Patent Description:
Due to the expensive nature of drilling fluids and certain drilling fluid additives, if separating the solids from the fluids is not efficient, the cost of a drilling operation may be substantially increased. As such, drilling operators adjust parameters of the separators used to separate the solids from the fluids in order to reclaim as much valuable drilling fluid and additives as possible. Visual inspection and manual adjustments to separators may result in inefficiencies due to the inconsistent interpretation of the separation process, as well as the relatively slow nature of manually adjusting a separator into an optimal operation condition. This is a problem as these inconsistences and time-consuming processes result in loss of drilling fluid and fluid additives, which may increase the drilling cost, as well as decrease the profitability of the operation.

<CIT> relates to a system for monitoring the fluid front on a shaker table. The system comprises a shaker table or shaker table screen configured to be adjusted based on information compiled by a processor and at least one camera configured to monitor the shaker table. The camera is connected to the processor. The processor is configured to perform detection and localization o the fluid front on the shaker table using machine vision techniques. According to the present technology, there are provided systems and methods as set out in the accompanying claims.

An object of the present invention is therefore to provide an improved system and method for separating solids from fluids which at least mitigate the aforementioned problems.

According to the present invention there is provided a system for separating solids from fluids, the system comprising a separator comprising a deck having a feed inlet and a solids outlet, and a plurality of screens disposed on the deck, an image sensor disposed proximate the solids outlet, the image sensor to capture images of the solids outlet of the separator, and send the captured mages to a remote location for analysis.

Preferably, the slurry properties are sent to the remote location in real-time.

Preferably, the image sensor is disposed above the solids outlet.

Preferably, the separator further comprises a skid on which the separator and image sensor are disposed.

Preferably, the remote location comprises a control module to process the captured images and calculate a solids overflow volume.

Preferably, the remote location comprises a control module to determine a fluid endpoint of the separator when the separator is operating.

Preferably, the remote location comprises a control module to identify a cuttings size distribution.

Preferably, the remote location comprises a control module to determine an integrity of at least one of the plurality of screens.

Preferably, the separator further comprises a second image sensor disposed along a side of the deck.

According to another aspect of the present invention there is provided a method of monitoring a separator, the method comprising capturing an image of the solids outlet of the separator, sending the image of the separator to a control module disposed at a remote location, analyzing the image with the control module to determine a separation property, and modifying the operation of the separator based on the determined separation property.

Preferably, the separation property comprises a fluid endpoint of the separator when the separator is operating.

Preferably, the method further comprises providing closed-loop control of a fluid endpoint, and maintaining an optimum fluid endpoint while the separator is operating.

Preferably, analyzing the image with the control module to determine a separation property comprises determining a solids overflow volume based on the image.

Preferably, analyzing the image with the control module to determine a separation property comprises identifying a cuttings size distribution based on the image.

Preferably, the separation property comprises a screen parameter.

Preferably, the method further comprises automatically actuating at least one of a plurality of separators based on the separation parameter.

Preferably, the method further comprises adjusting at least one of a basket angle and a motor speed based on the separation property.

According to another aspect of the present invention there is provided a system comprising a first separator, a first image sensor disposed proximate the first separator, a second separator, a second image sensor disposed proximate the second separator; and a control module disposed at a remote location, the controller to receive a first image from the first image sensor and a second image from the second image sensor and determine, based on the first image and the second image, a first separator parameter of the first separator and a second separator parameter of the second separator.

Preferably, the control module is configured to adjust an operating parameter of at least one of the first separator and the second separator based on at least one of the first image, the second image, the first separator parameter, and the second separator parameter. The present invention is best understood from the following detailed description by way of example only and with reference to the accompanying Figures.

Embodiments of the present disclosure may provide image sensors, such as camera systems, disposed proximate separators to capture still and/or video images. The still and/or video images may be used to analyze properties of a slurry as a solid phase is separated from an effluent phase. Based on the slurry properties, aspects of the separator may be adjusted in order to increase the performance of the separator. Increased performance of the separator may thereby allow the solid phase to be separated from the effluent/fluid phase more efficiently, thereby producing a dryer solid phase and/or an effluent phase containing fewer residual solids.

Referring to <FIG>, a schematic, side view of a separator having an image sensor according to one or more embodiments of the present disclosure is shown. In this embodiment, separator <NUM> includes a deck <NUM> with multiple screens <NUM> disposed thereon. As illustrated, separator <NUM> has three screens <NUM>, however, in other embodiments, separator <NUM> may have more or less than three screens <NUM>. For example, in certain implementations, a separator may have one, two, four, five, six, or more screens <NUM>. Separators <NUM> having different configurations, including different numbers of screens <NUM> are discussed below with respect to <FIG>.

In operation, a slurry <NUM> includes a solid phase <NUM> and an effluent phase <NUM>. The slurry <NUM> is passed over screens <NUM>, thereby allowing solid phase <NUM> to be separated from effluent phase <NUM>. The solid phase <NUM> may include, for example, solids such as drill cuttings, drilling fluid additives, such as barite, and other types of solids used in drilling operations. Effluent phase <NUM> may include various drilling fluids, also known as drilling mud. The drilling fluids may include water, oil, synthetic fluids, and/or combinations thereof as well as other kinds of fluids. As slurry <NUM> passes over screens <NUM>, the effluent phase <NUM> may pass through the screens <NUM> for collection in a separator reservoir (not shown) or another holding area that is capable of collecting fluids.

Solid phase <NUM> traverses deck <NUM> as the effluent phase <NUM> falls through the screens <NUM>. This separates, at least to some degree, the effluent phase <NUM> and the solid phase <NUM>. The solid phase <NUM> then exits separator <NUM> at a solids outlet <NUM>. Solids outlet <NUM> is illustrated as a fall-off point at a distal end <NUM>, i.e., the opposite end of separator <NUM> from where slurry <NUM> is introduced. In other embodiments, collection vessels (not shown) may also be used to collect and/or store solid phase <NUM>.

In this embodiment, an image sensor <NUM> is disposed proximate the distal end <NUM> of the separator <NUM>. Proximate, in this context, means close enough to the solids outlet <NUM> to capture an image from which the slurry properties of interest may be determined. Image sensor <NUM> may be, for example, one of various types of cameras including, but not limited to, video in standard visible spectrum, infrared, radar, laser, microwave, LIDAR, and the like. Image sensor <NUM> may take one or more of still and/or motion images. As such, image sensor <NUM> may sense or otherwise capture images from which may be derived one or more slurry properties and output or otherwise send the images including the slurry properties to a remote location, which is discussed in detail below, for analysis.

The image itself is a set of ordered data representing the environment sensed by the image sensor <NUM> and, in particular, the slurry <NUM> as it exits the solids outlet <NUM> of the separator <NUM>. The ordered data may be, but is not necessarily, rendered for human perception, such as by display or reproduction on paper. However, such rendering is not pertinent to the analysis by the control module. As mentioned above, the image may be still or moving. It may be captured using visible light, ultraviolet ("UV") light, infrared, or some other technology suitable for remote sensing that will capture an image amenable to automated processing and analysis. The choice of technology is implementation specific in light of desired operational principles and will affect the implementation of the image sensor <NUM> in ways that will become apparent to those skilled in the art having the benefit of this disclosure.

Image sensor <NUM> may be disposed, for example, between three and seven feet from distal end <NUM> of separator <NUM>. In certain embodiments, image sensor <NUM> may be disposed between five and six feet from distal end <NUM> of separator <NUM>. As illustrated, image sensor <NUM> is not connected to separator <NUM>, and as such, does not experience vibration while separator <NUM> is in operation. In other embodiments, image sensor <NUM> may be connected to separator <NUM> and include a dampening device (not shown) disposed at the connection between image sensor <NUM> and separator <NUM>. The dampening device may be used to decrease the amount of vibration experienced by image sensor <NUM> during operation of separator <NUM>.

Image sensor <NUM> may also be disposed at a height that is between three and seven feet from a base <NUM> of separator. In certain embodiments, the image sensor <NUM> height may be between five and six feet. The height of image sensor <NUM> may further depend on the type of separator that is being monitored. For example, in certain embodiments where separator <NUM> has a deck <NUM> that is relatively tall, image sensor <NUM> may be disposed greater than seven feet, while in embodiments where separator <NUM> deck <NUM> is relatively low, image sensor <NUM> may be disposed less than three feet. In operation, image sensor <NUM> should have a relatively unobstructed view of distal end <NUM> of separator, including a fluid endpoint. The fluid endpoint generally occurs about a portion of the second to last screen or about <NUM>/<NUM> of the total screen area. In certain embodiments, the fluid endpoint may include a portion of the screening area that includes more than the last screen <NUM>. Additionally, image sensor <NUM> may be oriented so that more than just the last screen <NUM> is captured.

In operation, image sensor <NUM> may capture images that show operational aspects of separator <NUM> including, for example, properties of slurry <NUM> as it traverses deck <NUM>. The images may be used to determine separator properties that may affect the operation of separator <NUM>. Examples of properties of the slurry may include location of the slurry, relative location of solid phase <NUM>, relative location of effluent phase <NUM>, size of particles within solid phase <NUM>, fluid endpoint location, and the like. Fluid endpoint refers to the point on the screens <NUM> where the fluid laden slurry ,e.g., slurry <NUM>, ends and beyond which moist solids, e.g., solid phase <NUM>, continue to travel towards solids outlet <NUM>. The fluid endpoint may also be referred to as the "beach position".

If the fluid endpoint is too long, i.e., to distant from solids outlet <NUM>, then the final screens <NUM> are operating on dryer solids and the life of screen <NUM> may be shortened. If the fluid endpoint is too short, then the final screens <NUM> are operating too wet and may discard solids with excess fluids. The loss of fluids may be expensive for an operator in terms of lost base liquid and increased disposal costs. An "optimized" endpoint is one that balances these considerations to achieve a desired level of moistness and fluids in the solid phase <NUM> as it exits the separator <NUM>.

In certain embodiments, an optimized fluid endpoint may refer to a fluid endpoint that is approximately <NUM>/<NUM> of the total length of the screening area. In operation, a relatively long fluid endpoint may be an indicator that separator <NUM> may be capable of handling greater flow rates or may have finer screens <NUM> installed. A relatively short fluid endpoint may be an indicator that separator <NUM> is overloaded. As such, determining the fluid endpoint may allow separator <NUM> operation to be optimized based on current conditions.

The fluid endpoint may be affected by the amount and properties of slurry <NUM> on separator <NUM>. The fluid endpoint may also be affected by separator <NUM> basket angle of inclination, motor speed, and screen <NUM> mesh size. As such, by measuring the fluid endpoint and comparing that to a desired fluid endpoint, separator <NUM> may be adjusted, such as by adjusting basket angle of inclination and/or motor speed to maintain the desired fluid endpoint.

In addition to fluid endpoint, other slurry properties and/or separator parameters may be analyzed and/or determined based on images captured by image sensor <NUM>. For example, the images may include solid phase <NUM> overflow, the size of the solids in solid phase <NUM>, images of screens <NUM> that allow damage to be detected, screen size and shape, operating hours, presence of foam, changes in the slurry <NUM> and other such properties and parameters that affect separator <NUM> performance.

Embodiments of the present disclosure may be used to control separator <NUM> operation in various ways. For example, embodiments of the present disclosure may allow for a closed-loop control of the fluid endpoint of a single separator <NUM>. Embodiments may also allow closed-loop control of the fluid endpoint of multiple separators <NUM>, solid phase <NUM> discard management, screen <NUM> visualization and identification, and the like. Each of the above identified types of control provided through embodiments of separators <NUM> with image sensors <NUM> are discussed in detail below.

In one embodiment, image sensors <NUM> may be used to allow closed-loop control of the fluid endpoint of a single separator <NUM>. In such an embodiment, if multiple separators <NUM> are in operation, the fluid endpoint of all the separators <NUM> may be individually adjusted to achieve optimized operation. For example, if the desired fluid endpoint is <NUM> (<NUM> inches) and the measured fluid endpoint is <NUM> (<NUM> inches), an individual separator <NUM> may be adjusted to a more downhill position by a small increment. Such adjustment may occur by sending a signal to an actuator to move the orientation of the basked in a more downhill direction. The actuator could include a pneumatic valve (not shown) connected to a bellows (not shown), a linear electrical actuator (not shown), an electrically actuated hydraulic valve connected to a piston (not shown), or similar devices capable of adjusting an angle of a basket.

After a period of time that allows separator <NUM> to achieve a steady-state and have a stable fluid endpoint, another measurement may be taken. As such, multiple measurements may occur over a period of several seconds, the average of which may result in an updated fluid endpoint based on the adjustments. Thus, if the new measurement is <NUM> (<NUM> inches), a control signal would again be given to adjust the shaker to a more downhill position. This process may repeat over a selected period of time until the measured fluid endpoint was optimized, e.g., <NUM> (<NUM> inches), within a tolerance band, e.g., <NUM> (<NUM> inches), etc..

In certain implementations, a separator <NUM> may not be able to be adjusted any further to achieve an optimized fluid endpoint. In such a circumstance, a signal may be sent that alerts an operator of the condition. In response, an operator could, for example, change a screen size, turn on/off other separators <NUM>, change a motor speed, change a separator <NUM> motion, etc. Accordingly, by determining a fluid endpoint, automated changes to separator <NUM> functionality may be controlled, thereby allowing separator <NUM> operation to be optimized. In certain embodiments, such measuring and adjusting may occur in real-time or substantially real-time. Real-time and/or substantially real-time refers to measuring and adjusting that occurs as operational conditions change, thereby allowing separator <NUM> functionality to be adjusted within a matter of seconds or minutes. Manual adjustment to separator functionality may not occur in real-time or substantially real-time, and as such, may take longer than the automated adjustments provided by the present disclosure.

In other embodiments, image sensors <NUM> may be used to allow closed-loop control of the fluid endpoint of multiple separators <NUM>. By capturing and analyzing images using image sensors <NUM> for multiple separators <NUM>, optimized fluid endpoints for each of the separators <NUM> may be provided. Because changing the angle of a basket changes the maximum flow rate separator <NUM> can handle, i.e., separator <NUM> capacity, such embodiments may expand the range of operating conditions where separators <NUM> may operate at optimum efficiency. In certain embodiments image sensors <NUM> may take images, overlay them, and use comparative analysis to determine a condition. In other embodiments, actual measurements may be taken and then compared to a known optimal value. In still other embodiments, software to run the image sensors <NUM> may be taught what the beach position looks like and then determine how to distinguish the transition between the liquid slurry part and the dryer solids part.

In still other embodiments, image sensors <NUM> may be used to allow for more effective solid phase <NUM> discharge management. In such an embodiment, image sensors <NUM> may be used to estimate and/or measure a volume of solids that are discarded by separator <NUM>. In operation, image sensors <NUM> may be used to track individual solids, e.g., cuttings, as they traverse deck <NUM> of separator <NUM>. As such, the speed of travel of the solids may be determined. Such image sensors <NUM> may include a distance measuring device, or multiple image sensors <NUM> thereby providing stereo vision, then the solids bed depth may be measured. The solids bed depth refers to the height of all of the solids moving across deck <NUM> of separator <NUM>.

The measurement of the profile of the solids bed depth and the speed of travel of the solids may be used to determine a solid discard rate. The solids discard rate could thus be calculated for each separator <NUM> in operation. By taking the integral of the solids discard rate, a total volume of cuttings could be calculated for each separator <NUM>. Such a calculation may thus provide a general indication of individual separator <NUM> performance, as well as an understanding as to how separators <NUM> are performing relative to one another. Such a calculation may also allow an operator to know when a drilled hole is returning more solids than normal. Returning more solids than normal may occur if a rheology, i.e., viscosity, of a drilling fluid has increased in order to clean more solids from the drilled hole. In certain embodiments, solids size may also be measured using image sensors <NUM>. Solids size may also provide an indication as to drill bit performance and/or other tools associated with a drilling operation.

In still other embodiments, image sensors <NUM> may be used to allow for automated measuring of a condition of one or more screens <NUM>. The measurement of the condition of the screens <NUM> may occur after separator <NUM> is turned off and after screens <NUM> have been washed. During operation, separator <NUM> screens <NUM> experience wear and may eventually become worn beyond operational limits or experience tears or broken cloth. Damaged cloth (not separately shown) allows larger solids than intended to pass through screens <NUM> and into the drilling fluid system. Large solids may damage downstream equipment, such as drilling fluid pump liners and downhole motors. Large solids may also turn into many smaller solids that deteriorate drilling fluid, thereby making the drilling fluid less effective in the drilling operation. Image sensors <NUM> may thus be used to detect damaged cells in screens <NUM>, calculate a percentage of cells on a particular screen <NUM> that are damaged, record data about screens, and/or alert an operator that one or more screens <NUM> need to be repaired or replaced.

In certain embodiments, image sensors <NUM> may also be used to determine and track other information about screens <NUM>. For example, image sensors <NUM> may be used to determine and/or track screen <NUM> type, screen <NUM> mesh size, operating hours of individual screens <NUM>, the number of screens <NUM> used for a particular well, the number of screens <NUM> used based on feet drilled per time increment, screen <NUM> make/model, and the like.

Embodiments of the present disclosure may also be used to optimize separator parameters based on changing conditions of a drilling fluid, slurry <NUM>, drilling operation, drilling equipment, etc. Additional embodiments and methods of operation are discussed in detail below with respect to <FIG>.

Referring to <FIG>, a side view of a separator having an image sensor according to one or more embodiments of the present disclosure is shown. In this embodiment, separator <NUM> includes a deck <NUM> with multiple screens <NUM> disposed thereon. As illustrated, separator <NUM> has four screens <NUM>, however, in other embodiments, separator <NUM> may have more or less than four screens <NUM>.

In operation, a slurry <NUM> is passed over screens <NUM>, thereby allowing solids to be separated from an effluent phase <NUM>. As slurry <NUM> passes over screens <NUM>, the effluent phase <NUM> may pass through the screens <NUM> for collection in a separator reservoir (not shown) or another holding area that is capable of colleting fluids. Solid phase <NUM> traverses deck <NUM> and exits separator <NUM> at a solids outlet <NUM>. Solids outlet <NUM> is illustrated as a fall-off point at a distal end <NUM> of separator <NUM>.

In operation, separator <NUM> functions similar to separator <NUM> of <FIG>. However, separator <NUM> includes a drying screen <NUM> located at distal end <NUM>. Drying screen <NUM> may be used to remove residual effluent phase <NUM> from solids before the solids are discharged from separator <NUM>.

In this embodiment, image sensor <NUM> is disposed proximate separator <NUM> distal end <NUM>. As such, image sensor <NUM> may sense or otherwise capture images that include aspects of one or more slurry properties and output or otherwise send the images including the images showing certain slurry properties to a remote location. For brevity, image sensor <NUM> may be oriented and function as discussed above with respect to <FIG>. In this orientation, image sensor <NUM> may be disposed around the third screen, near distal end <NUM>, or at another location that provides for image capturing as solids are discarded.

Referring to <FIG>, a side view of a separator having an image sensor according to one or more embodiments of the present disclosure is shown. In this embodiment, separator <NUM> includes a basket assembly <NUM> with multiple screens <NUM> disposed on a number of decks. Basket assembly <NUM> includes an upper screen deck <NUM>, a middle screen deck <NUM>, and a lower screen deck <NUM>.

In operation, a slurry <NUM> is passed over screens <NUM>, thereby allowing a solid phase <NUM> to be separated from an effluent phase <NUM>. As slurry <NUM> passes over screens <NUM>, the effluent phase <NUM> may pass through the screens <NUM> for collection in a separator reservoir (not shown) or another holding area that is capable of collecting fluids. Solid phase <NUM> traverses deck <NUM> and exits separator <NUM> at a solids outlet <NUM>. Solids outlet <NUM> is illustrated as a fall-off point at a distal end <NUM> of separator <NUM>.

In this embodiment, image sensor <NUM> is disposed proximate separator <NUM> distal end <NUM>. As such, image sensor <NUM> may sense or otherwise capture images that include aspects of one or more slurry properties and output or otherwise send the images including the slurry properties to a remote location. For brevity, image sensor <NUM> may be oriented and function as discussed above with respect to <FIG>. In this orientation, image sensor <NUM> may be focused on the solids as they fall off separator <NUM>.

Referring to <FIG>, a side view of a separator having an image sensor connected to a remotely located control module, according to one or more embodiments of the present disclosure is shown. In this embodiment, separator <NUM> is schematically represented having a first image sensor <NUM> disposed at a distal end <NUM>. A second image sensor <NUM> may also be disposed proximate a side or above separator <NUM>. Second image sensor <NUM> may be oriented to the side and/or above separator <NUM>, thereby allowing second image sensor <NUM> to capture additional information about separator <NUM>, screens <NUM>, a slurry, etc..

As illustrated, first image sensor <NUM> may be oriented to capture information from distal end <NUM> of separator, as illustrated with viewing angle <NUM>. As such, first image sensor <NUM> may function as discussed above with respect to <FIG>. Second image sensor <NUM> may be oriented to capture information from a top and/or side of separator <NUM>, as illustrated with viewing angle <NUM>. As such, second image sensor <NUM> may provide a view of the entire top portion of separator <NUM> or a subset of the top portion of separator <NUM>. The additional viewing angle <NUM> provided by second image sensor <NUM> may thereby allow additional slurry properties to be identified, such as information available at a feed inlet <NUM> of separator <NUM>. Information from feed inlet <NUM> may include, for example, information from a feed system, slurry pond, slurry feed rate, original condition of the slurry, etc..

Separator <NUM> and first image sensor <NUM> are shown disposed on a skid <NUM>. Second image sensor <NUM> may also be disposed on skid <NUM> or may alternatively be disposed on another apparatus attached to skid <NUM>, such as a boom (not shown) that allows second image sensor <NUM> to be moved around different locations relative to separator <NUM>. For example, second image sensor <NUM> may be moved from a side of separator <NUM> to above separator <NUM> and may also be adjusted to different heights and/or orientations. First image sensor <NUM> and/or second image sensor <NUM> may be disposed on skid <NUM> to prevent the vibration of separator <NUM> from affecting the quality of the images that are captured by first image sensor <NUM> and/or second image sensor <NUM>. Collectively, separator <NUM> and first image sensor <NUM> and/or second image sensor <NUM> disposed on skid <NUM> may be referred to as a separation assembly <NUM>.

Both first image sensor <NUM> and second image sensor <NUM> are operationally connected <NUM> to a control module <NUM> disposed at a remote location. The connection <NUM> between first image sensor <NUM> and second image sensor <NUM> may be wired or wireless and may include, for example, WiFi® connection, radio frequency connections, Bluetooth® connections, near field connections, and the like. As such, as first image sensor <NUM> and second image sensor <NUM> sense slurry properties and/or separator <NUM> parameters and/or collect data, such as images, from separator <NUM>, the sensed information may be sent to control module <NUM> for analysis.

As indicated above, control module <NUM> is located remote from separator <NUM>. The remote location refers to a location where analysis is performed that is separate from where the images are collected. Said another way, the information is analyzed at a different location than on separator <NUM>. A remote location may refer to, for example, an on-rig control and/or processing area, an off-rig management center, by an operator located at a different rig, and/or other areas removed from separator <NUM>.

In still other embodiments, additional image sensors or other orientations of image sensors may be provided. For example, in one implementation a single image sensor may be used, disposed at distal end <NUM>, along a side of separator <NUM>, above a separator <NUM>, or at a feed inlet <NUM> of separator <NUM>. In other implementations, multiple image sensors may be disposed at one or more locations about separator <NUM>, such as those locations discussed above. In still other implementations, more than one or two image sensors may be used. For example, three, four, or more image sensors may be disposed at various locations about separator <NUM>.

In certain embodiments employing more than one image sensor, each image sensor may be substantially the same, e.g., each image sensor may capture the same type of information. In other embodiments, each image sensor may be different, e.g., one image sensor may capture images in the visual spectrum, while another image sensor may capture infra-red. In still other embodiments, where more than one image sensor is employed, both image sensors may be located at the same location about separator <NUM>, i.e., both disposed at distal end <NUM>; however, each image sensor may be used to collected different information. Similarly, in embodiments where more than one image sensor is employed, the image sensors may be disposed to capture information from different locations about separator <NUM>.

Referring to <FIG>, a side view of a separator, according to one or more embodiments of the present disclosure is shown. In this embodiment, a separator <NUM> is illustrated having four screens <NUM> (only two indicated). A last/final screen <NUM> is disposed at a distal location <NUM> of separator <NUM>. An image sensor (not shown) may be oriented, as discussed above, about distal end <NUM>, thereby be capable of capturing information from last/final screen <NUM>.

In this example, a fluid endpoint <NUM> is illustrated. As explained above, fluid endpoint <NUM> refers to the line where the fluid laden slurry ends and beyond which moist solids continue to travel towards solids outlet <NUM>. Fluid endpoint <NUM> may change over time due to operational changes that occur at the drilling rig. Also as discussed above, the fluid endpoint <NUM> may be used to access the operational conditions of separator <NUM>, the drilling operation, drilling equipment, and the like. As such, maintaining an optimum fluid endpoint <NUM> may be used increase the efficiency of the separatory operation.

Referring to <FIG>, a top view of a separator, according to one or more embodiments of the present disclosure is shown. In this embodiment, a separator <NUM> is illustrated having four screens <NUM> (only two indicated). A last/final screen <NUM> is disposed at a distal location <NUM> of separator <NUM>. An image sensor (not shown) may be oriented, as discussed above, about distal end <NUM>, and thereby be capable of capturing information from last/final screen <NUM>.

As with <FIG> illustrates a fluid endpoint <NUM>. As a slurry traverses separator <NUM> in direction A, fluid endpoint <NUM> may move. For example, fluid endpoint <NUM> in an optimized location may occur <NUM> (<NUM> inches) from distal end <NUM>. However, in operation, fluid endpoint <NUM> may be located less than <NUM> (<NUM> inches) or more than <NUM> (<NUM> inches) from distal end <NUM>. In such occurrences, knowing the actual fluid endpoint <NUM> compared to the optimized fluid endpoint <NUM> may allow operational aspects, such as basket angle and/or motor speed, to be adjusted to cause fluid endpoint <NUM> to move closer to the optimized fluid endpoint <NUM>. Methods for adjusting such operational aspects of separator <NUM> may include those discussed in detail above with respect to <FIG>.

Referring to <FIG>, a schematic representation of multiple separators connected to a remotely located control module, according to one or more embodiments of the present disclosure is shown. In operation, a drilling location may have multiple separators <NUM>/<NUM>. While two separators <NUM>/<NUM> are shown, in operation, drilling operations may have more than two separator <NUM>/<NUM>, such as three, four, five, or more, depending on the operational requirements of the drilling rig.

As illustrated, each separator <NUM>/<NUM> includes image sensors <NUM>/<NUM>, respectively, such as the image sensors <NUM>/<NUM> discussed above with respect to <FIG>. Image sensors <NUM>/<NUM> capture slurry properties and/or separator parameters from separators <NUM>/<NUM> and send such captured properties/parameters to a control module <NUM>, that is located remote from separators <NUM>/<NUM>. Control module <NUM> may thereby use the captured information and send control signals to one or more of separators <NUM>/<NUM>. For example, control module <NUM> may turn off or turn on one or more of separators <NUM>/<NUM> in response to a change in a condition, such as a fluid endpoint, of a slurry on one or more of separators <NUM>/<NUM>.

The captured information may also be analyzed by control module <NUM> to determine if equipment associated with one or more of separators <NUM>/<NUM> is damaged or not operating as expected. This information may be used, through control signals, to adjust a property of one or more of separators <NUM>/<NUM> and/or may be used to alert an operator as to the condition of separators <NUM>/<NUM>.

Referring to <FIG>, a flow chart of a method of monitoring a separator according to one or more embodiments of the present disclosure is shown. In operation, the method includes capturing (block <NUM>) an image of a separator. Capturing the image may include taking still shots or video through one of a number of visual or non-visual spectra, as discussed in detail above. The image may further include a plurality of images, where each image is of the same spectrum or the images are of different spectra, e.g., a first image may be in one spectrum while a second image is in a second, different spectrum. Capturing the image may further include taking a plurality of images over a set time sequence. For example, images could be taken substantially consistently or video could be substantially constantly recorded. In other examples, images may be taken every second, every <NUM> second, every minute, every several minutes, or according to a schedule defined by an operator. Images may also be taken on an as needed basis, as may occur when trying to identify damage to a screen, which may occur when the separator is off and has been washed. Thus, in certain examples, images may be captured while the separator is operating, while in other embodiments images may be captured while the separator is not operating.

In operation, the method further includes sending (block <NUM>) the image of the separator to a control module disposed at a remote location. The control module may include a computer system or computing device, such as will be discussed in detail with respect to <FIG>. The image may be sent individually, or batches of images may be sent, where the batches of images include at least two images. The images may be sent over wired or wireless connections and may be sent as they are taken or according to a defined time sequence. For example, images may be sent to the control module as soon as they are captured by an image sensor. In another example, the image sensor may include a storage device that allows a number of images to be captured, stored, and then sent to the control module when a certain number of images have been captured or, for example, every second, <NUM> seconds <NUM> seconds, <NUM> seconds, every minute, etc..

In operation, the method further includes analyzing (block <NUM>) the image with the control module to determine a separation property. The separation property may include, for example, a slurry property and/or a separator parameter, such as those discussed above. The separation property may further include a functional aspect of the separator, while the separator is in operation. Examples of such separation properties may include, for example, a fluid endpoint, a screen parameter, a solid discharge rate, a solid speed, a solids overflow volume, a solid size, a solid distribution, a separator capacity, etc. Examples of screen parameters may include make, model, mesh size, condition, operating hours, i.e., time in use, etc. Additional properties may include, for example, rate of penetration, mud pump rate, fluid type, hold size, depth, total vertical depth, formation type, drilling rig operational status, etc..

In operation, the method further includes modifying (block <NUM>) the separator based on the determined separation property. Modifying may include changing an operational aspect of the separator or changing an operational parameter of one separator relative to another. Examples of modifying a separator may include adjusting a basket angle, adjusting a motor speed, changing a screen, repairing a screen, turning a separator on, turning a separator off, adjusting a feed rate of a slurry, adjusting a screen mesh size, adjusting a flow weir, isolating a separator, adjusting a valve position, e.g., between open/closed and/or a position therebetween, changing a motion, e.g., between linear and elliptical, etc..

The modifying may occur automatically in response to the analyzing. For example, if a specific separation property is determined, a specific modification may be preprogrammed into control module. As such, control module may automatically make an adjustment to a separator when the specific separation property is identified. As such, the modification to the separator may occur in real-time or substantially in real-time, as discussed above. In still other embodiments, rather than automatically make the adjustment, the control module may send an alert to an operator about the condition of a separator. The alert may be visual, such as a display on a monitor, computer, tablet, phone, etc., or may be auditory, in the form of an alarm or other signal.

In certain embodiments, the control module may include or have access to machine learning, such as deep machine learning in the form of, for example, artificial neural networks. Examples of types of artificial neural networks that may be used include convolutional, recursive, recurrent, sequence-to-sequence, shallow, multilayer, etc. In such embodiments, the artificial neural networks may be trained with conditions that allow separation property to be determined quickly, without the need for time consuming measurements or calculations. As such, control modules using artificial neural networks may be capable of predicting when a separation property is likely to occur and take preemptive action. Such preemptive action may include modifying a separator or otherwise alerting an operator that a specific condition is likely to occur. Because such control modules may include predictive logic, the control modules may be used to forecast operational conditions of a separator or other equipment in a drilling operation.

In operation, certain information may be inputted into control module because control module is used for a particular separator. Examples of information that may be inputted may include screen parameters, basket angle, motor speed, type of drilling fluid, type of drilling rig, type of drill bit, expected solids size, type or types of image sensors, number of image sensors, rate of image capture, rate of image receipt, hours in operation, information from drilling fluid reports, etc. Additional information may also be provided to control module during a drilling/separation operation. The additional information may include, for example, weight on bit, revolutions per minute of a drill bit, reamer, or the like, formation data, depth of hole, size of hole, type of solids, e.g., formation type, type of drilling fluid, type of separator motion, g-force of separator motion, amount of side-to-side motion of a separator, number of separators in use, number of separators at a drilling site, etc..

Information may also be provided to an operator. Examples of information that may be output to a user may include, fluid endpoint, separator efficiency, hours in use, separator loading, health of separator, health of screens, cost analysis, volumes of solids discharged, volume of solids per screen, health of separator over time, drilling rig status, drill bit health, separator operational status, e.g., on/off/fault, etc..

Referring to <FIG>, a schematic representation of a computer processing device <NUM> that may be used to implement functions and processes in accordance with one or more examples of the present disclosure is shown. For example, such computer processing device <NUM> may be used to perform the analyzation of the images captured by the image sensors, as described above. Such computer processing devices <NUM> may also be used to run or train artificial neural networks or other deep machine learning logic. In certain implementations, computer processing devices <NUM> may be low power computation systems that perform calculations based on captured images and/or send or receive control signals for adjusting aspects of one or more separators. <FIG> illustrates a computer processing device <NUM> that may be used to implement the systems, methods, and processes of this disclosure. For example, computer processing device <NUM> illustrated in <FIG> could represent a client device or a physical server device and include either hardware or virtual processor(s) depending on the level of abstraction of the computing device. In some instances (without abstraction), computer processing device <NUM> and its elements, as shown in <FIG>, each relate to physical hardware. Alternatively, in some instances one, more, or all of the elements could be implemented using emulators or virtual machines as levels of abstraction. In any case, no matter how many levels of abstraction away from the physical hardware, computer processing device <NUM> at its lowest level may be implemented on physical hardware.

More particularly, computer processing devices such as the computer processing device <NUM> may be used to implement the control module, such as the control module <NUM> in <FIG> and control module <NUM> in <FIG>. In general, the control modules <NUM>, <NUM> may be implemented in hardware, software, or a combination of hardware and software. For example, a control module may be implemented in an Electrically Erasable, Programmable, Read-Only Memory ("EEPROM"), an Application Specific Integrated Circuit ("ASIC"), or a processing resource executing instructions stored in a non-transitory computer readable memory.

<FIG> shows a computer processing device <NUM> in accordance with one or more examples of the present disclosure. Computer processing device <NUM> may be used to implement aspects of the present disclosure, such as processing images, analyzing slurry properties, determining separator parameters, displaying slurry properties and/or separator parameters, and the like. Computer processing device <NUM> may include one or more central processing units (singular "CPU" or plural "CPUs") <NUM> or other kinds of processing resources such a graphics processors or processor chipsets. Processor chipsets may include, for example, a general CPU, a graphics co-processor, a math co-processor, etc. and various combinations thereof.

The CPU(s) <NUM> may be disposed on one or more printed circuit boards (not otherwise shown). Each of the one or more CPUs <NUM> may be a single-core processor (not independently illustrated) or a multi-core processor (not independently illustrated). Multi-core processors typically include a plurality of processor cores (not shown) disposed on the same physical die (not shown) or a plurality of processor cores (not shown) disposed on multiple die (not shown) that are collectively disposed within the same mechanical package (not shown). Computer processing device <NUM> may include one or more core logic devices such as, for example, host bridge <NUM> and input/output ("IO") bridge <NUM>.

CPU <NUM> may include an interface <NUM> to host bridge <NUM>, an interface <NUM> to system memory <NUM>, and an interface <NUM> to one or more IO devices, such as, for example, graphics processing unit ("GFX") <NUM>. GFX <NUM> may include one or more graphics processor cores (not independently shown) and an interface <NUM> to display <NUM>. In certain examples, CPU <NUM> may integrate the functionality of GFX <NUM> and interface directly (not shown) with display <NUM>. Host bridge <NUM> may include an interface <NUM> to CPU <NUM>, an interface <NUM> to IO bridge <NUM>, for examples where CPU <NUM> does not include interface <NUM> to system memory <NUM>, an interface <NUM> to system memory <NUM>, and for examples where CPU <NUM> does not include integrated GFX <NUM> or interface <NUM> to GFX <NUM>, an interface <NUM> to GFX <NUM>. One of ordinary skill in the art having the benefit of this disclosure will recognize that CPU <NUM> and host bridge <NUM> may be integrated, in whole or in part, to reduce chip count, motherboard footprint, thermal design power, and power consumption. IO bridge <NUM> may include an interface <NUM> to host bridge <NUM>, one or more interfaces <NUM> to one or more IO expansion devices <NUM>, an interface <NUM> to keyboard <NUM>, an interface <NUM> to mouse <NUM>, an interface <NUM> to one or more local storage devices <NUM>, and an interface <NUM> to one or more network interface devices <NUM>.

Each local storage device <NUM> may be a solid-state memory device, a solid-state memory device array, a hard disk drive, a hard disk drive array, or any other non-transitory computer readable medium. Each network interface device <NUM> may provide one or more network interfaces including, for example, Ethernet, Fibre Channel, WiMAX, Wi-Fi®, Bluetooth®, or any other network protocol suitable to facilitate networked communications. Computer processing device <NUM> may include one or more network-attached storage devices <NUM> in addition to, or instead of, one or more local storage devices <NUM>. Network-attached storage device <NUM> may be a solid-state memory device, a solid-state memory device array, a hard disk drive, a hard disk drive array, or any other non-transitory computer readable medium. Network-attached storage device <NUM> may or may not be collocated with computer processing device <NUM> and may be accessible to computer processing device <NUM> via one or more network interfaces provided by one or more network interface devices <NUM>.

One of ordinary skill in the art having the benefit of this disclosure will recognize that computer processing device <NUM> may include one or more application-specific integrated circuits ("ASICs") that are configured to perform a certain function, such as, for example, hashing (not shown), in a more efficient manner. The one or more ASICs may interface directly with an interface of CPU <NUM>, host bridge <NUM>, or IO bridge <NUM>. Alternatively, an application-specific computing system (not shown), sometimes referred to as mining systems, may be reduced to only those components necessary to perform the desired function, such as hashing via one or more hashing ASICs, to reduce chip count, motherboard footprint, thermal design power, and power consumption. As such, one of ordinary skill in the art will recognize that the one or more CPUs <NUM>, host bridge <NUM>, IO bridge <NUM>, or ASICs or various sub-sets, super-sets, or combinations of functions or features thereof, may be integrated, in whole or in part, or distributed among various devices in a way that may vary based on an application, design, or form factor in accordance with one or more example examples. As such, the description of computer processing device <NUM> is merely exemplary and not intended to limit the type, kind, or configuration of components that constitute a computing system suitable for performing computing operations, including, but not limited to, hashing functions. Additionally, one of ordinary skill in the art will recognize that computer processing device <NUM>, an application-specific computing system (not shown), or combination thereof, may be disposed in a stand-alone, desktop, server, or rack mountable form factor.

One of ordinary skill in the art will recognize that computer processing device <NUM> may be a cloud-based server, a server, a workstation, a desktop, a laptop, a netbook, a tablet, a smartphone, a mobile device, and/or any other type of computing system in accordance with one or more example examples.

Examples in the present disclosure may also be directed to a non-transitory computer-readable medium storing computer-executable instructions and executable by one or more processors of the computer via which the computer-readable medium is accessed. A computer-readable media may be any available media that may be accessed by a computer. By way of example, such computer-readable media may comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that may be used to carry or store desired program code in the form of instructions or data structures and that may be accessed by a computer. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray® disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers.

Note also that the software implemented aspects of the subject matter claimed below are usually encoded on some form of program storage medium or implemented over some type of transmission medium. The program storage medium is a non-transitory medium and may be magnetic, e.g., a floppy disk or a hard drive or optical, e.g., a compact disk read only memory, or "CD ROM", and may be read only or random access. Similarly, the transmission medium may be twisted wire pairs, coaxial cable, optical fiber, or some other suitable transmission medium known to the art.

Claim 1:
A system for separating solids from fluids, the system comprising:
a separator (<NUM>, <NUM>) comprising:
a deck (<NUM>, <NUM>, <NUM>, <NUM>) having a feed inlet (<NUM>) and a solids outlet (<NUM>, <NUM>, <NUM>, <NUM>); and
a plurality of screens (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) disposed on the deck (<NUM>, <NUM>, <NUM>, <NUM>); and
an image sensor (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) disposed proximate the solids outlet (<NUM>, <NUM>, <NUM>, <NUM>), the image sensor (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) configured to:
capture images of the solids outlet of the separator (<NUM>, <NUM>), and
send the captured images to a remote location for analysis.