DRILL CUTTING WASHING APPARATUS

Abstract

A portable apparatus for sieving, washing, and drying particle samples onsite that are generated from well drill cutting. The apparatus comprises a sievewash chamber to initially remove contaminates from the samples, and a final wash-spin-dry chamber to completely clean and dry the samples for analysis. The two chambers function under the operational control of a computerized system comprising a processor, a user display, and a database storing computer code for operating the apparatus in various cleaning cycles. The sieve-wash chamber comprises two vertically stacked baskets: a coarse basket on top to hold the drill cutting samples; and, a caged basket underneath to catch clean samples as they fall through the coarse mesh screen on the bottom of the coarse basket. The caged basket with the samples is then manually transferred to the wash-spin-dry chamber for processing by motorized rotation of the basket at high rpm's.

Description

BACKGROUND OF THE INVENTION

1. Field of Invention

The invention relates to a sieving, washing, and drying apparatus for cleaning drill cutting samples from oil, gas and the like well drilling.

2. Description of Related Art

During the process of drilling in the soil and/or rock, be it for oil, natural gas, or other deposits, the cutting of the drill bit against the terrain generates drill cuttings that are used to analyze the progress of the drilling and the types of deposits uncovered. The drill cuttings must thus be cleansed of debris, oil, mud, chemicals used in the drilling, etc. in order for the cuttings to be analyzed accurately. The standard method of cleaning the drill cuttings comprise manual washing and drying, a time consuming and man hour costly process. In recent years, efforts have been made to automate the washing of sample drill cuttings.

For example, WO/2008/007987 by Ryan entitled “Washing Apparatus and Components for a Washing Apparatus” discloses an apparatus for washing drill cutting samples obtained for oil and gas wells by rotating them in a container on a conveyor belt between a wash, rinse and dry station. A nozzle that sprays water substantially upward into container bodies comprising three screens that house samples of drilling bits. Water is thus forced up through a first screen and up through another coarse screen to thereby impinge on and agitate the drill cutting samples located in the upper part of the body. As a consequence, dirt, mud and any other unwanted materials are washed from the drill cutting samples, and the finer shaped samples drop through the coarse screen to reside in the lower part of the container body.

Additionally, U.S. patent application Ser. No. 2011/0277798 by Hillier entitled “Sample washer for drilling cuttings” discloses the use of sieve-like mesh bottomed containers for washing drilling cutting samples with hot water to allow draining off of the water; and then for drying samples by applying vacuum pressure to the containers to suction off water, and any remaining chemicals and other deposits.

None-the-less, there is still a need within the industry for onsite, speedy, and thorough automated methods of cleaning drill cutting samples, while minimizing the exposure of employees to cleaning chemicals and toxic fumes.

SUMMARY OF THE INVENTION

The present disclosure is directed to a portable apparatus for sieving, washing, and drying particle samples of contaminating material and chemicals generated from well drill cutting. The apparatus comprises a sieve-wash chamber to initially clean large deposits of contaminates off of the samples, and a final wash-spin dry chamber to completely clean and prep the samples for analysis. The two chambers function under the operational control of a computerized system comprising a processor, a human machine interface—display, and a database storing computer code for operating the apparatus in various cleaning cycles.

The sieve-wash chamber comprises two vertically stacked baskets: a coarse basket on top to hold the drill cutting samples; and, a caged basket underneath to catch clean samples as they fall through the coarse mesh screen on the bottom of the coarse basket. It is noted, though, that some samples may not requiring sieving, in which case the sieve-wash chamber may be operated with just the caged basket holding the drill cutting samples.

Due to its ease of portability, the apparatus may be used on-site of a drilling operation to expedite the analysis of samples from drill cutting. The water inlet only need be connected to a hot water source, such as a tap faucet head, and the water outlet source may comprise any container for drainage of the used water.

And, the computerized system may operate both the sieve-wash chamber and the wash-spin chamber simultaneously to further expedite processing of multiple samples. For example, while a first sample is being spun dry in the wash-spin chamber, a second sample that does not require sieving is being cleansed in the first sieve-wash chamber.

The apparatus is further powered by a readily available energy source, such as a normal electrical outlet (e.g. 120 VAC). In one embodiment, a brushless motor powers rotation of the final wash-chamber.

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,

FIG. 1 is a top plan view of one embodiment of the sieving and washing apparatus comprising the sieve-wash chamber and the wash-spin chamber.

FIG. 2 is a rear perspective view of the apparatus illustrating the source of power, water and discharge.

FIG. 3 is a cross-sectional side view of the sieving-wash chamber illustrating the stacked baskets

FIG. 4a is a top perspective view of the wash-spin chamber without a caged basket.

FIG. 4b is a top perspective view of the wash-spin chamber with a cage basket.

FIG. 5 is a side view of the internal compartment of the apparatus below the sieve wash chamber.

FIG. 6 is a perspective view of the top and bottom baskets.

FIG. 7 is a schematic of the electrical circuit comprising the computer system in communication with the motor and chambers.

FIG. 8 is a top view of the computer display.

DETAILED DESCRIPTION

An exemplified embodiment of the portable washing apparatus 10 for cleaning samples of drilling cutting bits is disclosed with reference to FIGS. 1-5, and mainly comprises the following: a sieve-wash chamber 20 and a wash-spin chamber 40 functioning under the operational control of a computer system 60 comprising a human machine interface display 62. The sieve-wash chamber 20 comprises two vertically stacked baskets to wash and sieve the samples (see FIG. 3); a top solid-walled basket 22 and a bottom caged basket 24. The washed samples and caged basket are then manually transferred from the sieve-wash chamber 20 to the wash-spin chamber 40 in the caged basket housing the cleansed samples (see FIGS. 4A and 4B). In the wash-spin chamber 40, the samples are further washed and dried via spinning at speeds of up to about 3000 revolutions per minute (RPM's) to remove excess water.

Similarly, FIGS. 1 and 2 illustrate the top and rear view, respectively, of the apparatus 10 comprising its primary components of: the computer system 60 with a display 62; the wash-spin chamber 40; the sieve-wash chamber 20; the water inlet hose 70, and the water outlet hose 80.

The apparatus of the present disclosure is portable in nature by weighing, in one embodiment, about 20 lbs., and having the dimensions of about 21 inches in length by 12 inches in width by 10 inches in height (i.e. 21*12*10″).

FIG. 1 is a top plan view of the apparatus 10 displaying the sieve-wash chamber 20 with a first water tube 102 comprising a rotating nozzle 38 (as shown in FIG. 3) with a swivel connector 39 supported by the lid 76 of the sieve-wash chamber 20. The nozzle 38 may include apertures 45 along one side of each arm 41 so as to cause the nozzle 38 to rotate about the swivel connection 43 as water exits the apertures. The first water tube 102 is connected to the water inlet hose 70 via the plumbing shown within the internal compartment of the apparatus 10 as illustrated in FIG. 5.

The sieve-wash chamber 20 is hollow with a means to drain water and debris out of the chamber, and further comprises an external cylindrical wall 23 of sufficient height and diameter to house two baskets holding drill cutting samples. The wall 23 may comprise the same material as the external surface of the device, such as stainless steel, and the wall 23 is about 3-5 millimeters in thickness, and 4-6 inches in diameter.

As shown in FIG. 3, within the sieve-wash chamber 20 reside two vertically stacked cylindrical baskets: a top solid-walled basket 22; and, a bottom caged basket 24. With reference to FIG. 6, the solid-walled basket 22 comprises: a cylindrical solid side wall 30; and, a mesh bottom 32 wherein the bottom is formed of a large mesh pattern having apertures of sufficient size to permit the drill cutting samples to fall below into the caged basket 24 under the force of water pressure, while leaving large debris within the solid-walled basket 22. The caged basket 24 is formed in a similar manner with a cylindrical mesh side wall 30; and a mesh bottom 32 wherein both of the side wall and bottom are formed with a mesh pattern less coarse than the solid-walled basket 22 to retain the drill cutting samples therein while permitting water and finer debris to fall therethrough. The open top 35 of each of the top and bottom baskets 22 and 24 includes an annular notch 37 around the outside thereof which is sized to be received within a corresponding inner ridge 36 of a lid 39 or a similar inner ridge of another container. The lid 39 may optionally include a taper around the outside of the inner ridge 36 to self-align the baskets when stacked to compensate for when an off balance load is applied such as when a sample is introduced therein. Additionally, the bottoms 32 of the top and bottom baskets 22 and 24 also include similar tapers 33. The tapers 31 and 33 may have a taper angle of 3 to 5 degrees.

Within the bottom of sieve-wash chamber 20 resides a means of draining the water and debris and chemicals washed off of the samples from the apparatus 10. In one embodiment, an aperture 29 lying in the bottom of the sieve-wash chamber 20 may drain the wash-off into a hose connected to the water outlet hose 80. In particular the aperture 29 may be in fluidic communication with a drain pipe 84 extending to the as illustrated in FIG. 5 which in turn drains into the wash-spin chamber 40. As illustrated in FIG. 1, the water outlet hose 80 may then drain the contents of the wash-spin chamber 40.

Once the baskets 22, 24 are secured in the sieve-wash chamber 20, the user adds cleaning solution (e.g. soap, degreaser, etc.) by pouring a small amount into the top basket 22. The user then secures the chamber lid 28 to contain the sample in both baskets and also contain the wash solution in the sieve-wash chamber and inputs cleaning cycle selections (i.e. computer commands) into the computer display 62. The user may select a default time for the sieving-washing process (e.g. 30 sec), or the user may program in a custom length of time.

The methods of cleansing the samples may vary. In one embodiment, the samples are cleansed in sieve-wash chamber 20 under the force of water being sprayed at a high water pressure from the rotating nozzle 38 attached to the chamber lid 28. In another embodiment, this cleansing process is augmented by the rotation of the chamber at low or high revolutions-per-minute (e.g. up to 3000 rpm) and/or by the agitation or vibration of the sieve-wash chamber 20.

After the caged basket 24 is removed from the sieve-wash chamber 20, the cleaning soap can again be added thereto before the a lid 39 is placed on the caged basket 24 to secure the samples for the final wash and drying phase within the wash-spin chamber 40 as further described below.

FIGS. 1, 4A, and 4B illustrate the wash-spin chamber 40. In FIG. 4A, the wash-spin chamber 40 is without a basket; and, it FIG. 4B it has the caged basket 24 loaded horizontally into the wash-spin chamber 40. The basket is secured between two metal discs 44a,b. Attached to the disc 44a is the drive mechanism 46 that is connected to a motor (not shown) residing in the internal compartment of the apparatus 10 under the computer system.

The wash-spin chamber 40 is locked when in use to prevent user injury. In one embodiment, the wash-spin chamber 40 will not operate unless the chamber lid and lock are secured as determined by any suitable sensor switch or the like.

In response to user input into display 62, the final wash phase occurs by opening the second valve 108 and providing water to a spray nozzle 48 within the wash-spin chamber 40 which is oriented towards the caged basket 24 located therein. The final wash-drying phase may be programmed into the computer system 60 to occur in various modes. For example, the final wash and spin phase may occur concurrently, sequentially (wash then spin), or the user may select one phase (wash or spin).

The motor spins the caged basket 24 via rotating the drive mechanism 46 around a horizontal axis at high revolutions-per-minute to remove the excess water and other liquids-debris from the samples within the basket. The excess water then drains out of wash-spin chamber 40 via a water outlet drain 82, which connects to the water outlet hose 80 within the apparatus 10 internal compartment (see FIG. 5). The speed (i.e. rpm's) and duration may be set by the user, or may be pre-programmed into the computer system 60.

In one embodiment, the computerized system 60 may be set via the human machine interface-display 62 to run both the sieve-wash chamber 20 and the wash-spin chamber 40 simultaneously to further expedite processing of multiple samples.

In one embodiment, a first sample is run through the sieve-wash chamber 20 to remove debris, chemicals, mud, etc. from the drilling cutting samples within the solid-walled basket 22. The sieved samples are caught in a first caged basket 24 during the sieving and washing process within sieve-wash chamber 20. The caged basket 24 with the samples is then manually transferred by the user to the wash-spin chamber 40 and fixed into place in a horizontal position.

Optionally another second caged basket 24 housing drill cutting samples that do not need to be sieved, due for example to the lack of debris, may be placed within the sieve-wash chamber 20 for its initial washing. Because a solid-walled basket 22 is not required for such sieving, the caged basket 24 is placed on the top layer in the sieve-wash chamber 20.

When both chamber 20 and 40 are running concurrently, the fluid flow rate within the water inlet hose 70 and the water outlet hose 80 must be balanced to prevent the buildup of fluid within wash-spin chamber 40.

A back perspective view of one embodiment of the apparatus is shown in FIG. 2 to illustrate a water inlet hose 70 attached to the apparatus 10 via as connector 72 and on the other end (not shown) to a source of hot water, such as a tap-faucet, also via a female connector. The water to the apparatus through the water inlet hose 70 may be provided by an external pump (not shown) or from any pressurized water source, such as from a faucet or the like.

The water outlet hose 80 is also shown in FIGS. 1, 2-5. A water outlet drain (not shown) within the sieve-wash chamber 20 removes the water from the sieve-wash chamber 20 and redirects it to water outlet hose 80 through the wash-spin chamber 40 for disposal. Likewise, a water outlet drain 82, as shown in FIG. 1, drains the water removed from the samples during the operation of the wash-spin chamber 40, and redirects it to water outlet hose 80 for disposal.

With reference to FIG. 5, the apparatus is illustrated from the end of the sieve-wash chamber 20 with the cover removed to illustrate the plumbing for the apparatus located under the sieve-wash chamber 20. The apparatus 10 includes a water manifold 100 in fluidic communication with the water inlet hose 70 including valves for distributing water to each of the chambers as directed by the computer system 60 as described below. In particular, the water manifold 100 includes a first water tube 102 interrupted by a first valve 104 therein and a second water tube 106 interrupted by a second valve 108 therein. The first water tube 102 transmits water from the water manifold 100 to the nozzle 38 in the sieve-wash chamber 20 while the second water tube 106 transmits water to spray nozzle 48 in the wash-spin chamber 40 as illustrated in FIG. 1. Each of the first and second valves 104 and 108 is selectably controlled by the computer system 60 to provide water to the intended chambers according to the program selected by a user.

The drive mechanism 46 within the spin-wash chamber 40 may be powered via one or more brushless motors 66 powered by 120 volt alternating current source (see FIG. 2, 90). It is noted, though, that one of skill in the art could readily substitute another power source and/or type of motor to operate the computer system, and chambers 20 and 40. Optionally, the motor 66 may include a servo amplifier 68 as illustrated in FIG. 7 to provide for precise control of the speed, duration, acceleration, deceleration and direction of the motor 66. The drive mechanism 46 provides an axially movable disk 44a which is biased towards a corresponding rotatable disk 44b so as to retain the caged basket 24 therebetween.

With reference to FIG. 7 a schematic of the electrical circuit comprising the computer system in communication with the motor and chambers is shown. As illustrated, the apparatus 10 includes a power supply 61 as are commonly known to provide power to the computer system 60. The computer system 60 is connected to the first and second valves 104 and 108 as well as to the motor 66 to control the operation thereof. The apparatus 10 may also include one or more sensors 64 for determining the status of the apparatus, including water levels, open lids etc.

Apparatus 10 comprises a computer system 60 storing comprising computer code stored in memory on the system server, be it local or remote. The code comprises non-transitory computer readable medium containing computer executable instructions to carry out, by the processor(s), the methods disclosed herein for sieve-washing and final washing-drying of drill cutting samples.

The computer system 60 further comprises a display 62, one embodiment of which is shown in FIG. 8. The display may comprise one or more input keys 65 for controlling the operation of the apparatus including optionally for dedicated for emergency override to shut down the operation of the chamber 20 and/or 40 as needed. Other input keys may be used to program and store on the computer system customized cleaning cycles, comprising for example: durations of operation of the chambers 20, 40; periods of time of washing, and spinning; rpm's of spinning the caged basket, etc. In this system, the user may also input acceleration speed, deceleration speed, direction of spin, duration of spin, duration of cycles, dry only, wash only, sieve only, velocity of basket, saving of default settings or savings of custom settings.

Although preferred embodiments of the sample drill cutting sieving and washing apparatus of the present invention have been illustrated and described, it is to be understood that the present disclosure is made by way of example and that various other embodiments are possible without departing from the subject matter coming within the scope of the following claims, which subject matter is regarded as the invention.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.

Claims

1. An apparatus for cleansing soil samples comprising:

a first chamber comprising: an outer cylindrical wall enclosing two vertically aligned cylindrical baskets, comprising a top basket and a bottom basket of equal dimensions and of sufficient size to house drilling cutting particles; a top lid impermeable to liquids; a water inlet attached to the top lid with a sprayer to distribute water into the top basket; a water outlet attached to the bottom of the chamber to remove liquids and debris from the chamber bottom;

a second chamber housing a means for securing and rotating the basket at a high speed sufficient to remove liquid from the contents of the basket;

a computer system, comprising: a processor; user input interface; a non-transitory computer readable data storage device comprising computer readable program instructions for receiving and storing user input to control the operation of the first and second chamber.

2. The apparatus of claim 1, wherein the bottom end of the top basket comprises a mesh screen with apertures of sufficient size to allow the drilling cutting particles to drain out of the top basket into the bottom basket, while retaining debris in the top basket.

3. The apparatus of claim 1, wherein the means for rotating the basket containing the drilling cutting particles comprises a motor attached to a drive mechanism.

4. The apparatus of claim 3 further comprising two parallel discs attached to the drive mechanism to lock the basket containing the drill cutting particles into a horizontal position, wherein one disc is adjoined to the basket's lid and one disc is adjoined to the basket's bottom.

5. The apparatus of claim 1 further comprising, a water inlet hose to deliver clean hot water to the first and second chamber.

6. The apparatus of claim 5, further comprising an outlet hose for draining debris and liquids out of the first and second chamber.

7. The apparatus of claim 1, wherein said sprayer is rotatable above said top basket.

8. A method of using a portable apparatus to clean and dry particles obtained from well drilling in preparation for analysis of the particles, the method comprising:

programming a computer system to operate a first chamber to sieve and wash the particles, and a second chamber to rinse and dry the particles, wherein the system comprises: a processor; user input interface; a non-transitory computer readable data storage device comprising computer readable program instructions for receiving and storing user input to control the operation of the first and second chamber;

utilizing the first chamber to sieve and wash the particles, the chamber comprising: an outer cylindrical wall enclosing two vertically aligned cylindrical baskets, comprising a top basket and a bottom basket of equal dimensions and of sufficient size to house drilling cutting particles; a top lid impermeable to liquids; a water inlet attached to the top lid with a sprayer to distribute water onto said top basket; a water outlet attached to the bottom of the chamber to remove liquids and debris from the chamber bottom; wherein the particles are placed into the top basket, and sieved into the bottom basket when water is sprayed into the top basket;

placing the bottom basket with the sieved particles into the second chamber, wherein the chamber comprises a means for securing and rotating the basket at high rotational speeds;

pumping water into the second chamber while rotating the basket to remove residual debris from the particles; and,

shutting off the flow of water while continuing to rotate the basket to dry the particles.

9. The method of claim 8, wherein the bottom end of the top basket comprises a mesh screen with apertures of sufficient size to allow the drilling cutting particles to drain out of the top basket into the bottom basket, while retaining debris in the top basket.

10. The method of claim 8, wherein the means for rotating the basket containing the drilling cutting particles comprises a motor attached to a drive mechanism.

11. The method of claim 10 further comprising two parallel discs attached to the drive mechanism to lock the basket containing the drill cutting particles into a horizontal position, wherein one disc is adjoined to the basket's lid and one disc is adjoined to the basket's bottom.

12. The method of claim 8, further comprising a water inlet hose to deliver clean hot water to the first and second chamber.

13. The method of claim 12, further comprising an outlet hose for draining debris and liquids out of the first and second chamber.

14. The method of claim 8, further comprising operating the first and second chambers concurrently.