Patent Publication Number: US-2021180417-A1

Title: Cuttings Volume Measurement Away From Shale Shaker

Description:
BACKGROUND 
     During the drilling of a hydrocarbon-producing well, a drilling fluid or “mud” is continuously circulated from a surface location down to the bottom of the wellbore being drilled and back to the surface again. The returning mud includes drill cuttings derived primarily from the formation being penetrated by a drill bit. In the case of multilateral wells, the drill cuttings may also include metal drill cuttings generated from milling or drilling through casing walls to form a lateral wellbore. Some downhole operations may also include borehole reaming operations, which can result in a unique type of cuttings returning to surface. 
     Recovery of drill cuttings can be closely monitored during drilling operations. Excessive cuttings, cavings accumulation due to poor hole cleaning, and borehole instability may cause costly stuck pipe incidents. Wellbore instability and stuck pipe incidents can be large contributors to drilling-related non-productive time (NPT). Drilling cuttings/cavings monitoring may be useful for early detection and mitigation of such events. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following figures are included to illustrate certain aspects of the present disclosure and should not be viewed as exclusive examples. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure. 
         FIG. 1  is a schematic diagram of an exemplary drilling system that may employ the principles of the present disclosure; 
         FIG. 2  is a schematic diagram of an example of an imaging system; 
         FIG. 3  is a front view of the imaging system; and 
         FIG. 4  is a schematic diagram of another example of the imaging system. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure is related to wellbore drilling operations and, more particularly, to monitoring drilling fluid returns and adjusting operational parameters of solids-control equipment used to identify the density and/or cuttings size distribution of the wellbore cuttings. As discussed below, the solids control equipment may include at least one shaker, conveyor belt, or actuator table. During operations, drill cuttings suspended within spend drilling fluid may be monitored with one or more cuttings detection devices as the drill cuttings traverse a conveyor belt or actuator table. Data from drill cuttings may then be generated and transmitted to an information handling system where the drill cuttings data is analyzed. Processed drill cuttings data may then be generated and analyzed to determine properties of the cuttings, including, for example, cuttings size distribution and a density of the drill cuttings. Observing characteristic of drill cuttings returning to the surface during drilling operations may increase the effectiveness and efficiency of the drilling operations, which may reduce the cost of drilling wells for oil and gas exploration and subsequent production. 
       FIG. 1  illustrates is an exemplary drilling system  100  that may employ the principles of the present disclosure, according to one or more examples. It should be noted that while  FIG. 1  generally depicts a land-based drilling assembly, those skilled in the art will readily recognize that the principles described herein are equally applicable to subsea drilling operations that employ floating or sea-based platforms and rigs, without departing from the scope of the disclosure. As illustrated, drilling system  100  may include a drilling platform  102  that supports a derrick  104  having a traveling block  106  for raising and lowering a drill string  108 . Drill string  108  may include, but is not limited to, drill pipe or coiled tubing, as generally known to those skilled in the art. A kelly  110  supports drill string  108  as it is lowered through a rotary table  112 . A drill bit  114  is attached to the distal end of drill string  108  and is driven either by a downhole motor and/or via rotation of drill string  108  by rotary table  112 . As drill bit  114  rotates, it creates a borehole  116  that penetrates various subterranean formations  118 . 
     A pump  120  (e.g., a mud pump) circulates drilling fluid  122  through a feed pipe  124  and to kelly  110 , which conveys drilling fluid  122  downhole through the interior of drill string  108  and through one or more orifices in drill bit  114 . Drilling fluid  122  is then circulated back to the surface via an annulus  126  defined between drill string  108  and the walls of borehole  116 . At the surface, the recirculated or spent drilling fluid  122  exits annulus  126  and may be conveyed to one or more fluid processing units, such as solids control equipment  128  via an interconnecting flow line  130 . 
     The returning or spent drilling fluid  122  may contain cuttings and debris derived from borehole  116  as drill bit  114  grinds and scrapes the bottom and walls of borehole  116 . The spent drilling fluid  122  may also contain various solid additives, such as lost circulation materials, added to drilling fluid  122  to enhance its operation. After passing through the fluid processing units, including the solids control equipment  128 , a “cleaned” drilling fluid  122  may be deposited into a nearby retention pit  132  (i.e., a mud pit or suction tank). One or more chemicals, fluids, or additives may be added to drilling fluid  122  via a mixing hopper  134  communicably coupled to or otherwise in fluid communication with retention pit  132 . 
     Solids control equipment  128  may be configured to substantially remove drill cuttings, solids, and other unwanted debris from drilling fluid  122  and thereby separate waste from reusable particulates or materials. Solids control equipment  128  may include, but is not limited to, one or more shakers (e.g., shale shaker), a desilter, a desander, any combination thereof, and the like (typically solids separation units, based on particle size range). To remove drill cuttings and other unwanted solids from returning drilling fluid  122 , shakers used in solids control equipment  128  may include one or more shaker screens (not shown) across which the drill cuttings may traverse to be separated from drilling fluid  122 . 
     A common problem encountered with solids control equipment  128  can be the inefficient removal of unwanted solids and other particulates. For example, when solids control equipment  128 , such as shakers, may not be properly tuned, they may sometimes pass unwanted solids or other contaminating particulates into retention pit  132 , thereby providing a less effective drilling fluid  122  that is recirculated back into borehole  116 . In other cases, un-tuned solids control equipment  128  may inadvertently remove valuable additive components or materials from drilling fluid  122 , likewise having an adverse effect on the performance of drilling fluid  122 . 
     In examples, shaker screens used in solids control equipment  128  should be able to handle the full circulation rate of the drilling fluid  122 , thereby generating the bulk of drilling waste while simultaneously reclaiming the bulk of drilling fluid  122 . Shaker screens may typically be the only equipment that is changed or altered to handle fluctuating deviations in drilling fluid  122  properties, such as changes in flow rate of drilling fluid  122 , or drilling conditions, such as the rate of penetration of drill bit  114 . Moreover, shaker screens may also typically be the only equipment in conventional drilling systems that separate solids based on size. 
     As disclosed below, solids control equipment  128  and, more particularly, one or more shakers of solids control equipment  128  may be attached to an imaging system  136  configured to help optimize operating parameters of the shakers. As described herein, imaging system  136  may be configured to provide an operator with a real-time indication of the efficiency of solids control equipment  128 , thereby allowing the operator to proactively adjust and otherwise alter one or more operating parameters of solids control equipment  128  (e.g., the shakers) to optimize its operation. Exemplary operating parameters of solids control equipment  128  that may be adjusted may include, but are not limited to, increasing or decreasing an inclination angle (i.e., slope) of a shaker screen, increasing or decreasing a vibration amplitude of a shaker, increasing or decreasing a vibration frequency of a shaker, altering the size (i.e., mesh size) of a shaker screen, altering a configuration or mesh profile (e.g., alternative hole shapes) of a shaker screen, changing the operating speed (i.e., RPM) of a centrifuge, altering the frequency on variable speed drive (VSD) equipment), and any combination thereof. 
     In examples, imaging system  136  (photo, acoustic, inductive, capacitive etc.) may include or may otherwise be communicably coupled to an automated control system (not shown). When detection limits obtained by imaging system  136  surpass a predetermined operational threshold for drilling fluid  122 , the automated control system may be configured to autonomously adjust the one or more operating parameters to bring operation back to suitable operational limits and otherwise optimize operation of solids control equipment  128 . Fine-tuning solids control equipment  128  may ensure that drilling fluid  122  is maintained at proper and efficient operating levels. Moreover, when proper solids control practices are utilized, the cost to maintain drilling fluid  122  and related equipment may decrease greatly. 
       FIG. 2  illustrates solids control equipment  128 , more specifically a shaker  200 , conveyor belt  202 , and an imaging system  136  in accordance with some embodiments. As illustrated, solids control equipment  128  may be connected to an information handling system  204 . Systems and methods of the present disclosure may be implemented, at least in part, with information handling system  204 . Information handling system  204  may include any instrumentality or aggregate of instrumentalities operable to compute, estimate, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an information handling system  204  may be a processing unit  206 , a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. Information handling system  204  may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, ROM, and/or other types of nonvolatile memory. Additional components of information handling system  204  may include one or more disk drives, one or more network ports for communication with external devices as well as various input and output (I/O) devices, such as an input device  208  (e.g., keyboard, mouse, etc.) and a video display  210 . Information handling system  204  may also include one or more buses operable to transmit communications between the various hardware components. 
     Alternatively, systems and methods of the present disclosure may be implemented, at least in part, with non-transitory computer-readable media  212 . Non-transitory computer-readable media  212  may include any instrumentality or aggregation of instrumentalities that may retain data and/or instructions for a period of time. Non-transitory computer-readable media  212  may include, for example, storage media such as a direct access storage device (e.g., a hard disk drive or floppy disk drive), a sequential access storage device (e.g., a tape disk drive), compact disk, CD-ROM, DVD, RAM, ROM, electrically erasable programmable read-only memory (EEPROM), and/or flash memory; as well as communications media such wires, optical fibers, microwaves, radio waves, and other electromagnetic and/or optical carriers; and/or any combination of the foregoing. 
     During operations, information from solids control equipment  128  may be gathered and/or processed by information handling system  204 . For example, information recorded by imaging system  136  may be stored on memory and then processed by information handling system  204 . The processing may be performed real-time during data acquisition. Without limitation, information from imaging system  136  may be processed by information handling system  204 , which may then control shaker  200  and conveyor belt  202  based at least in part on the information processed from imaging system  136 . Processed information may therein be displayed for personnel to observe and stored for future processing and reference. 
     It should be noted, however, that imaging system  136  schematically depicted in  FIG. 2  is only an example of one type of imaging system, device, or apparatus that may be used in keeping with the principles of the present disclosure. Indeed, other types and configurations of imaging systems that incorporate other computer design configurations may alternatively and suitably incorporate the principles of the present disclosure, without departing from the scope of the disclosure. Accordingly, the following description of the imaging system  136  is provided for illustrative purposes only and should not be considered limiting. 
     In examples, imaging system  136  may be located on or near the drilling platform  102  (e.g., referring to  FIG. 1 ). In other examples, however, any of the component parts or modules shown in  FIG. 2  may be located at a remote location, without departing from the scope of the disclosure. For instance, some of the data and processing modules of imaging system  136  may be located at a remote operation center, where the data could be received and analyzed by a geologist, a mud logger, or another type of logging professional. In addition, the remote location may include a mobile device, such as a tablet or handheld computer, and the data and/or resulting computational analysis may be transmitted via a data delivery system, or via any other mobile transfer standard utilized in the industry. 
     As illustrated, imaging system  136  may include one or more cuttings (or solids) detection devices communicably coupled to and otherwise in communication with information handling system  204 . As illustrated in  FIGS. 2 and 3 , detection devices may be a camera  214  and a laser  216  in accordance with some embodiments. Camera  214  and laser  216  may be positioned adjacent, above, to the side, and/or the like of conveyor belt  202 . Camera  214  and a laser  216  may be configured to monitor drill cuttings  218  as they move with conveyor belt  202 . 
     In examples, camera  214  may be a high-speed camera capable of capturing images and/or video of drill cuttings  218  in real-time or at timed intervals dependent upon the drilling operation (e.g., drilling, circulating, cleaning, etc.). Camera  214 , for instance, may include one or more charge coupled device (CCD) cameras, one or more low light or infrared cameras, a 3D laser scanner, a conoscopic holography camera, a coherent laser radar, one or more touch probes, a magnetic position tracker, or any combination thereof. In at least one example, camera  214  may include a high-speed microscope. Additionally, camera  214  may be configured to be used in conjunction with one or more light sources, such as a white light source, an incandescent light source (e.g., a tungsten filament light bulb), an infrared light source, laser  216 , one or more light emitting diodes (LEDs), or any combination thereof. 
     As illustrated in  FIGS. 2 and 3 , laser  216  may be used as a light source, which may illuminate drill cuttings  218  with a known wavelength of electromagnetic radiation in accordance with some embodiments. As a result, drilling fluid  122  (e.g., referring to  FIG. 1 ) and various additives suspended therein (e.g., lost circulation materials, etc.) may become relatively transparent in contrast to the adjacent drill cuttings  218  such that only drill cuttings  218  may be visible for image capture. In some examples, one or more energy modification devices (not shown), such as a polarizer, a beam splitter, and/or a filter may interpose drill cuttings  218  to reduce the number or breadth of wavelengths seen by camera  214 . For instance, a polarizer may be used to align light energy in either the ‘P’ or ‘S’ directions (so that the processed energy is p-polarized, or s-polarized), or to generate a blend of P and S polarized energy. A beam splitter may be used to reduce the spectrum of the received energy to some selected or preferred range of wavelengths. Lastly, a filter may be used to further narrow the range to a select spectrum prior to image detection. 
     As illustrated in  FIG. 3 , camera  214  and laser  216  may be configured to illuminate drill cuttings  218  (e.g., referring to  FIG. 2 ) in a field of view  220  on conveyor belt  202 . As illustrated, a frame  222  may support camera  214  and laser  216 , which may help in processing drill cuttings  218 . Processing drill cutting  218  may result in the determination of various characteristics of drill cuttings  218 , such as cuttings size distribution or density of the drill cuttings  218  traversing conveyor belt  202 . As used herein, the “density” of drill cuttings  218  refers to the amount of drill cuttings  218  traveling on conveyor belt  202  over a certain time period or, in other words, flow rate of drill cuttings  218 . Upon receiving the image data derived from camera  214 , a software program stored in processing unit  206  may be programmed with instructions that, when executed by a processor(s) in processing unit  206 , perform desired measurements or analysis on drill cuttings  218  to determine cuttings size distribution and/or density of drill cuttings  218 . In an example, the software may include a three-dimensional (3D) face recognition program or particle size analysis program to measure and determine the desired characteristics of drill cuttings  218 . Drill cuttings  218  may be analyzed in real-time by the software to determine the real-time cuttings size distribution and/or density of drill cuttings  218  traveling on conveyor belt  202 . 
     With continued reference to  FIGS. 2 and 3  conveyor belt  202  may be placed underneath shaker  200  where drill cuttings  218  may fall from shaker  200  on to conveyor belt  202 . The length and width of the shaker screen may be customized per operational needs. In examples, conveyor belt  202  may be mounted on a grating where drill cuttings  218  may fall on conveyor belt  202 , which may carry drill cuttings  218  over to the edge of conveyor belt  202 . Additionally, conveyor belt  202  may be driven by one or more motors  224  (electric or Pneumatic). Various types of motors  224  may be considered such as AC motors, DC Motors, Servo motors, Stepper Motors etc. For electric motors, junction boxes may be needed to provide power and capture signals. Additionally, motor  224  and conveyor rollers  226  may be connected by various options such as gear arrangement, chains, and/or sprockets. Motors  224  may move a track  232 , which may also be identified as a belt, in which drill cuttings  218  may be disposed on. Track  232  may move based at least in part on gear arrangements, sprockets, and one or more motors  224 . Additionally, track  232  may include an oleo phobic or hydrophobic coating, which may prevent drill cuttings  218  from sticking the surface of track  232 , which may skew measurements. 
     During operations, the speed of conveyor belt  202  may be easily determined as well as controlled for a particular RPM of motor  224 . Speed of conveyor belt  202  may be controlled by information handling system  204 , which may be based at least in part on information from imaging system  136 . For example, conveyor belt  202  may speed up or slow down based on the number of drill cuttings  218  passing through field of view  220  of imaging system  136 . Additionally motor  224  may have an RPM sensor to produce a feedback signal. The speed of motor  224  may be changed electronically and remotely from information handling system  204  based on the feedback signal from the RPM sensor and/or the size and number of drill cuttings  218 . 
     To determine the size of drill cuttings  218 , imaging system  136  may be calibrated to identify the different sizes of drill cuttings  218 . As illustrated in  FIG. 2 , this calibration may be performed automatically using calibration blocks  228 . In one or more examples, there may be any number of calibration blocks  228  attached to conveyor belt  202 . Each calibration block  228  may be a different size. Additionally, each calibration block  228  may include a radio frequency identification (RFID) tag that may identify each calibration block  228  individually and the size of the calibration block  228 . During calibration operations, information handling system  204  may activate auto flushing mechanisms, not illustrated, which may clean conveyor belt  202 , which may leave each calibration block  228  exposed. Thus, when a calibration block  228  passes over field of view  220  (e.g., referring to  FIG. 3 ), the particular size of calibration block  228  is captured and recorded. This size is identified by the RFID tag on calibration block  228 . A RFID transmitter  230  (e.g., referring to  FIG. 3 ) may operate and function to identify the RFID tag. Additionally, size calibration may be performed in one rotation of conveyor belt  202 . The speed of conveyor belt  202  may be varied to accommodate imaging system  136  during the calibration mode. 
       FIG. 4  illustrates another example of illustrates solids control equipment  128 , which includes an actuator table  400 , a shaker  200 , and an imaging system  136 . As illustrated in  FIG. 4 , actuator table  400  may be disposed underneath shaker  200  from which drill cuttings  218  may fall from. As illustrated, actuator table  400  may include an actuator system  402  and one or more calibration block  228 , which may include RFID tags as discussed above. Actuator system  402  may include a plunger  404 , which may also be identified as a cylinder. Plunger  404  may be pneumatic, electric, or hydraulic. 
     During operations, shaker  200  may release a pre-determined amount of of drill cuttings  218  on actuator table  400 . After releasing drill cuttings  218 , shaker  200  may stop, which may allow imagining system  136  to scan actuator table  400  and drill cuttings  218  on actuator table  400 . The size of drill cuttings  218  may be determined from imaging system  136 , which has been calibrated using calibration blocks  228  as described above. After scanning drill cuttings  218 , actuator system  402  may extend plunger  404  across the length of actuator table  400 , which may remove drill cuttings  218  from actuator table  400  and a new batch of drill cuttings  218  may be release from shaker  200 . 
     Accordingly, the systems and methods disclosed herein may be directed to a method for receiving measurement data from a remote wireline system. The systems and methods may include any of the various features of the systems and methods disclosed herein, including one or more of the following statements. 
     Statement 1: A system for measuring drill cuttings may comprise a conveyor belt disposed below a shaker, wherein the shaker disposes the drill cuttings on to the conveyor belt, and an imaging system connected to the conveyor belt by a frame, wherein the frame positions the imaging system to form a field of view on the conveyor belt with the imaging system. The system may further include an information handling system configured to operate the shaker and the conveyor belt. 
     Statement 2: The system of statement 1, wherein the imaging system comprises a camera and a laser, wherein the camera is configured to measure a size of the drill cuttings. 
     Statement 3. The system of statements 1 or 2, further comprising one or more calibration blocks, wherein the one or more calibration blocks are different sizes. 
     Statement 4. The system of statement 3, wherein the one or more calibration blocks are attached to the conveyor belt and include a radio frequency identification (RFID) tag. 
     Statement 5. The system of statement 4, further comprising an RFID transmitter, connected to the frame, that is configured to read the RFID tags. 
     Statement 6. The system of statements 1-3, further comprising one or more motors, wherein the one or more motors are connected to the conveyor belt and are configured to operate the conveyor belt. 
     Statement 7. The system of statement 6, wherein the information handling system is further configured to operate the one or more motors based at least in part on information from the imaging system. 
     Statement 8. A system for measuring drill cuttings may comprise an actuator table disposed below a shaker, wherein the shaker disposes the drill cuttings on to the actuator table, and an imaging system connected to the actuator table by a frame, wherein the frame positions the imaging system to form a field of view on the actuator table with the imaging system. The system may further include an information handling system configured to operate the shaker and the actuator table. 
     Statement 9, The system of statement 8, wherein the imaging system comprises a camera and a laser, wherein the camera is configured to measure a size of the drill cuttings. 
     Statement 10. The system of statements 8 or 9, further comprising one or more calibration blocks, wherein the one or more calibration blocks are different sizes. 
     Statement 11. The system of statement 10, wherein the one or more calibration blocks are attached to the actuator table and include an RFID tag. 
     Statement 12. The system of statement 11, further comprising an RFID transmitter, connected to the frame, that is configured to read the RFID tags. 
     Statement 13. The system of statements 8-10, further comprising an actuator system attached to the actuator table, wherein the actuator system includes a plunger. 
     Statement 14. The system of statement 13, wherein the information handling system is further configured to operate the actuator system based at least in part on information from the imaging system. 
     Statement 15. A method for identifying a size of drill cuttings may comprise dropping drill cuttings on a conveyor belt from a shaker, operating the conveyor belt to move the drill cuttings through a field of view, viewing the drill cuttings in the field of view with an imaging system, and sizing the drill cuttings based at least in part on one or more calibration blocks attached to the conveyor belt. 
     Statement 16. The method of statement 15, wherein the imaging system comprises a camera and a laser. 
     Statement 17. The method of statements 15 or 16, wherein the one or more calibration blocks comprise an RFID tag. 
     Statement 18. The method of statement 17, further comprising identifying the one or more calibration blocks through the RFID tag with an RFID transmitter. 
     Statement 19. The method of statements 15-17, further comprising controlling a speed of the conveyor belt with an information handling system. 
     Statement 20. The method of statement 19, wherein the speed of the conveyor belt is based at least in part on the drill cuttings within the field of view. 
     The preceding description provides various examples of the systems and methods of use disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual examples may be discussed herein, the present disclosure covers all combinations of the disclosed examples, including, without limitation, the different component combinations, method step combinations, and properties of the system. It should be understood that the compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. 
     For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. 
     Therefore, the present examples are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular examples disclosed above are illustrative only and may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual examples are discussed, the disclosure covers all combinations of all of the examples. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative examples disclosed above may be altered or modified and all such variations are considered within the scope and spirit of those examples. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.