to remove obstructions by pumping of washing fluid into the device.
Materials used for construction of the frame members of various embodiments of vacuum enclosures of the present invention may include wood, plastic or metal and may be determined without undue experimentation. Advantageously, the materials are lightweight to minimize addition of extra loads to the shaker. It is known in the art that binding agents can be used bind the screen mesh to the screen frame with maximal adhesion to both materials while being able to handle high heat, strong vibration, abrasive cuttings and corrosive drilling fluids. Plastic composite screens tend not to use adhesives but rather heat the mesh and melt it into the screen frame to form a bond. Such binding agents may be adapted to construct various embodiments of the screened vacuum enclosure without undue experimentation.
In accordance with another aspect of the invention, the screened vacuum enclosure is used as part of a vacuum-based shaker system for separation of drilling fluid from drill cuttings.
In
In certain alternative embodiments, each one of the three upstream screen beds 3b, 3c and 3d has a screened vacuum enclosure placed thereon. These three screened vacuum enclosures are modified to function simply as screen frames by closure of each of the nine vacuum ports. More detail of this modification is provided hereinbelow.
Referring now to
Referring now to
Turning now to
Shown in
The skilled person will readily recognize that a number of variations in connections between the vacuum distributor 40 and the vacuum ports are possible. The vacuum ports 226a-f may be provided with inner threads which facilitate the process of making connections to adapters, plugs or even direct connection of threaded vacuum conduits which extend to a vacuum distributor or vacuum sources. In certain embodiments, each vacuum line extending to each vacuum port may be controlled individually to increase or decrease vacuum pressure provided to the hollow frame body of the screened vacuum enclosure 210. This will alter the air flow dynamics within the hollow body of the screened vacuum enclosure 210 to alter the vacuum-driven air flow on the screen to facilitate separation of drilling fluids of different consistencies from drill cuttings with different characteristics with the aim of achieving an optimal balance between recovery of optimal volumes of drilling fluid with minimal generation of undesired fine particles of drill cuttings.
Referring now to
Referring now to
The use of a screened vacuum enclosure on a downstream screen bed may require additional modification of the vacuum shaker system for optimal operation. In one particular situation, it may be advantageous to have one or more of the upstream screens placed at the same level as the screen of the screened vacuum enclosure so that drill cuttings can vibrate off the upstream screen directly onto the downstream screen of the screened vacuum enclosure. It is expected that most existing screen frames will have a narrower depth than that of the screened vacuum enclosure and this differential depth will pose a problem if it is desired that the upstream and downstream screens are placed at the same level.
This problem is conveniently addressed by configuring one or more substantially identical screened vacuum enclosures to function solely as screen frames by installing plugs in all of the vacuum ports and placing these modified screened vacuum enclosures on one or more of the upstream screen beds. Since the depth of the screened vacuum enclosures is substantially identical, the levels of all of the screens should be substantially identical. If it is found that the plugs prevent adequate alignment of the adjacent longitudinal outer frame members of adjacent screened vacuum enclosures, the outer frame members may be fitted with gaskets to bridge the gaps between the adjacent screened vacuum enclosures. The manner of constructing and fitting of gaskets to the screened vacuum enclosures is within the knowledge of the person skilled in the art.
In all example embodiments described herein, the vacuum ports are located on the front side surface of the downstream longitudinal member. Alternative embodiments have ports located on the underside of either the downstream or upstream longitudinal member. The provision of ports in the upper surfaces of the upstream or downstream longitudinal members is also possible, but expected to be less advantageous because of potential interference with the movement of drill cuttings across the screen of the screened vacuum enclosure.
As understood by the foregoing description, alternative embodiments of the first and second embodiment of the screened vacuum enclosure may be constructed which employ any number of vacuum ports and vacuum pipes. While the maximum number of vacuum ports and pipes in the embodiments described above is nine ports and nine pipes, the skilled person will recognize that it is possible to design alternative embodiments with more ports and pipes. Such alternatives are also within the scope of the invention. Advantageously, both of the embodiments described above and additional embodiments may be constructed using the example kit described below.
In the present example, there is provided a kit for assembly of screened vacuum enclosures of embodiments 1 and 2 for use in separating drilling fluid from drill cuttings on a shaker. In one embodiment, the kit comprises outer frame members including two longitudinal outer frame members and two transverse outer frame members and inner frame members including two longitudinal inner frame members and two transverse inner frame members. The kit also includes a covering floor structure designed to substantially cover the bottom of the frame. An adhesive for attaching the floor to the lower surface of the frame and for attaching a commercially obtained screen to the upper surface of the frame may also be provided.
The transverse outer frame members include a set of notches for holding the ends of inner longitudinal frame members. The two longitudinal inner frame members are each provided with two different sets of openings along their length. One set of openings has two rectangular openings provided to allow passage of the two transverse inner frame members to hold them in place in relation to the inner longitudinal members, thereby forming a rigid double cross-like structure. The other set of openings are round openings provided to hold the vacuum pipes. This double cross-like structure is installed inside the outer frame. The floor is attached either before or after the vacuum pipes are inserted according to the desired configuration. Lastly, the screen is attached. This structure can then be placed on the screen bed of a shaker and the vacuum conduit lines can be attached to the vacuum pipes. The vacuum lines extend to a vacuum distributor which is connected by a main vacuum conduit to a vacuum source and a drilling fluid storage tank.
An example of a process of assembly of two different embodiments of the screened vacuum enclosure is now described with reference to components and features best illustrated in
Certain embodiments of the kit include one or more screens while other embodiments do not include one or more screens. It may be advantageous to omit the screens from the kits because users may already have inventories of appropriate screens at their work locations. In any case, screens are obtainable from commercial manufacturers and need not be included as components of the kit. It is advantageous to assemble the screened vacuum enclosures at or near the work site so that the screened vacuum enclosures may be customized for the conditions at the site. For example, if a particular class of heavier rock cuttings is present in the drilling fluid as it emerges during the drilling operation, operators may elect to attach a heavier screen to the frame of the kit and to use the nine-pipe configuration of the embodiment of
The kit may include specific step-by step instructions such as those outlined above, to guide users in assembly of screened vacuum enclosures. The instructions may also include specific guidance for assembly and use of different embodiments with different vacuum pipe configurations when specific conditions are expected.
The BRANDT™ King Cobra shakers produced by Brandt of Houston, Tex., USA and marketed by National Oilwell Varco and the MONGOOSE PRO shakers marketed by MI Swaco/Schumberger are in wide use in drilling operations. It is advantageous to produce screened vacuum enclosures in accordance with specific embodiments of the present invention which are compatible with these shakers.
The skilled person is to understand that the dimensions of the example embodiments described below are not to be construed as limiting, but are provided simply by way of illustrating certain embodiments with specific examples. Alternative embodiments will have dimensions which vary from these examples if they are designed to be compatible with any other shaker systems. Alternative dimensions can be determined by the skilled person without undue experimentation.
Shown in Tables 1 to 3 are lists of dimensions for screened vacuum enclosures of embodiments 3 to 5 optimized for use in conjunction with the BRANDT King Cobra shaker and a second screened vacuum enclosure optimized for use in conjunction with the MONGOOSE PRO shaker.
Other than described herein, or unless otherwise expressly specified, all of the numerical ranges, amounts, values and percentages, such as those for amounts of materials, elemental contents, times and temperatures, ratios of amounts, and others, in the following portion of the specification and attached claims may be read as if prefaced by the word “about” even though the term “about” may not expressly appear with the value, amount, or range. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
Any patent, publication, internet site, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
While this invention has been particularly shown and described with references to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
This application claims priority to U.S. Provisional Patent Application No. 62/110,205 filed Jan. 30, 2015, and U.S. Provisional Patent Application No. 62/189,325 filed Jul. 7, 2015, each of which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62189325 | Jul 2015 | US | |
| 62110205 | Jan 2015 | US |
