DRILLING RIG WITH A MODULAR WELLBORE STRENGTHENING MATERIAL RECOVERY SYSTEM

Abstract

A drilling rig with a modular wellbore strengthening material recovery system having an active drilling fluid tank system and on an on-rig shaker. The drilling rig with the modular wellbore strengthening material recovery system can have a processor connected to data storage, a pump, a motor, a power supply, a high solids capacity accelerated settling device, and a recovery shaker. The recovery shaker can have a top vibrating screen deck, a bottom vibrating screen deck, and a vibrating hack flow pan, which can be fluidly connected between the top vibrating screen deck and the bottom vibrating screen deck.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application Ser. No. 62/400,585, filed on Sep. 27, 2016, for “Drilling Rig with a Modular Wellbore Strengthening Material Recovery System.”

FIELD

The present embodiments generally relate to an exploration or field development drilling rig for drilling a wellbore prior to running in casing.

BACKGROUND

A need exists for a drilling rig which can recycle material from drilling instead of disposing the material in the sea or on land.

A further need exists for a drilling rig that limits replacement of rig shakers.

The present embodiments meet these needs.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description will be better understood in conjunction with the accompanying drawings as follows:

FIG. 1 depicts a drilling rig according to one or more embodiments.

FIG. 2 depicts an exemplary recovery shaker according to one or more embodiments.

FIG. 3 depicts the processor connected to a network and client devices according to one or more embodiments.

FIG. 4 depicts a data storage according to one or more embodiments.

FIG. 5 depicts a dual power supply according to one or more embodiments.

The present embodiments are detailed below with reference to the listed Figures.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Before explaining the present apparatus in detail, it is to be understood that the apparatus is not limited to the particular embodiments and that it can be practiced or carried out in various ways.

The present embodiments generally relate to a drilling rig for drilling a casing free wellbore having a modular wellbore strengthening material recovery system.

The drilling rig can have an active drilling fluid tank system, a power supply, and an on-rig shaker, which can be connected to the power supply, for separating and containing a shaker underflow, on-rig shaker waste, and a waste containment system.

The continuous flow portable, modular wellbore strengthening material recovery system can be mounted to a drilling rig. The modular wellbore strengthening material recovery system can have a pump for fluidly receiving the on-rig shaker effluent forming a pressurized on-rig shaker effluent.

The pressurized on-rig shaker effluent can have an adjustable hydraulic head.

The modular wellbore strengthening material recovery system can have a motor for driving the pump connected to the power supply.

The modular wellbore strengthening material recovery system can have one or more high solids capacity accelerated settling devices.

Each high solids capacity accelerated settling device can be configured to receive the pressurized on-rig shaker effluent at a constant head forming effluent and an accelerated settling device underflow.

The modular wellbore strengthening material recovery system can have one or more recovery shakers connected to either an on rig power supply or a portable power supply.

Each recovery shaker receiving the accelerated settling device underflow can have a top vibrating screen deck, a bottom vibrating screen deck, and a vibrating back flow pan fluidly connected between the top vibrating screen deck and the bottom vibrating screen deck.

Each recovery shaker can separate out a recovered wellbore strengthening material from the top vibrating screen deck that can be flowed into the active drilling fluid tank system.

Each recovery shaker can separate out a top screen filtrate from the top vibrating screen deck and flow the top screen filtrate through the vibrating back flow pan to the bottom vibrating screen deck.

Each recovery shaker can generate a bottom screen effluent from the bottom vibrating screen deck that can be recycled to the active drilling fluid tank system. Waste from each recovery shaker can be transferred to the waste containment system on the drilling rig.

The embodiments can prevent accidents by eliminating the replacement of on-rig shakers with new shakers.

The embodiments prevent harm to wildlife by recycling material from drilling rather than disposing into the sea, which can destroy wildlife.

The embodiments prevent the replacement of iron work of the existing rig shakers.

Turning now to the Figures, FIG. 1 depicts a drilling rig according to one or more embodiments.

A drilling rig 9 for drilling a casing free wellbore having a continuous flow portable, modular wellbore strengthening material recovery system 8.

The drilling rig 9 can have an active drilling fluid tank system 11, a power supply 25 and a first on-rig shaker 12a. In embodiments, the drilling rig can have a second on-rig shaker 12b.

The on-rig shakers can be fluidly connected to a waste containment system 58, which, in embodiments can be part of the drilling rig.

Each on-rig shaker 12a and 12b can separate and contain a shaker underflow 14a and 14b. The first on-rig shaker produces shaker underflow 14a and the second on-rig shaker creates shaker underflow 14b. Both shaker underflows 14a and 14b flow to the active drilling fluid tank system 11.

Each on-rig shaker produces on-rig shaker waste 15a and 15b respectively. The on-rig shaker waste 15a and 15b flows to the waste containment system 58.

In embodiments, the on-rig shakers 12a and 12b can be connected in parallel. In embodiments, the on-rig shakers 12a and 12b can be connected in series.

The continuous flow portable, modular wellbore strengthening material recovery system 8 can include a pump 21 fluidly connected to the active drilling fluid tank system 11.

The pump 21 can fluidly receive on-rig shaker effluent 20 and form a pressurized on-rig shaker effluent 23a.

The pressurized on-rig shaker effluent 23a can have an adjustable hydraulic head.

The adjustable hydraulic head can range from 20 feet to 125 feet of head.

A motor 24 can be configured to drive the pump 21 and to provide a constant head to the pressurized on-rig shaker effluent 23a.

The motor 24 can connect to the power supply 25 or in other embodiments, an optional portable power supply 26.

The power supply 25 can be a rig based power supply or a portable power supply, such as portable power supply 26.

A generator, such as a diesel electric generator can be used as the portable power supply 26.

In embodiments, a pair of high solids capacity accelerated settling devices 30a and 30b can be used and configured to each receive the pressurized on-rig shaker effluent 23b and 23c respectively. The pressurized on-rig shaker effluent 23b and 23c can be maintained at a constant head forming effluent 32a and 32b respectively.

The effluent 32a and 32b matches the flow rate of the drilling rig less the solids removed through the process.

The effluent 32a and 32b can essentially clean drilling fluid minus the wellbore bore strengthening material and the drill solids down to a predefined micron diameter.

Each high solids capacity accelerated settling device can also generate an accelerated settling device underflow 34a and 34b respectively.

The high solids capacity accelerated settling devices 30a and 30b can be a hydrocyclone, a centrifuge, or another device that uses centrifugal force to accelerate settling of particulate from liquid by increasing the gravitational force (g force) on the contained slurry.

Two high solids capacity accelerated settling devices 30a and 30b are shown connected in parallel to treat pressurized on-rig shaker effluent 23b and 23c respectively, and to match a drilling fluid circulating volume for the drilling rig.

A feed manifold 73 can be mounted in fluid communication between the pump 21 and the pair of high solids capacity accelerated settling devices 30a and 30b.

A pressure transducer 71 can be connected to the feed manifold 73 prior to the pair of high solids capacity accelerated settling devices 30a and 30b.

Usable pressure transducers can detect pressures from 0.5 psi to 250 psi and provide bidirectional communication with a processor 16.

The pressure transducer 71 can be in communication with the processor 16 to provide detected pressure of the pressurized on-rig shaker effluent 23b and 23c entering the high solids capacity accelerated settling devices 30a and 30b.

The processor 16 can be electrically connected to the power supply 25 or to the portable power supply 26.

For example, the pressure transducer can detect a pressure of 20 psi which is below preset limits stored in a data storage connected to the processor. The processor can use computer instructions to compare the detected pressure to the preset limits and increase motor speed to increase the fluid pressure.

The continuous flow portable, modular wellbore strengthening material recovery system 8 can include at least one recovery shaker.

Two recovery shakers are shown, a first recovery shaker 40a and a second recovery shaker 40b as part of the continuous flow portable, modular wellbore strengthening material recovery system 8.

Each recovery shaker 40a and 40b can be fluidly connected to the high solids capacity accelerated settling devices 30a and 30b respectively. Each recovery shaker 40a and 40b can receive a stream from each of the accelerated settling device underflows 34a and 34b. Each recovery shaker 40a and 40b can be connected to either the power supply 25 or the portable power supply 26.

The recovery shakers 40a and 40b can have a horsepower from 2 horsepower to 10 horsepower.

The recovery shakers 40a and 40b can generate a recovered wellbore strengthening material 50a-50d.

The first recovery shaker 40a can generate recovered wellbore strengthening material 50a, 50c and 50d.

The second recovery shaker 40b can generate a recovered wellbore strengthening material 50b. The recovered wellbore strengthening material 50a-50d can transfer to the active drilling fluid tank system 11.

The effluent 32a from the high solids capacity accelerated settling device 30a can be combined with recovered wellbore strengthening material 50a forming a first combined stream 37a. The effluent 32b from the high solids capacity accelerated settling device 30b can be combined with recovered wellbore strengthening material 50b to generate a second combined stream 37b.

In embodiments, a mechanical conveyor 77 can transport the recovered wellbore strengthening material 50d from the first recovery shaker 40a to the active drilling fluid tank system 11. The mechanical conveyor 77 can electrically engage the power supply 25.

The mechanical conveyor 77 can be a screw conveyor, belt conveyor, a bucket conveyor, a progressive cavity pump, a pneumatic conveyor, or combinations thereof.

Bottom screen effluent 54a from the first recovery shaker 40a can be recycled to the active drilling fluid tank system 11, and bottom screen effluent 54b from the second recovery shaker 40b can be recycled to the active drilling fluid tank system 11.

Each recovery shaker 40a and 40b can have separate waste 56a and 56b respectively that can be transferred to the waste containment system 58.

In embodiments, a recovery pump 81 can receive clean drilling mud 85 from a drilling mud containment tank 87, which can be connected to the active drilling fluid tank system 11.

The recovery pump 81 mixes the clean drilling mud 85 with recovered wellbore strengthening material 50c.

The recovery pump transports the mixture back to the active drilling fluid tank system 11 without using effluent.

The recovery pump 81 can be powered by a recovery motor 83, which can be electrically connected to the power supply 25 or the portable power supply 26.

The recovery pump 81 can have an adjustable flow rate.

FIG. 2 depicts an exemplary recovery shaker according to one or more embodiments.

The first recovery shaker 40a can have a top vibrating screen deck 42, a bottom vibrating screen deck 46, and a vibrating hack flow pan 44 fluidly connected between the top vibrating screen deck 42 and the bottom vibrating screen deck 46.

The first recovery shaker 40a can separate various recovered wellbore strengthening materials as multiple streams 50a, 50c, and 50d from the top vibrating screen deck 42 to combine with the aforementioned effluent, and form a combined stream.

In embodiments, a top screen filtrate 52a can flow from the top vibrating screen deck 42 through the vibrating back flow pan 44 and a top screen filtrate 52b from the vibrating back flow pan 44 can flow to the bottom vibrating screen deck 46.

The bottom screen effluent 54a from the bottom vibrating screen deck 46 can be recycled to the active drilling fluid tank system 11.

The first recovery shaker 40a can separate waste 56 from the bottom vibrating screen deck 46 that is transferred to the waste containment system 58.

FIG. 3 depicts the processor connected to a network and client devices according to one or more embodiments.

The processor 16 of the continuous flow portable, modular wellbore strengthening material recovery system 8 can be connected to a network 61 according to one or more embodiments.

The network 61 can be in communication with at least one client device 63a and 63b, enabling remote users to monitor, control, and record separation of recovered wellbore strengthening material from drilling mud.

The processor 16 can be connected to a data storage 18 containing data and computer instructions.

The processor 16 can be a computer, a laptop, a programmable logic circuit, or any known device capable of bi-directional communication.

The term “data storage” as used herein refers to a non-transitory computer readable medium, such as a hard disk drive, solid state drive, flash drive, tape drive, and the like.

The term “non-transitory computer readable medium” excludes any transitory signals but includes any non-transitory data storage circuitry, e.g., buffers, cache, and queues, within transceivers of transitory signals.

FIG. 4 depicts a data storage according to one or more embodiments.

The data storage 18 can contain computer instructions 19 to instruct the processor to provide a variable frequency control to the motor of the pump to control on-rig shaker effluent pumped from the active drilling fluid tank system.

The data storage 18 can have computer instructions 22 to instruct the processor to control pump speed based on detected inlet pressure from the pressure transducer by computing a comparison between the detected inlet pressure and preset pressure limits.

In embodiments, preset pressure limits 27 can be stored in the data storage 18.

FIG. 5 depicts a dual power supply according to one or more embodiments.

In embodiments, the first on-rig shaker 12a can be connected to the power supply 25 and to the portable power supply 26.

In embodiments, the second on-rig shaker 12b can be connected to the power supply 25 and to the portable power supply 26.

The processor 16 and the motor 24 can be connected to the power supply 25 and to the portable power supply 26.

In embodiments, the first recovery shaker 40a and the second recovery shaker 40b can be connected to the power supply 25 and to the portable power supply 26.

In embodiments, the mechanical conveyor 77, the recovery pump 81 and the recovery motor 83 can be connected to the power supply 25 and to the portable power supply 26.

In embodiments, the drilling rig can include a jack up, a tension leg platform, a drill ship, a SPAR™, a semisubmersible, or a land based drilling rig.

In embodiments, the motor can be configured to variably drive the pump.

In embodiments, the recovered wellbore strengthening material can comprise, but is not limited to: ground walnut shells, calcium carbonate, ground cotton hulls, ground cane stalks, ground pecan shells, bark, mineral fiber, hair, flaky pieces of plastic, flakes of cellophane sheeting, granular limestone, granular marble, chips of wood, granular particles of FORMICA® and combinations thereof.

The recovered wellbore strengthening material can also be known as loss circulation material in the oil and gas industry.

In embodiments, the recovered wellbore strengthening material can include particles with a diameter from 0.01 inches to 0.75 inches.

In embodiments, the active drilling fluid tank system can include at least one of: multiple tanks fluidly connected, a sand trap, fluid process pits connected in series, and a suction tank.

In embodiments, a plurality of high solids capacity accelerated settling devices connected in parallel can be used. The plurality of high solids capacity accelerated settling devices can be configured to treat the pressurized on-rig shaker effluent to match a drilling fluid circulating volume for the drilling rig.

In embodiments, the recovery shaker can have from 3 vibrating screen decks to 7 vibrating screen decks.

In embodiments, the drilling rig can have a plurality of single deck recovery shakers connected in series.

The portable power supply can be a diesel or gas standalone generator capable of providing at least enough power to run a 100 horsepower pump and 10 horsepower shakers, wherein each shaker can have a 5 horsepower motor. The portable power supply can be configured to provide at least 150 horsepower, consistently.

Each high solids capacity accelerated settling device can be configured to provide higher solids flow rates than commercially available units. Each high solids capacity accelerated settling device can be configured to provide variable cut points fix use during operation to vary efficiency of each high solids capacity accelerated settling device.

The casing free wellbore can be an exploration or production wellbore.

Continuous flow from the drilling rig can be from 600 gallons/min to 4000 gal/min, such as 1000 gal/min.

The network can be any known network in the industry, such as a satellite network, a global communication network such as the internet, a local area network, a wide area network, a cellular network or combinations thereof.

The processor can be any known processor in the industry, such as a computer, a laptop, a programmable logic circuit, a wearable computer, a cellular phone, a tablet computer, or a cloud based processing system.

The mesh of the top vibrating screen deck can be from 10 mesh to 100 mesh.

The mesh of the bottom vibrating screen deck can be from 40 mesh to 500 mesh.

The recovery shaker can generate vibrations with frequencies from 10 Hz to 100 Hz.

The high solids capacity accelerated settling devices can have a capacity of from 50 gallons to 700 gallons per minute. In embodiments, three high solids capacity accelerated settling devices can be used with a total capacity of 1500 gallons per minute.

While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.

Claims

1. A drilling rig with a modular wellbore strengthening material recovery system, comprising:

a. an active drilling fluid tank system, a power supply, and an on-rig shaker connected to the power supply, for separating and containing a shaker underflow and on-rig shaker waste, and a waste containment system;

b. a pump mounted to the drilling rig fluidly receiving an on-rig shaker effluent forming a pressurized on-rig shaker effluent, the pressurized on-rig shaker effluent having an adjustable hydraulic head;

c. a motor for driving the pump connected to the power supply;

d. at least one high solids capacity accelerated settling device configured to receive the pressurized on-rig shaker effluent at a constant head ranging from 20 feet to 125 feet of head, forming effluent and an accelerated settling device underflow has a capacity of from 700 gallons per minute to 2100 gallons per minute removing wellbore strengthening material; and

e. a recovery shaker connected to the power supply, the recovery shaker receiving the accelerated settling device underflow, the recovery shaker comprising: (i) a top vibrating screen deck; (ii) a bottom vibrating screen deck; and (iii) a vibrating back flow pan fluidly connected between the top vibrating screen deck and the bottom vibrating screen deck, the recovery shaker separating: (iv) a recovered wellbore strengthening material from the top vibrating screen deck flowed into the active drilling fluid tank system, wherein the recovered wellbore strengthening material comprises particles with a diameter from 0.01 inches to 0.75 inches; 1. a top screen filtrate from the top vibrating screen deck flowed through the vibrating back flow pan to the bottom vibrating screen deck; 2. a bottom screen effluent from the bottom vibrating screen deck recycled to the active drilling fluid tank system; and 3. a waste transferred to the waste containment system.

2. The drilling rig of claim 1, further comprising a processor in communication with a data storage, the data storage containing computer instructions to instruct the processor to provide a variable frequency control to the motor of the pump to control the on-rig shaker effluent pumped from the active drilling fluid tank system.

3. The drilling rig of claim 2, wherein the processor is electrically connected to the power supply.

4. The drilling rig of claim 1, wherein the motor is configured to variably drive the pump.

5. The drilling rig of claim 1, further comprising a mechanical conveyor for transporting the recovered wellbore strengthening material to the active drilling fluid tank system, and wherein the mechanical conveyor electrically engages the power supply.

6. The drilling rig of claim 1, using the effluent for transporting the recovered wellbore strengthening material to the active drilling fluid tank system.

7. The drilling rig of claim 1, further comprising a recovery pump for receiving a clean drilling mud from a drilling mud containment tank, the recovery pump mixing the clean drilling mud with the recovered wellbore strengthening material and transporting mixed clean drilling mud with the recovered wellbore strengthening material to the active drilling fluid tank system without using the effluent, wherein the recovery pump and a recovery motor are electrically connected to the power supply.

8. The drilling rig of claim 1, further comprising at least one of: a jack up, a tension leg platform, a drill ship, a Spar, a semisubmersible, or a land based drilling rig.

9. The drilling rig of claim 1, wherein the recovered wellbore strengthening material comprises: ground walnut shells, calcium carbonate, ground cotton hulls, ground cane stalks, ground pecan shells, bark, mineral fiber, hair, flaky pieces of plastic, flakes of cellophane sheeting, granular limestone, granular marble, chips of wood, granular particles of Formica and combinations thereof.

10. The drilling rig of claim 1, wherein the recovered wellbore strengthening material comprises particles with a diameter from 0.01 inches to 0.75 inches.

11. The drilling rig of claim 1, wherein the on-rig shaker comprises a plurality of on-rig shakers connected in parallel, and each on-rig shaker fluidly connected to the active drilling fluid tank system and the waste containment system and electrically connected to the power supply.

12. The drilling rig of claim 1, wherein the active drilling fluid tank system comprises at least one of: multiple tanks fluidly connected, a sand trap, fluid process pits connected in series, and a suction tank.

13. The drilling rig of claim 2, wherein the processor communicates with a network and the network communicates with at least one client device.

14. The drilling rig of claim 1, wherein the adjustable hydraulic head ranges from 20 feet to 125 feet of head.

15. The drilling rig of claim 1, further comprising a plurality of high solids capacity accelerated settling devices connected in parallel, the plurality of high solids capacity accelerated settling devices each configured to treat each pressurized on-rig shaker effluent to match a drilling fluid circulating volume for the drilling rig.

16. The drilling rig of claim 2, further comprising a pressure transducer connected to a feed manifold, the feed manifold in fluid communication between the pump and the at least one high solids capacity accelerated settling device, wherein the pressure transducer is in communication with the processor and the data storage further comprises computer instructions to control pump speed based on detected inlet pressure from the pressure transducer by computing a comparison between the detected inlet pressure and preset pressure limits stored in the data storage.

17. The drilling rig of claim 1, further comprising a portable power supply for powering the processor, the motor, the recovery motor, the recovery pump, the mechanical conveyor, the recovery shaker and a second recovery shaker.

18. The drilling rig of claim 1, wherein the recovery shaker comprises from 3 vibrating screen decks to 7 vibrating screen decks.

19. The drilling rig of claim 1, further comprising a plurality of recovery shakers connected in parallel, wherein each recovery shaker is connected to the power supply.

20. The drilling rig of claim 1, further comprising a plurality of single deck recovery shakers connected in series.