Solids testing systems and methods

Abstract

A solids testing system includes a solids / liquids separator with a container and a screen. The solids testing system also includes an imaging device and a controller configured to control the solids / liquid separator to facilitate separation of a large solids fraction from a first fluid flow; control, the imaging device to capture imagery of the large solids fraction remaining on a first side of the screen after the separation of the large solids fraction from the first fluid flow; and analyze the imagery to identify one or more characteristics of the large solids fraction remaining on the first side of the screen after the separation of the large solids fraction from the first fluid flow. The solids testing system may identify one or more additional characteristics of a small solids fraction in the first fluid flow, wash and / or dry the large solids fraction, and / or dilute the small solids fraction.

Description

PATENT Docket No. IS22.0296-WO-PCT SOLIDS TESTING SYSTEMS AND METHODS CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority benefit of United States Provisional Patent Application Serial No.63 / 689,614 filed August 30, 2024, which is entirely incorporated herein by reference. BACKGROUND

[0002] This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and / or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

[0003] Natural resources, such as oil and gas, are used as fuel to power vehicles, heat homes, and generate electricity, in addition to various other uses. Once a desired resource is discovered below a surface of the earth, drilling systems are often employed to carry out drilling operations to access the desired resource. During the drilling operations, drilling fluid is pumped through a drill string into a wellbore to facilitate drilling a well. The drilling fluid then flows through an annular space defined between the drill string and the wellbore to return to equipment located at a surface. It is presently recognized that it is desirable to monitor properties of the drilling fluid, including any solids within the drilling fluid (e.g., lost circulation materials; wellbore strengthening materials; fluid loss agents, cuttings). SUMMARY

[0004] A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide thePATENT Docket No. IS22.0296-WO-PCT reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below

[0005] In certain embodiments, a solids testing system includes a solids / liquids separator with a container and a screen. The solids testing system also includes an imaging device and a controller configured to control the solids / liquid separator to move the screen to facilitate separation of a large solids fraction from a first fluid flow. The controller is also configured to control the imaging device to capture imagery of the large solids fraction remaining on a first side of the screen after the separation of the large solids fraction from the first fluid flow, and analyze the imagery to identify one or more characteristics of the large solids fraction remaining on the first side of the screen after the separation of the large solids fraction from the first fluid flow.

[0006] In certain embodiments, a method includes controlling, using one or more processors, a solids / liquid separator to facilitate separation of a large solids fraction from a first fluid flow. The method also includes controlling, using the one or more processors, an imaging device to capture imagery of the large solids fraction remaining on a first side of a screen after the separation of the large solids fraction from the first fluid flow. The method further includes analyzing, using the one or more processors, the imagery to identify one or more characteristics of the large solids fraction remaining on the first side of the screen after the separation of the large solids from the first fluid flow. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Various features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying figures in which like characters represent like parts throughout the figures, wherein:PATENT Docket No. IS22.0296-WO-PCT

[0008] FIG.1 is a schematic diagram of a drilling rig that may include a system with a solids testing system, in accordance with an embodiment of the present disclosure;

[0009] FIG.2 depicts a flow chart of one example method of operating the solids testing system of FIG. 1 to separate solids of a drilling fluid and acquire digital images of the solids, in accordance with an embodiment of the present disclosure;

[0010] FIG.3 depicts a schematic diagram of the solids testing system of FIG. 1, in accordance with an embodiment of the present disclosure;

[0011] FIG. 4 depicts a flow chart of one example method of operating the solids testing system of FIG.1 to automatically characterize solids in a drilling fluid, in accordance with an embodiment of the present disclosure;

[0012] FIG.5 depicts a block diagram of the solids testing system of FIG.1 that may be utilized to characterize lost circulation materials (LCM) in the drilling fluid, in accordance with an embodiment of the present disclosure;

[0013] FIG.6 is a front view of the system that includes the solids testing system of FIG.1, wherein an inset is a schematic diagram of a portion of the system, in accordance with an embodiment of the present disclosure;

[0014] FIG.7 is a schematic diagram of the solids testing system of FIG.1, in accordance with an embodiment of the present disclosure;

[0015] FIG.8 is a perspective top view of a portion of the solids testing system of FIG. 1, including a screen and an imaging device, in accordance with an embodiment of the present disclosure;

[0016] FIG.9 is a perspective top view of a portion of the solids testing system of FIG.1, including a screen and multiple imaging devices, in accordance with an embodiment of the present disclosure;PATENT Docket No. IS22.0296-WO-PCT

[0017] FIG. 10 is cross-sectional side view of a container and additional components that may be utilized in the solids testing system of FIG. 1, in accordance with an embodiment of the present disclosure;

[0018] FIG.11 is a schematic diagram of additional components that may be utilized in the solids testing system of FIG.1, wherein a screen is at a first chamber with an associated imagery system and discharged fluid is guided to a second imagery system, in accordance with an embodiment of the present disclosure;

[0019] FIG.12 is a schematic diagram of the additional components of FIG.11, wherein the screen is at a second chamber, in accordance with an embodiment of the present disclosure;

[0020] FIG.13 is a schematic diagram of the additional components of FIG.11, wherein the screen is at the first chamber and in a discharge position, in accordance with an embodiment of the present disclosure;

[0021] FIG.14 is a schematic diagram of the additional components of FIG.11, wherein an additional imagery system is provided to monitor a small solid fraction, in accordance with an embodiment of the present disclosure

[0022] FIG. 15 depicts first and second cross plots that distinguish cuttings particles from lost circulation materials (LCM) particles, in accordance with an embodiment of the present disclosure;

[0023] FIG.16 depicts a segmented image and corresponding two-dimensional cross plot distinguishing cuttings particles from first and second LCM particles, in accordance with an embodiment of the present disclosure; and

[0024] FIG.17 depicts a segmented image and corresponding two-dimensional cross plot distinguishing cuttings particles from first and second additives and particle size distribution (PSD) outputs, in accordance with an embodiment of the present disclosure.PATENT Docket No. IS22.0296-WO-PCT DETAILED DESCRIPTION

[0025] One or more specific embodiments of the present disclosure will be described below. These described embodiments are only exemplary of the present disclosure. Additionally, in an effort to provide a concise description of these exemplary embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0026] During drilling operations, drilling fluid is pumped through a drill string into a wellbore to facilitate drilling a well. The drilling fluid then flows through an annular space defined between the drill string and the wellbore to return to equipment located at a surface. Solid drilling fluid additives are commonly added to the drilling fluid. For example, lost circulation materials (LCM) and / or wellbore strengthening materials (WSM) are commonly added to the drilling fluid to seal loss regions and prevent the drilling fluid from flowing into a formation. The LCM and / or WSM may include low-cost products from various industries, for example, including ground nut shells (e.g., nut plug; ground walnut hulls, ground pecan hulls), mica, ground rubber, G-SealTMsized graphite bridging agent and variations thereof (e.g., G-Seal Plus and G-Seal Plus Coarse; chemically inert and thermally stable), SAFE-CARB ground marble bridging agent (e.g., high-purity, acid-soluble calcium carbonate), and / or various polymeric materials. The LCM may be a type of WSM, and certain materials may be considered to be both LCM and WSM. To facilitate discussion, certain examples herein relate to and describe LCM; however, it should be appreciated that the techniques may also be utilized with any solid drilling fluid additives, including WSM. Indeed, it should be appreciated that as used herein thePATENT Docket No. IS22.0296-WO-PCT term LCM may refer to substantially any solid drilling fluid additive particles, including WSM and / or fluid loss agent (FLA).

[0027] It is presently recognized that it may be desirable to evaluate the drilling fluid to identify type(s) and / or amount(s) of the LCM in the drilling fluid, which may aid in optimizing the drilling fluid (e.g., formulation of the drilling fluid, including the LCM) and may further provide information about a structure of the wellbore and / or the formation. Accordingly, present embodiments relate to systems and methods that enable efficient evaluation of the drilling fluid, including solids in the drilling fluid, such as LCM and / or cuttings carried from the wellbore to the surface by the drilling fluid. For example, a system (e.g., testing system) may include a solids testing system that operates to acquire imagery (e.g., a calibrated color digital image; laser diffraction) of solid particles separated from a drilling fluid circulating in a wellbore, wherein the solid particles include at least LCM particles. In operation, the system processes the imagery to identify individual ones of the solid particles depicted in the imagery. The system extracts color features and / or texture features based on the solid particles depicted in the imagery. The system processes the color features and / or texture features to identify LCM particles among the solid particles and to classify each of the LCM particles into one of multiple LCM classes and thereby obtain an LCM particle classification. The system further processes LCM classification to generate a consolidated summary. The system may utilize these techniques for large solids fractions, which may be separated via a screen. In certain embodiments, the solids testing system may operate to acquire imagery (e.g., a calibration digital image; may be black and white digital image without color;) of solid particles that pass through the screen (e.g., a small solids fraction that passes with liquid through the screen). Thus, the system may utilize color imagery to assess the large solids fraction that are concentrated onto the screen, while assessment of the small solids fraction may not include or be based on color imagery and may involve dilution due to abundance of the small solids fraction in the liquid downstream of the screen.

[0028] In certain embodiments, at least some components of a system (e.g., testing system) may be located onsite (e.g., on a skid placed at the surface abovePATENT Docket No. IS22.0296-WO-PCT the wellbore). In certain embodiments, at least some components of the system may be subject to ATEX, UKEX, and / or IECex standards. For example, at least some components of the system may be subject to ATEX, UKEX, and / or IECex standards due to presence of flammable fluid (e.g., the drilling fluid and / or cleaning fluid) and / or due to being in an area with a potential presence of explosive gases. Accordingly, certain containers (e.g., chambers) and certain non-rated components, such as an imaging device (e.g., camera) may be positioned within an enclosure that is purged and pressurized. Further, certain containers may be made to be explosion proof, flame proof, and / or infallible (e.g., continuous, one- piece construction and weldments; devoid of fittings) in portions that contain sample fluid (e.g., sample of the drilling fluid; fluid that may be capable of releasing flammable gases / vapors). In this way, the system enables the sample fluid to circulate through the system in a manner certified by ATEX, UKEX, and / or IECex (e.g., in compliance with ATEX, UKEX, and / or IECex standards).

[0029] ATEX refers to “Atmospheres Explosibles” and is a set of European Union regulations related to products used in explosive environments. UKEX refers to “The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations” and is a set of regulations that apply to products sold in Great Britain. IECex refers to “International Electrotechnical Commission for Explosive Atmospheres” and is a set of regulations accepted in several countries and related to products used in explosive environments. It should be appreciated that the system may be subject to any of a variety of regulations set forth by one or more countries, agencies, or so forth, and features of the system may enable the system to satisfy or meet any of a variety of regulations set forth by one or more countries, agencies, or so forth.

[0030] The system described herein may be an automated system that is configured to circulate and test the sample fluid, as well as circulate the cleaning fluid, via automated processes (e.g., move between at least some steps without human intervention). Additionally, the system may include or operate in coordination with other types of testing systems, such as a fluid testing system that performs rheological tests on liquid portions of the drilling fluid.PATENT Docket No. IS22.0296-WO-PCT

[0031] FIG.1 is schematic diagram of a drilling rig 8 that includes a system 10 that evaluates a drilling fluid, wherein the system 10 includes a solids testing system (STS) 12, in accordance with an embodiment of the present disclosure. The solids testing system 12 is configured to evaluate solid drilling fluid additives, such as lost circulation materials (LCM), and drilled cuttings contained in the drilling fluid. As noted, while certain examples herein relate to and describe LCM, it should be appreciated that the techniques may also be utilized with any solid drilling fluid additives, including wellbore strengthening materials (WSM). Indeed, it should be appreciated that as used herein the term LCM may refer to substantially any solid drilling fluid additive particles, including WSM and / or fluid loss agent (FLA).

[0032] As shown, the system 10 may include other types of testing systems, such as a fluid testing system (FTS) 14 that is configured to evaluate rheological properties of the drilling fluid.

[0033] The drilling rig 8 may be positioned over a subterranean formation. The drilling rig 8 may include, for example, a derrick and a hoisting apparatus for raising and lowering a drill string 16 that extends into a wellbore 18. The drill string 16 may support a drill bit 20 and / or one or more downhole measurement tools 22 (e.g., a logging while drilling tool and / or a measurement while drilling tool). The drilling rig 8 further includes a mud pump 24 that pumps the drilling fluid into a conduit 23, to the drill string 16, and to the wellbore 18 (e.g., used in drilling the wellbore 18), as shown by arrow 25. The drilling fluid returns through an annular space defined between the drill string 16 and a wall of the wellbore 18, as shown by arrow 26. The drilling fluid then flows through a return conduit 28 and solids control equipment 30 (e.g., a shale shaker, which removes large cuttings, such as cuttings over about 20, 10, 5, 3, or 2 millimeters (mm) in size) to a mud pit 32. In some embodiments, particles in a large solids fraction may include a size between about 0.2 to 2mm or 0.3 to 3 mm, while particles in a small solids fraction may include a size less than about 0.2 or 0.3 mm. However, it should be appreciated that it is envisioned that the system 10 may be implemented with large cuttingsPATENT Docket No. IS22.0296-WO-PCT have any suitable size or size range, as well as the large solids fraction and the small solids fraction having any suitable size or size range.

[0034] The LCM may be added from one or more LCM sources to the drilling fluid to seal loss regions and prevent the drilling fluid from flowing (and being lost) at the wellbore 18 (e.g., into the formation). The LCM may include low-cost products from various industries, for example, including ground nut shells, mica, ground rubber, and / or various polymeric materials. LCM particles are commonly sized and shaped to be kept in the drilling fluid background as wellbore strengthening materials to continuously seal cracks and vugs in the wall of the wellbore 18 and to flow through the drill bit 20. The LCM circulate with the drilling fluid, and thus are transported to into the wellbore 18 and return through the annular space to the return conduit 28 and the mud pit 32. In certain embodiments, the solids control equipment 30 may not totally remove the LCM from the drilling fluid (e.g., due to density, shape and / or size; the LCM particles are smaller in size than the large cuttings).

[0035] The drilling rig 8 may include the system 10 that includes the solids testing system 12, which is configured to evaluate the solid materials in the drilling fluid. Further, it should be appreciated that the solids testing system 12 may evaluate any drilled cuttings that are not removed by the shale shaker (e.g., small cuttings less than about 20, 10, 5, 4, 3, or 2 millimeters (mm) in size). Indeed, the solids testing system 12 may extract and evaluate the solids, which may include the LCM particles and the cuttings, that are less than about 20, 10, 5, 4, 3, or 2 mm in size.

[0036] Further, as shown, the system 10 may include the fluid testing system 14 that is configured to evaluate rheological properties of the drilling fluid. The system 10 may be deployed at the drilling rig 8 (e.g., in an onsite laboratory). As described herein, the system 10 may test the drilling fluid at various times and / or at various stages during circulation of the drilling fluid, such as prior to providing the drilling fluid into the wellbore 18 and after the drilling fluid returns from the wellbore 18. Accordingly, the system 10 may be fluidly coupled to thePATENT Docket No. IS22.0296-WO-PCT conduit 23 (e.g., between the mud pit 32 and the drill string 16), the return conduit 28 (e.g., downstream of the shale shaker; between the shale shaker and the mud pit 32), and / or any other suitable source (e.g., active source of the drilling fluid; after mixing of the LCM, but prior to providing the drilling fluid to the wellbore 18 and / or mixing with the drilling fluid that returns from the wellbore 18). While the solids testing system 12 and the fluid testing system 14 may be utilized together and / or operate in a coordinated manner (e.g., share fluid lines, fluid sources, valves, manifolds, pumps, control systems), it should be appreciated that the solids testing system 12 may be entirely separate or independent of the fluid testing system 14 (e.g., separate fluid lines, fluid sources, valves, manifolds, pumps, control systems).

[0037] FIG.2 depicts a flow chart of one example method 100 of operating the solids testing system 12 of FIG. 1 to separate the solids of the drilling fluid and acquire digital images, in accordance with an embodiment of the present disclosure. Certain aspects of FIG. 2 may be implemented by a control system described herein, and further the control system may control (e.g., provide control signals to) hardware components of the solids testing system 12 to facilitate the aspects described with reference to FIG.2.

[0038] A borehole is drilled at 101, for example, using the drilling rig 8 described above with respect to FIG.1. The LCM and cuttings are circulated in the drilling fluid while drilling. The LCM and the cuttings generated while drilling are transported to the surface in the upwardly flowing drilling fluid. In the example embodiment depicted, LCM and cuttings samples (e.g., containing LCM and / or cuttings) may be obtained from one or more of at least three locations on the drilling rig. For example, a sample containing LCM and / or cuttings may be obtained from a flow line at 103, by screening drilling fluid from an active mud pit at 104, and / or by screening drilling fluid from a return mud pit at 105. Those of ordinary skill will readily appreciate that an active mud pit is a mud pit from which drilling fluid is pumped downhole while a return mud pit is a mud pit to which drilling fluid returns after passing through the shale shakers and / or other solids control equipment after returning to the surface.PATENT Docket No. IS22.0296-WO-PCT

[0039] Irrespective of how and where the samples are obtained, the samples may be prepared for image analysis at 106, for example, by washing via cleaning solvent and / or compressed air. The particles may be further placed in a tray having a high contrast (vivid) background color to enhance subsequent particle identification and segmentation in the acquired images, for example, pure magenta (e.g., with RGB values of 255, 0, 255), pure blue (e.g., with RGB values of 0, 0, 255), pure green (e.g., with RGB values of 0, 255, 0), and so forth. In general, such colors do not exist in nature and, accordingly, enable detection of the particles (e.g., help instance segmentation models avoid detecting the background of the tray as part of the particles). The tray of prepared particles may be placed in front of a digital camera and at least one digital image may be taken, for example, a white light image, or a first white light image and a second infrared or ultraviolet image, or even a first white light image, a second infrared image, and a third ultraviolet image. The disclosed embodiments are not limited in these regards; however, it will be appreciated that the acquisition of multiple images may be advantageous in that certain texture features may be more readily discerned in infrared or ultraviolet light than in white light.

[0040] In certain embodiments, the image acquisition process may advantageously make use of standardized and / or calibrated lighting, color enhancement, magnification, and / or focus / resolution settings. For example, in certain embodiments, color / illumination calibration is obtained by using colorimetry algorithms against previously analyzed photos and a current photo of interest, while resolution calibration may be based on lens focal length, focal distance, and sensor size / resolution for the current photo of interest as compared to that of previously analyzed photos. Images may be taken when the cuttings are wet or dry, with the humidity generally being controlled for dry cuttings images.

[0041] Further, as shown, the image acquisition process may include a first image acquisition process 107 with a first imaging system for a large solids fraction (e.g., separated via a screen; held on the screen; supported on a first side of the screen), as well as a second image acquisition process 108 with a second imaging system for a small solids fraction (e.g., that pass through the screen with liquidPATENT Docket No. IS22.0296-WO-PCT from the drilling fluid; to a second side of the screen). As noted herein, the method 100 may utilize color imagery to assess the large solids fraction that are concentrated onto the screen, while assessment of the small solids fraction may not include or be based on color imagery and may involve dilution due to abundance of the small solids fraction in the liquid downstream of the screen. It should be appreciated that imagery of the small solids fraction may be captured and analyzed at any suitable location and via any suitable technique. For example, the imagery of the small solids fraction may be captured in-line, such as via a focused beam reflectance measurement (FBRM) or any other suitable device or system capable of carrying out such measurements.

[0042] FIG.3 depicts a schematic diagram 200 of the solids testing system 12 of FIG.1, in accordance with an embodiment of the present disclosure. As shown, a volume of drilling fluid is isolated or captured via a fluid management device 201 (e.g., via manipulation of valves or other fluid management devices). The volume of drilling fluid is known (e.g., known, defined, measured). A separator 202 (e.g., solid / liquid separator) separates a large solids fraction as represented by block 203, wherein the large solids fraction may include particles greater than about 0.2 or 0.3 mm and / or also less than about 2 or 3 mm, for example. Further, the separator 202 allows collection of a volume of liquids with a small solids fraction, wherein the small solids fraction may include particles less than about 0.2 or 0.3 mm, for example. The separator 202 may include a screen to facilitate the separation of the large solids fraction for analysis by a first imaging system 206, while the volume of liquids with the small solids fraction passes through the screen for collection and / or sampling by a second imaging system 205.

[0043] FIG.4 depicts a flow chart of one example method 300 of operating the solids testing system 12 of FIG.1 to automatically characterize solids in a drilling fluid, in accordance with an embodiment of the present disclosure. Certain aspects of FIG.4 may be implemented by a control system described herein, and further the control system may control (e.g., provide control signals to) hardware components of the solids testing system 12 to facilitate the aspects described with reference to FIG. 4. The method 300 includes steps 301 to 313 as shown toPATENT Docket No. IS22.0296-WO-PCT conduct analysis of particles, such as LCM particles and / or cuttings. The steps 301 to 313 may be understood with reference to description herein, and further it should be appreciated that adjusting solid mud additives formulation in step 309 and / or optimizing surface equipment in step 313 may include automated actions (e.g., adjust equipment and / or operating parameters of the equipment automatically by a control system) and / or manual optimization (e.g., by a human operator). For example, the optimizing surface equipment may include adjusting operating parameters of centrifuges and / or selecting certain centrifuges based on the particular size distribution and / or other information obtained via carrying out the method 300.

[0044] It should be appreciated that the calibrated digital image may be processed with a segmenting algorithm to obtain segmented images. The segmenting algorithm may be configured, for example, to identify individual particles (e.g., cuttings particles and LCM particles) in the calibrated images. Via the segmenting algorithm, individual cuttings and LCM particles are identified and outlined in the imagery (although other methods of particle demarcation may be employed). Moreover, each identified particle may be identified by a corresponding set of pixels in the imagery. Stated another way the segmented image may include a pixel-by-pixel segmentation in which each pixel in the image is assigned to the background or to a single individual particle.

[0045] The segmented image may be processed to extract texture and / or color features from one or more of the identified particles in the segmented image. For example, the image may be evaluated particle by particle to extract the color and / or texture features thereof. The extracted color and / or texture features may be processed to identify (or distinguish) LCM particles from among the other non-LCM identified particles (such as cuttings particles). The extracted color and / or texture features may be further processed at to classify each of the identified LCM particles into one of a plurality of LCM classes to obtain an LCM classification of the image (and the drilling fluid). By classifying it may be meant that the identified LCM particles are distributed into groups having common features representative of individual types of LCM particle (e.g., nut plugs, calcite, cellulose, petroleumPATENT Docket No. IS22.0296-WO-PCT coke, polymeric beads). Further, the cuttings may also be classified and / or analyzed.

[0046] A summary may include, for example, particle size distribution (PSD) per solid type, estimate of volume per solids type per volume of drilling fluid, and so forth. At least some steps of the method 300 performed automatically without human intervention. The method 300 may further optionally include adjusting the LCM composition of the fluid based on the consolidated summary, for example, by adding additional LCM to the drilling fluid prior to recirculating the fluid downhole.

[0047] In example embodiments, the segmenting algorithm may employ a Mask Region-Based Convolutional Neural Network (Mask R-CNN) such as disclosed in U.S. Patent Application Ser. No. 17 / 647,407, which is hereby incorporated by reference in its entirety for all purposes. The Mask R-CNN may be configured to identify various objects (such as individual cuttings and solid additive particles) in the digital images and thereby generate the segmented image. The Mask R-CNN may produce, for example, bounding boxes and mask images. The bounding boxes may be defined as a set of x-y coordinates in an image that indicates an image region that contains an object of interest. The bounding box may include a confidence score that ranges from 0 to 1 (e.g., with greater values indicating higher confidence regarding) for each object of interest. The mask image may indicate (e.g., highlight or otherwise bound) regions of interest that have a confidence score that exceeds a threshold.

[0048] It will be appreciated that Mask R-CNN is a model architecture that falls in the supervised learning category, meaning that it utilizes a training dataset that consists of images and corresponding labels. For example, the Mask R-CNN model may be trained using images containing solid additive particles of various sizes, shapes, colors, and types. The Mask R-CNN model may be further trained with images containing rock cuttings of various sizes, shapes, colors, and types (lithologies). Model training may also include using training images containing both LCM and rock cuttings. It will be further appreciated that the Mask R-CNN model may be continuously, periodically, responsively, and / or dynamically retrainedPATENT Docket No. IS22.0296-WO-PCT during a drilling operation. For example, segmentation errors may be identified and corrected and then used to generate labeled training images that may be used to retrain (or further train) the Mask R-CNN model.

[0049] FIG.5 depicts a block diagram of the solids testing system 12 of FIG.1 that may be utilized to characterize the LCM and the cuttings in the drilling fluid, in accordance with an embodiment of the present disclosure. Certain aspects of FIG. 5 (e.g., certain modules of FIG. 5) may be implemented by a control system described herein, and further the control system may control (e.g., provide control signals to) hardware components of the solids testing system 12 to facilitate the aspects described with reference to FIG.5.

[0050] The solids testing system 12 includes the one or more imaging devices 401 configured to take one or more calibrated digital images of solid particles. The solids testing system 12 may further include a segmenting module 402 configured to process a calibrated digital image to obtain a segmented image including segmented LCM particles and cuttings. An identification module is configured to identify and classify particles in a segmented image. The identification module may be configured, for example, to extract color and / or texture features from the segmented image to distinguish LCM particles from cuttings particles and to optionally further classify the LCM particles and / or cuttings into distinct groups (e.g., to distinguish a first type or kind of LCM particle from a second type or kind of LCM particle and cuttings).

[0051] The identification module may include a color and texture feature extraction module 403 and a geometry feature extraction module 404 that may be configured to extract and evaluate color related features, texture related features, and / or shape and / or size related features of each of the individual particles. The color and texture feature extraction module 403 may be configured, for example, to extract average (such as mean, median, or mode) red, green, and blue intensities or distributions of or standard deviations of red, green, and blue intensities, and / or an average luminance of each particle. The color and texture feature extraction module 403 may be further configured to extract aPATENT Docket No. IS22.0296-WO-PCT histogram, a variance, a skewness, and / or a kurtosis of the red, green, and blue intensities. Moreover, for infrared and / or ultraviolet images, the color related features may include average (such as mean, median, or mode) infrared and / or ultraviolet intensities or distributions of or standard deviations of infrared and / or ultraviolet intensities and / or an average infrared or ultraviolet luminance of each particle. The color related features may further include a histogram, a variance, a skewness, and / or a kurtosis of the infrared and / or ultraviolet intensities. The extracted color features may be evaluated by a color measurement module at 409 to provide a description or classification of the particle color.

[0052] The color and texture feature extraction module 403 may be further configured, for example, to extract texture related features that quantify spatial relationships and / or directional changes in pixel color and / or brightness in each particle. Extracted texture related features may include, for example, edge detection, pixel to pixel contrast, correlation, and / or entropy. In addition, in certain embodiments, texture related features may be extracted with techniques such as image texture filters (e.g., Gabor filters, and so forth), an autoencoder, and / or other deep learning based techniques. Moreover, directional changes may be evaluated, for example, for symmetry and used to generate spectra that may be further compared with reference spectra to assign a texture classification to each particle via texture classification module 408, which may be configured to classify each particle as homogeneous, heterogeneous, grainy, laminate, etc.

[0053] The geometry feature extraction module 404 may be configured, for example, to extract shape and / or size related features of each particle. The shape and size related features may include, for example, a particle diameter, an area, a perimeter, a maximum axis, a minimum axis, a particle aspect ratio, and / or an internal angle measurements. Moreover, the geometry feature extraction module 404 may be configured to evaluate spatial relationships of the pixels grouped in each particle to extract particle circularity, solidity, elongation, roundness, and / or convex hull area. A geometry classification module 411 may be configured to evaluate the shape and size related features and to further classify the individual particles. For example, individual particles may be classified as beingPATENT Docket No. IS22.0296-WO-PCT a plate, a fiber, circular or oval particulate, sharp angled particulate, etc. as well as being classified in one of various size bins (e.g., based on the diameter, cross sectional area, and / or perimeter of the particle).

[0054] An additive and cuttings classification module 406 may be configured to evaluate the extracted color and / or texture features to distinguish between LCM particles and cuttings particles and to further classify the LCM particles and cuttings according to particle type or kind. For example, the LCM particles may be classified as flake (such as shredded paper, mica, etc.), general particulates (such as nut plugs, calcite, etc.), fibrous (such as cellulose, nylon, etc.), dark particulates (such as petroleum coke, lignosulphonates, etc.), and / or UV reactive (such as polymeric beads, calcite, etc.). Particles identified as cuttings may be labeled as such and optionally identified (e.g., lithography).

[0055] It will be appreciated that the classification module 406 may include a trained machine learning algorithm or any other deep learning algorithm. The classification module 406 may be trained using extracted color and / or texture features of different LCM particle types and / or cuttings (obtained from segmented images as described above). The classification module 406 may make use of a database 405 (e.g., image database, including visible, infrared, and / or ultraviolet images). Such a database may be maintained on-site (e.g., at the rig location) or off-site (e.g., at an off-site processing center or other location).

[0056] The LCM particles may be identified by the classification module 406, for example, according to a location of the particle in a multi-dimensional space of extracted color and texture features. For example, as described above, a set of color and texture features may be computed (e.g., for each of the selected cuttings and / or LCM particles). The set of computed color and texture features may include a large number of features, for example, including at least 16 features (e.g., at least 32, 48, 64, 80, 96, 112, or 128 color and texture features).

[0057] The particle may then be classified according to values of those features, for example, that cause like particles to cluster in the aforementioned multi- dimensional feature space. The particle may alternatively (and / or additionally) bePATENT Docket No. IS22.0296-WO-PCT classified based on a nearest neighbor classification of the particle in the multi- dimensional space of extracted color and texture features. In example embodiments a classification (e.g., LCM particle type) of each of the particles may be assigned based on the clustering. In such an embodiment, groups of particles located in the same cluster (or local region of the hyperspace) may be assigned the same classification. In still further example embodiments, the particle may be classified using a neural network (NN) that is trained based on a set of extracted color and texture features. One example classification methodology is described in more detail herein by way of example for a simplified two-dimensional feature space. It will be appreciated that in practice the classification generally makes use of a larger number of extracted color and texture features (e.g., up to 16 or more features defining a multi-dimensional feature space).

[0058] It will be understood that from time to time, the classification module 406 may mislabel one or more segmented particles or fail to identify any appropriate category for a segmented particle. In such instances, the particle(s) may be further evaluated using a clustering and labeling module 407 that is configured, for example, to enable a human operator to manually label the particle(s). The re-labeled image (including the labeled particles) may then be used to further train (or retrain) the classification module 406.

[0059] A characterization module 410 may be configured to receive the classification and to summarize the makeup of the LCM and / or cuttings in the drilling fluid. For example, the characterization module 410 may be configured to output the relative amounts of each type of LCM in the drilling fluid (e.g., a first percentage of a first LCM type and a second percentage of a second LCM type, as well as cuttings including cuttings lithotypes). The characterization module 410 may be further configured to process the texture classification, the color classification, and / or the shape and size classification to further describe and summarize the features of each of the classified types. In such embodiments, the characterization module 410 may provide a listing of the relative amounts of each type of LCM in the drilling fluid along with an average and distribution of color and / or texture features of each LCM type. The characterization module 410 mayPATENT Docket No. IS22.0296-WO-PCT be further configured to compare the average and distribution of features of each LCM type with corresponding known features of the LCM prior to use in the drilling operation. In this way degradation (or change) of the LCM may be automatically monitored and / or output by the system 10 while drilling. In certain embodiments, the system 10 may be configured to provide control signals to automatically change (e.g., modify) the drilling fluid, such as by controlling valves that adjust flow of certain LCM particles into the drilling fluid (e.g., to increase the LCM particles to reach or maintain a target level; in response to and / or based on the degradation of the LCM as identified by the system 10).

[0060] The characterization module 410 may be further configured to estimate a quantity of each type of particles in the drilling fluid. For example, the characterization module 410 may be configured to count the number of LCM particles and / or cuttings in the image and to compute the number of LCM particles and cuttings per unit volume of drilling fluid, for example, by dividing the number of particles in the image by a drilling fluid volume corresponding to the image. In example embodiments, the drilling fluid volume may be obtained by multiplying the drilling fluid flow rate by an elapsed time used to collect the particles in the image, or based on a known volume extracted and collected at the solids testing system 12.

[0061] In other example embodiments, the characterization module 410 may be configured to count the number of cuttings particles and the number of LCM particles in the image or to estimate the volume of cuttings particles and the volume of LCM particles in the image (e.g., from the diameter or cross sectional area of each of the cuttings and LCM particles). The characterization module 410 may be further configured to estimate the mass of cuttings particles and the mass of LCM particles in the image (e.g., from the estimated volumes and densities of the cuttings and LCM particles).

[0062] In certain embodiments, the characterization module 410 may be configured to estimate a number of LCM particles per unit volume of drilling fluid from the number of LCM particles in the image and the volume of cuttings in thePATENT Docket No. IS22.0296-WO-PCT image. For example, the number of LCM particles per unit volume of drilling fluid may be computed by dividing the number of LCM particles in the image by the volume of cuttings in the image and them multiplying by a ratio of volume rate of penetration of drilling (the rate of penetration of drilling times the cross-sectional area of the wellbore) to the drilling fluid flow rate as shown in the following equation: CLCM=NLCMVcuttings·VROPFlow (Equation 1)

[0063] where CLCM represents the number of LCM particles per unit volume of drilling fluid, NLCM represents the number of LCM particles in the image, Vcuttingsrepresents the volume of cuttings in the image, VROPrepresents the volume rate of penetration (the rate of penetration times the cross sectional area of the drill bit), and Flow represents the drilling fluid flow rate. As shown, a particle size distribution (PSD) per solid type may be determined at module 412 (e.g., per type of LCM and cuttings).

[0064] It should be appreciated that at least the large solids fractions, including LCM and cuttings, may be evaluated via processing module 400 of FIG.5. In some embodiments, the small solids fractions, including LCM and cuttings, may be evaluated via the processing module 400 of FIG.5 or in a similar manner. However, the small solids fractions may also be evaluated via another processing module and / or other process techniques. Processes and techniques set forth in FIGS.1-5 may be implemented via any of a variety of hardware components and systems, such as for example certain hardware components and systems described herein. While certain aspects are discussed with respect to large solids fraction in FIGS. 6-17, it should be appreciated that small solids fractions may be monitored as well (e.g., at any suitable time and via any suitable components in techniques, such as in parallel; in-line; simultaneously; sequentially).

[0065] FIG.6 is a front view of the system 10, which includes the solids testing system 12, in accordance with an embodiment of the present disclosure. As shown, the system 10 may include a frame 40 that supports various components of the solids testing system 12. For example, the frame 40 may support an enclosure 42 (e.g., container) of the solids testing system 12, and the enclosure 42 may enclosePATENT Docket No. IS22.0296-WO-PCT various other components of the solids testing system 12. In certain embodiments, the enclosure 42 encloses one or more fully enclosed and sealed interior chambers that house a screen, one or more imaging devices (e.g., cameras; optical sensors; image sensors), one or more light sources, and so forth. In operation, the enclosure 42 may be purged and pressurized via a flow of compressed air into the enclosure 42 to block ingress of other gases into the enclosure 42, which may enable introduction of sample fluid (e.g., drilling fluid) and / or other fluid (e.g., cleaning fluid) that may be flammable (e.g., capable of releasing flammable gases) into the one or more chambers within the enclosure 42. For example, pressure within the enclosure 42 may block ingress of the gases into the enclosure 42, which may block (e.g., prevent) arcing, sparking, and fire conditions within the enclosure 42 and enable use of various types of equipment within the enclosure 42 (e.g., solids testing equipment, electrically powered equipment).

[0066] As shown in FIG. 6, the system 10 may also include the fluid testing system 14. In some such cases, the frame 40 may also support various components of the fluid testing system 14, such as a respective enclosure that encloses a fluid container, a rheology sensor (e.g., viscometer), and so forth. However, it should be appreciated that the solids testing system 12 may be utilized without the fluid testing system 14 (e.g., the system 10 may be devoid of the fluid testing system 14; the solids testing system 12 and the fluid testing system 14 are supported on separate frames). As shown, the system 10 may include a control system 50, which may include a processor 52 and a memory device 54. Further, the control system 50 may include a display screen 56 (e.g., user interface), which may be supported on the frame 40 and / or be located remotely from the frame 40.

[0067] As shown, the system 10 may include a first source inlet 60 and a second source inlet 62. The first source inlet 60 may receive a first flow of a first fluid from a first source, and the second source inlet 62 may receive a second flow of a second fluid from a second source. In certain embodiments, the first fluid may include an active drilling fluid (e.g., prior to sending to a wellbore), and the second fluid may include a returned drilling fluid (e.g., after being returned from the wellbore). The system 10 is configured to route the first fluid and the second fluidPATENT Docket No. IS22.0296-WO-PCT (e.g., in an alternating manner) through a pump 64 (e.g., source pump) to a filter 66 (e.g., crossflow filter) that separates a filtrate from solids. The solids may exit the system 10 via a first source outlet 70 and a second source outlet 72 (e.g., to return to the first source and the second source, respectively).

[0068] Further, the system 10 is configured to route the first fluid and the second fluid (e.g., in an alternating manner) to the solids testing system 12. For example, various valves may be operated in coordination to direct a portion (e.g., a sample) of the drilling fluid (e.g., either the first fluid or the second fluid) to the solids testing system 12 (e.g., via the pump 64, upstream of the filter 66), and also to return the portion of the drilling fluid into circulation after completion of evaluation of the portion of the drilling fluid by the solids testing system 12 (e.g., upstream or downstream of the filter 66). As shown, the fluid testing system 14 may also be fluidly coupled to the first source inlet 60, the second source inlet 62 (e.g., via the pump 64 and the filter 66) to perform other tests (e.g., rheology tests) on the drilling fluid. In some such cases, the fluid testing system 14 may also return the drilling fluid to the first source and the second source.

[0069] FIG. 7 is a schematic diagram of the solids testing system 12, in accordance with an embodiment of the present disclosure. As shown, a first valve may control a flow of the drilling fluid (e.g., feed fluid) to a fluid manipulation device, such as a pump 80. For example, the pump 80 may pump or provide the drilling fluid to a separator 82 that includes a container 84 (e.g., housing) that supports a screen 86 (e.g., mesh filter or screen). The separator 82 may include or be operated with an agitator, such as a motor and / or an ultrasonic transducer, that moves or shakes the screen 86 relative to the container 84 to facilitate separation of solids and liquids in the drilling fluid by the screen 86, as well as to facilitate distribution of the solids across the screen 86.

[0070] In certain embodiments, the separator 82 may include or be operated with a washing system 88, such as a cleaning fluid source, a cleaning fluid pump, an air source, and an air applicator. Thus, the cleaning fluid (e.g., washing fluid; base fluid; oil or water) and / or air (e.g., compressed air) may be applied to (e.g.,PATENT Docket No. IS22.0296-WO-PCT sprayed onto) the drilling fluid on the screen 86 to facilitate the separation of the solids and the liquids in the drilling fluid. An additional cleaning stage may include a chemical solution, such as Iso-propyl alcohol, Xylene or Propylene glycol normal propyl ether (PnP), any other surfactants may be utilized, and / or application of heat (e.g., via heated air through spray bars or nozzles; application of heat lamps) to facilitate drying of the solids may also be employed. In certain embodiments, the drilling fluid may be diluted to reduce viscosity. The washing system 88 may utilize or include sprayer, spray bars, nozzles, centrifuges, ultrasonic baths, or any suitable features to facilitate washing the solids and separating the solids from the liquids. In certain embodiments, the separator 82 may include or be operated with a vacuum system 90 that applies vacuum pressure (e.g., suction) at a bottom side of the screen 86. In this way, the liquids may fall or move through openings in the screen 86 to a collection bin 92 (e.g., collection tray or container), while the solids may remain on a top side (e.g., top surface) of the screen 86.

[0071] The separator 82 may include or be operated with one or more imaging devices 94 (e.g., cameras) and one or more light sources 96 (e.g., ultra-violet (UV), infrared (IR), and / or white light sources). The one or more imaging devices 94 may capture imagery (e.g., images; still images and / or moving images, such as videos) of the solids on the top side of the screen 86, such as while the one or more light sources 96 emit light to illuminate the solids on the top side of the screen 86. The one or more imaging devices 94 may provide the imagery to the control system 50, which may analyze the imagery to identify the LCM particles and / or other solid particles depicted in the imagery.

[0072] After the solids testing system 12 obtains the imagery in this way, the solids may be directed or routed to the collection bin 92 (e.g., via motion of the screen 86). Then, the drilling fluid (e.g., the recombined solids and liquids in the collection bin 92) may be discharged via the pump 80, such as to return the drilling fluid to the first source outlet 70 or the second source outlet 72 of FIG.2.

[0073] FIG.8 is a perspective top view of a portion of the solids testing system 12 of FIG.1, including the screen 86 and one imaging device 94, in accordancePATENT Docket No. IS22.0296-WO-PCT with an embodiment of the present disclosure. As shown, the imaging device 94 is positioned relative to the screen 86, such that a field of view of the imaging device 94 includes the screen 86. In this way, the imaging device 94 may capture the imagery of the solids on the top side of the screen 86.

[0074] In certain embodiments, the imaging device 94 may be operated to capture the imagery over time (e.g., multiple still images over time; video images over time). In some such cases, the imaging device 94 may be operated in coordination with the agitator and / or an actuator (e.g., hydraulic, pneumatic, or electric actuator) that moves the screen 86, which moves the solids on the top side of the screen 86 in order to get true representation of the solids particle type and numbers In this way, the imaging device 94 may capture multiple images of the same solids located on the vibrating screen, but in between each image capture the vibrating screen is agitating to re-distribute the large solids on its surface. Thus, the control system 50 may analyze the imagery captured over time and with the solids in various positions to identify the solids with greater accuracy (e.g., as compared to imagery with the solid particles in only the first position or one position).

[0075] It is presently recognized that it may be desirable to capture the imagery in a manner that enables three-dimensional (3D) reconstruction of the solids on the top surface of the screen 86. In certain embodiments, the control system 50 may analyze the imagery captured over time and with the solids in various positions / angles to carry out the 3D reconstruction. Further, in some embodiments, the imaging device 94 may be movable relative to the screen 86 or vice-versa. For example, as shown in FIG.9, the imagery may include a set of images at various angles and enable application of the 3D reconstruction by photo-gravimetry, which would then allow determination of each particle (e.g., LCM, cuttings), as well as respective volumes, colors, and textures, for example.

[0076] FIG.10 is a perspective top view of a portion of the solids testing system 12 of FIG. 1, including the screen 86 and multiple imaging devices 94, in accordance with an embodiment of the present disclosure. As shown, each of thePATENT Docket No. IS22.0296-WO-PCT multiple imaging devices 94 is positioned relative to the screen 86, such that a respective field of view of each of the multiple imaging devices 94 includes the screen 86. In this way, the multiple imaging devices 94 may capture the imagery of the solids on the top side of the screen 86. The imagery captured by the multiple imaging devices 94 may be processed and combined via image processing techniques that provide such 3D reconstruction. The multiple imaging devices 94 may be positioned at different angles, and the multiple imaging devices 94 may include any suitable number (e.g., 2, 3, 4, or more) imaging devices 94.

[0077] FIG.11 is cross-sectional side view of the separator 82 and additional components that may be utilized in the solids testing system 12, in accordance with an embodiment of the present disclosure. The separator 82 may include the container 84 with a wall 1100 (e.g., annular wall) that defines an interior volume 1102. The container 84 may support the screen 86, the one or more imaging devices 94, the one or more light sources 96, one or more inlets 1104 (e.g., nozzles) for the washing system 88 (e.g., to provide the cleaning fluid and / or compressed air to the interior volume 1102). Further, the container 84 may include a vacuum port 1106 to fluidly couple to the vacuum system 90, as well as an inlet 1108 to receive the drilling fluid, and an outlet 110 to discharge the drilling fluid (e.g., to the collection bin 92 of FIG.3).

[0078] In FIG.11, the screen 86 may be rotatable relative to the container 84. For example, the screen 86 may be coupled (e.g., fixed) to a shaft 112 (e.g., pin). Further, an actuator 114 (e.g., hydraulic, pneumatic, or electric actuator) may be coupled to the shaft 112 and may be configured to drive rotation of the shaft 112 within the container 84. Accordingly, in this way, the actuator 114 is also configured to drive rotation of the screen 86 within the container 84, as shown by arrow 116. Thus, in operation, after the one or more imaging devices 94 captures the imagery of the solids as described herein, the control system 50 may instruct the actuator 114 to drive the rotation of the shaft 112 and the screen 86 within the container 84 (e.g., from a first, closed or level position to a second, open or tilted position; collection position to a discharge position), which causes the solids to fall from the screen 86 to the outlet 110 (e.g., via gravity). In certain embodiments, the washingPATENT Docket No. IS22.0296-WO-PCT system 88 may additionally provide the cleaning fluid and / or the compressed air toward the screen 86 while the screen 86 is rotated (e.g., opened; tilted) to facilitate release or discharge of the solids from the screen 86 to the outlet 110. In certain embodiments, additional imagery may be captured by the one or more imaging device 94 to confirm that the solids were successfully (e.g., completely) removed from the screen 86 prior to returning the screen 86 to the first level position and / or prior to completing a subsequent test for another sample of drilling fluid. If the additional imagery indicates that the solids were not successfully removed from the screen 86, the control system 50 may provide additional cleaning fluid and / or compressed air, rotate the screen 86 back and forth, vibrate the screen 86 via the agitator, or any of a variety of other techniques to dislodge and remove the solids from the screen 86.

[0079] In certain embodiments, the agitator is provided to move the screen 86 relative to the container 84 to facilitate the separation of the solids and the liquids. In FIG.6, the agitator is one or more ultrasonic transducers 122 coupled to the screen 86 (e.g., mounted on a screen frame of the screen 86). As shown, the separator 82 may include various structural features to facilitate construction operations, access for maintenance operations, and / or efficient testing operations. For example, the container 84 may include two parts, an upper part and a lower part that are clamped together via a clamp 118 (e.g., annular clamp). In this way, the upper part may be removed to enable inspection and / or maintenance of components within the container 84 (e.g., inspection, repair, and / or replacement of the screen 86). As another example, a seal element 120 (e.g., gasket; annular seal element) may be provided about the screen 86 to provide a seal (e.g., annular seal) between the screen 86 and the wall 1100 of the container 84. In this way, the solids may be retained or held on the top surface of the screen 86 while the screen 86 is in the first position, and further, such construction may enable the vacuum system 90 of FIG.3 to effectively apply vacuum pressure to facilitate the separation of the solids and the liquids in the drilling fluid. It should be appreciated that other features may be incorporated into the solids testing system 12 of FIG.11, such as one or more actuators to move the one or more imaging devices 94 relative to thePATENT Docket No. IS22.0296-WO-PCT container 84, such as to provide clearance for rotation of the screen 86 within the container 84 and / or to adjust a respective field of view and / or focus of the one or more imaging devices 94, for example.

[0080] FIG.11 is a schematic diagram of the solids testing system 12 of FIG.1 with the screen 86 positioned at a first chamber 150 of multiple chambers, in accordance with an embodiment of the present disclosure. As shown, the solids testing system 12 may include the multiple chambers, including the first chamber 150 that is configured to prepare the solids for analysis (e.g., wash the solids; separate the solids from the liquids in the drilling fluid) and a second chamber 152 that is configured to receive the screen 86 with the solids for analysis (e.g., to capture the imagery of the solids via the one or more imaging devices 95). As shown, a flow control system 154 may route volumes (e.g., known and / or specified volumes) of the drilling fluid, the cleaning fluid, and / or the compressed air into the first chamber 150. For example, the drilling fluid may be provided onto the screen 86 at the first chamber 150, and then the cleaning fluid may be applied to the wash the liquid away from the solids on the screen 86, and then the compressed air may be applied to force the liquid through the screen 86 to discharge the liquid. The liquid passing through is captured to be guided to an additional imaging device (e.g., second imagery system, with one or more imaging device).

[0081] In certain embodiments, the solids testing system 12 may implement a calibration plate 156 to facilitate calibration of the solids testing system 12. The calibration plate 156 may include a color and / or a pattern to facilitate calibration of the solids testing system 12 with respect to color and / or size (e.g., including texture). As shown in FIG.7, while the screen 86 is within the first chamber 150 (e.g., to prepare the solids on the screen 86), the calibration plate 156 may be in the second chamber 152 (e.g., to calibrate the solids testing system 12). Thus, the one or more imaging devices 94 that are supported by and / or located at the second chamber 152 may operate to capture calibration imagery of the calibration plate 156, and the control system 50 may utilize the calibration imagery as reference imagery to analyze the imagery of the solids and to identify the solids (e.g., the color, the size, the type, and so forth).PATENT Docket No. IS22.0296-WO-PCT

[0082] In certain embodiments, the screen 86 may be supported on a track 158, such that the screen 86 may move (e.g. slide) between the first chamber 150 and the second chamber 152. Further, in certain embodiments, the screen 86 and the calibration plate 156 may be coupled (e.g., fixed) to one another, such that the screen 86 and the calibration plate 156 move together along the track 158. Additionally, as shown, the solids testing system 12 may include a calibration plate cover 160, which may cover the calibration plate 156 at certain times, such as when the screen 86 is at the second chamber 152. In certain embodiments, the calibration plate cover 160 may provide a platform (e.g., mounting surface) to support other components of the solids testing system 12, such as hardware components of the control system 50. In this way, the solids testing system 12 may have a compact structure.

[0083] FIG.12 is a schematic diagram of the solids testing system 12 of FIG. 11 with the screen 86 positioned at the second chamber 152 of the multiple chambers, in accordance with an embodiment of the present disclosure. Once the solids are prepared on the screen 86 (e.g., the separation of the solids and the liquids is complete; adequately separated from the liquid for testing purposes) as shown and described with reference to FIG.11, the screen 86 may move from the first chamber 150 to the second chamber 152 as shown in FIG.8. In cases with the calibration plate 156 coupled to the screen 86, as shown, such movement of the screen 86 may also cause the calibration plate 156 to move to the calibration plate cover 160. However, as noted herein, the calibration plate 156 may not be coupled to the screen 86 and may instead be moved separately or in another manner.

[0084] With the screen 86 at the second chamber 152, the control system 50 may operate the one or more imaging device 94 and the one or more light sources 96 to capture imagery of the solids. For example, the control system 50 may instruct one of the one or more light sources 96 to emit light at a first wavelength (e.g., UV or IR light) and may instruct the one or more imaging devices 94 to capture the imagery of the solids while the solids are illuminated by the light at the first wavelength. Then, the control system 50 may instruct one of the one or morePATENT Docket No. IS22.0296-WO-PCT light sources 96 to emit light at a second wavelength (e.g., white light) and may instruct the one or more imaging devices 94 to capture the imagery of the solids while the solids are illuminated by the light at the second wavelength. As noted herein, the control system 50 may also instruct the agitator to move the screen 86, such as to shift the particles in the solids to enable the one or more imaging devices 94 to capture the imagery with the particles in the solids at multiple different positions. Additionally or alternatively, the one or more imaging devices 94 may capture the imagery in a manner that enables the control system 50 to perform 3D reconstruction techniques to facilitate analysis of the particles in the solids.

[0085] As shown in FIG. 12, a transparent cover 162 (e.g., glass) may be positioned between the screen 86 and the one or more imaging devices 94 and / or between the screen 86 and the one or more light sources 96. The transparent cover 162 may protect the one or more imaging devices 94 and / or the one or more imaging devices 94 from debris (e.g., dust) and / or may provide separation from flammable fluids (e.g., the drilling fluid; the cleaning fluid).

[0086] FIG.13 is a schematic diagram of the solids testing system 12 of FIG. 11 with the screen 86 rotated to a discharge position, in accordance with an embodiment of the present disclosure. Once the one or more imaging devices 94 capture the imagery of the solids on the screen 86, the screen 86 may move from the second chamber 152 to the first chamber 150. In cases in which the calibration plate 156 is coupled to the screen 86, such movement of the screen 86 may also cause the calibration plate 156 to move to the second chamber 152. Thus, the solids testing system 12 may be calibrated (e.g., re-calibrated) prior to testing another sample of the drilling fluid. However, as noted herein, the calibration plate 156 may not be coupled to the screen 86 and may instead be moved separately or in another manner.

[0087] When the screen 86 reaches the first chamber 150, an actuator (e.g., hydraulic, pneumatic, or electric actuator) may drive the screen 86 to move from a first, level position to a second, discharge position, as shown in FIG. 13. For example, the actuator may drive the screen 86 to rotate to reach the second,PATENT Docket No. IS22.0296-WO-PCT discharge position to cause the solids to fall from the screen 86 (e.g., via gravity). In certain embodiments, the solids testing system 12 may additionally provide the cleaning fluid and / or the compressed air toward the screen 86 while the screen 86 is in the second, discharge position to facilitate release or discharge of the solids from the screen 86.

[0088] As shown, the system 10 and / or the solids testing system 12 may include the control system 50 with the processor 52 and the memory device 54. The control system 50 may provide control signals and analysis operations to carry out the techniques described herein, including to control movement of components (e.g., the screen 86), control operation of components (e.g., the actuator 114 and / or other actuators, the one or more imaging devices 94, the one or more light sources 96), and / or to analyze the imagery captured by the one or more imaging devices 94. For example, the control system 50 may receive signals (e.g., imagery from the one or more imaging devices 94; operator inputs), and the control system 50 may also provide control signals to control operation of components (e.g., the actuator 114 and / or other actuators, the one or more imaging devices 94, the one or more light sources 96, as well as to various pumps, valves, sensors, displays).

[0089] The processor 52 may be processing circuitry that includes one or more processors configured to execute software, such as software for processing the signals and / or the inputs, and / or generating the control signals to control operation of the components of the system 10 and / or the solids testing system 12. The memory device 54 may include one or more memory devices (e.g., a volatile memory, such as random access memory [RAM], and / or a nonvolatile memory, such as read-only memory [ROM]) that may store a variety of information (e.g., imagery; test and / or cleaning protocols) and may be used for various purposes. For example, the memory device 54 may store processor-executable instructions (e.g., firmware or software) for the processor 52 to execute, such as instructions for processing the signals and / or the inputs, and / or generating the control signals to control operation of the components of the system 10 and / or the solids testing system 12. The control system 50 may also include other components, such as a communication device to transmit signals (e.g., data, information, control signals)PATENT Docket No. IS22.0296-WO-PCT via wireless and / or wired protocols. Further, the control system 50 may also include or be coupled to an output device (e.g., display and / or speaker) to provide information for visualization by the operator, provide audible alarms, and so forth. The control system 50 may be local (e.g., on-board) a structure of the system 10 and / or the solids testing system 12. In certain embodiments, the control system 50 may be a distributed controller with portions in various locations (e.g., local, remote, cloud).

[0090] FIG. 14 is a schematic diagram of the multiple chambers and the additional components of FIG.11, wherein an additional imagery system 1000 is provided to monitor a small solid fraction, in accordance with an embodiment of the present disclosure. For example, liquid with the small solid fraction may pass through the screen 86, and a volume (e.g., known, defined volume) of the liquid with the small solid fraction may be separated (e.g., collected). In some embodiments, the volume of the liquid with the small solid fraction may be diluted (e.g., by a dilution system, such as with a base fluid) to facilitate image capture and analysis of the small solid fraction.

[0091] FIGS.15A and 15B (collectively FIG.15) depict first and second cross plots that distinguish cuttings particles from LCM particles, in accordance with an embodiment of the present disclosure. It should be appreciated that the cross plots are shown to facilitate discussion but, as with all figures herein, may not represent elements (e.g., particles) to scale (e.g., size) and / or with all features (e.g., differentiating features, such as size, texture, color, shape, and so forth). The cross plots were generated from the segmented image, which was generated from an image obtained from a sample including 12.5 weight percent LCM particles mixed with shale-like cuttings particles. As described above, the segmented image (4B) was obtained using a Mask R-CNN segmenting algorithm. The segmented image was evaluated to extract distinct color and texture features, thereby defining a 64- dimension feature space. The disclosed embodiments are, of course, not limited in this regard and may extract more or less include more or less color and texture features (e.g., 16, 24, 32, 48, 80, 96, 112, 128, and the like). The cross plot depicted on FIG.13A depicts a plot of mean particle blue intensity versus meanPATENT Docket No. IS22.0296-WO-PCT particle red intensity. Note that the cuttings particles 1510 are clearly distinguishable from the LCM particles 1520 indicating that in this example the cuttings particles and LCM particles can be distinguished solely from color related features. The cross plot depicted on FIG.13B was obtained by compressing the 64 distinct color and texture features to a two-dimensional cross plot (in which each dimension was related to both color and texture features) using t-distributed Stochastic Neighbor Embedding (t-SNE) to illustrate that the cuttings particles and LCM particles may be distinguished in a multi-dimensional color and texture feature space. Note that the LCM particles are clearly distinguished from the cuttings particles as indicated collectively at 1510 and 1520.

[0092] FIGS.16A and 16B (collectively FIG.16) depict another example segmented image (16A) and corresponding two-dimensional cross plot (16B) distinguishing cuttings particles 1510, from first and second LCM particles 1520 and 1530, in accordance with an embodiment of the present disclosure. It should be appreciated that the segmented image and corresponding two-dimensional cross plot are shown to facilitate discussion but, as with all figures herein, may not represent elements (e.g., particles) to scale (e.g., size) and / or with all features (e.g., differentiating features, such as size, texture, color, shape, and so forth). The original image (not shown) includes 12.5 weight percent first LCM particles and 12.5 weight percent petroleum coke second LCM particles mixed with shale-like cuttings particles. The segmented image (14A) was obtained using the Mask R-CNN segmenting algorithm described above. The segmented image was evaluated to extract distinct color and texture features, thereby defining a 64- dimension feature space. The disclosed embodiments are, of course, not limited in this regard and may extract more or less color and texture features as noted above. In the example embodiment depicted, the 64 distinct color and texture features were compressed to a two dimensional cross plot (in which each dimension was related to color and texture features) using t-distributed Stochastic Neighbor Embedding (t-SNE) to illustrate that the cuttings particles, the first LCM particles, and the second LCM particles may be distinguished in a multi- dimensional color and texture feature space. Note that the LCM particles arePATENT Docket No. IS22.0296-WO-PCT clearly distinguished from the cuttings particles as indicated collectively at 1510, 1520, and 1530. While this example includes both cuttings particles and LCM particles, it will be appreciated that the same methodology may be applied to samples including only LCM particles and that different LCM particles may be distinguished and characterized whether or not the samples (and images) including cuttings particles.

[0093] FIG. 17 depicts a segmented image 1700 and corresponding two- dimensional cross plot 1702 distinguishing cuttings particles from first and second additives and particle size distribution (PSD) outputs 1704, in accordance with an embodiment of the present disclosure.

[0094] The techniques disclosed herein enable efficient solids testing, including identification of concentration, type, size, and other characteristics of LCM and / or cuttings in drilling fluid. The techniques provide automatic extraction and washing of the drilling fluid to prepare the solids for image capture, and also utilize various image processing to analyze (e.g., via an artificial intelligence (AI) predictive model) imagery of the solids to carry out the identification of the concentration, type, size, and other characteristics of LCM and / or cuttings in drilling fluid. The image processing is capable of distinguishing the LCM from the cuttings. Accordingly, the techniques use an algorithm to automatically recognize or identify, based on the color and texture of each particle in the solids, the nature of each particle (e.g., lithotype for the cuttings; type and / or nature of LCM additives, such as graphitic, cellulosic, polymeric, fibers). Then, the techniques may also determine a particle size distribution (PSD), size, and / or shape, per type.

[0095] One end goal is to calculate / estimate volume and / or weight of each particle type per volume of drilling fluid, which corresponds to concentration. Knowing respective concentrations and nature during the drilling process may be utilized to maintain optimal drilling fluid performances. The information about the solids may be utilized to adjust content of the drilling fluid, such as to add more LCM and / or to dilute the LCM in the drilling fluid (e.g., to maintain or reach target quantities or concentrations; add more particular LCM if quantity is lower in returnPATENT Docket No. IS22.0296-WO-PCT drilling fluid; reduce a particular LCM is quantity is in excess in return drilling fluid). Further, the information about the solids may be utilized to minimize differences between active drilling fluid and return drilling fluid (e.g., adjust the content of the drilling fluid accordingly).

[0096] Further, information about the solids obtained via the techniques may be stored in a log (e.g., well log; database; surface logging computers) and may be utilized to generate information about the drilling fluid over time and the wellbore over time (e.g., at different depths). For example, the information about the LCM may be stored in a log for the drilling fluid, while the information about the cuttings may be added to a log for the wellbore (in combination with any information about the large cuttings filtered out of the drilling fluid by the shale shaker upstream of the solids testing system 12; lithotype of the cuttings is determined and utilized to complete a geological log based on the cuttings). Further, it should be appreciated that the control system 50 may account for recycling of the LCM and the cuttings (e.g., the LCM and the cuttings circulate with the drilling fluid, and thus same particles will be detected in multiple samples of the drilling fluid over time) when updating logs and / or combining data over time. In some embodiments, the solids testing system 12 may run multiple containers and multiple solids tests (e.g., as disclosed herein) in parallel to provide additional information across depths of the wellbore (e.g., multiple measurements, each corresponding to respective depth of the wellbore), and thus, a more complete well log (e.g., higher resolution; every 10 meters of the wellbore).

[0097] The solids testing system 12 operates to automatically collect a sample of the drilling fluid, and particularly a specific volume (e.g., target volume) to extract the solid contained in it. The specific volume of the sample of the drilling fluid may be any suitable volume, such as between 0.02 to 2 liters, or 0.05 to 1.5 liters, 0.08 to 1.25 liters, or less than or equal to about 1, 1.25, 1.5, or 2 liters. The specific volume may be dynamically modified (e.g., calculated and / or adjusted by the control system 50), such as based on a number of particles observed in imagery. For example, if a low number of particles is observed in imagery, then a next sample may be taken with a higher volume to provide more particles on the screenPATENT Docket No. IS22.0296-WO-PCT 86 for analysis. Similarly, if a high number of particles is observed in imagery, then a next sample may be taken with a lower volume to provide fewer particles for analysis and block overcrowding of the screen 86. From this solid / liquid extraction, the solids testing system 12 separate, cleans, and / or dries the solids to prepare the solids to be recorded in imagery (e.g., while the solids are illuminated with white light, UV and / or IR light). Further, the imagery may be captured while the screen 86 and the solids thereon are stationary and / or while the agitator moves the screen 86 and the solids thereon. From this imagery, multiple information is extracted, especially the type / nature of the solids contained in the drilling fluid (e.g., the solids are either solid materials drilling fluid additives or / and cuttings), then the solids testing system 12 may count the number of particulates per size for the specific volume of the drilling fluid. From this measurement, the solids testing system 12 may derive a volume or / and weight of solids to provide a concentration, and other measurements and / or information (e.g., rank by size and / or shape; particle size distribution (PSD) by type).

[0098] While the disclosure may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the following appended claims. Any features shown in FIGS.1-17 or described with reference to FIGS.1-17 may be combined in any suitable manner. For example, large solids fractions, small solids fractions, and well logging techniques may be combined in any suitable manner, and any of a variety of hardware components may be utilized or combined to carry out techniques disclosed herein.

[0099] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for (perform)ingPATENT Docket No. IS22.0296-WO-PCT (a function)…” or “step for (perform)ing (a function)…”, it is intended that such elements are to be interpreted under 35 U.S.C.112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C.112(f).

Claims

PATENT Docket No. IS22.0296-WO-PCT CLAIMS 1. A solids testing system, comprising: a solids / liquid separator, comprising: a container; and a screen; an imaging device; and a controller configured to: control the solids / liquid separator to facilitate separation of a large solids fraction from a first fluid flow; control the imaging device to capture imagery of the large solids fraction remaining on a first side of the screen after the separation of the large solids fraction from the first fluid flow; and analyze the imagery to identify one or more characteristics of the large solids fraction remaining on the first side of the screen after the separation of the large solids from the first fluid flow.

2. The solids testing system of claim 1, wherein the screen enables a small solids fraction contained in the first fluid flow to pass through the screen to a second side of the screen, and the controller is configured to: control an additional imaging device to capture additional imagery of the small solids fraction on the second side of the screen; and analyze the imagery to identify one or more additional characteristics of the small solids fraction on the second side of the screen.

3. The solids testing system of claim 2, comprising: a first valve configured to adjust from a respective closed configuration to a respective open configuration to enable the first fluid flow from a first source onto the screen;PATENT Docket No. IS22.0296-WO-PCT a second valve configured to adjust from a respective closed configuration to a respective open configuration to enable a second fluid flow from a second source onto the screen; a third valve configured to enable, on the second side of the screen, capture of a defined portion of the first fluid flow that contains the small solids fraction; and a fourth valve configured to operate to enable, on the second side of the screen, dilution of the defined portion of the first fluid flow that contains the small solids fraction.

4. The solids testing system of claim 3, wherein the first fluid flow is routed to the screen prior to being provided to a wellbore, and the second fluid flow is routed to the screen after returning from the wellbore.

5. The solids testing system of claim 2, comprising a washing system, a dilution system, a vacuum system, and the additional imaging device, and wherein the controller comprises a valves controller.

6. The solids testing system of claim 2, wherein the controller is configured to log the one or more characteristics of the large solids fraction, the one or more additional characteristics of the small solids fraction, or both in a well log.

7. The solids testing system of claim 2, wherein the large solids fraction, the small solids fraction, or both, comprise lost circulation materials, wellbore strengthening materials, drilled cuttings, or any combination thereof.

8. The solids testing system of claim 7, wherein the controller is configured to: analyze the one or more characteristics of the drilled cuttings;PATENT Docket No. IS22.0296-WO-PCT analyze one or more further characteristics of additional drilled cuttings separated via a shale shaker positioned between a wellbore and the solids testing system; and generate a wellbore map based on the one or more characteristics of the cuttings and the one or more further characteristics of the additional drilled cuttings.

9. The solids testing system of claim 8, wherein the controller is configured to generate the wellbore map based on a recycling process of the first fluid flow with the large solids fraction, the small solids fraction, or both.

10. The solids testing system of claim 2, wherein the controller is configured to control the additional imaging device to capture the additional imagery of a defined volume of the first fluid flow that contains the small solids fraction on the second side of the screen.

11. The solids testing system of claim 10, comprising a dilution system configured to adjust conditions to facilitate the capture of the additional imagery of the small solids fraction.

12. The solids testing system of claim 11, comprising a transparent flow cell to facilitate digital image analysis of the small solids fraction in the defined volume of the first fluid flow.

13. The solids testing system of claim 11, wherein the dilution system is configured to circulate the defined volume of the first fluid flow relative to the additional image device to facilitate the capture of the additional imagery of the small solids fraction.PATENT Docket No. IS22.0296-WO-PCT 14. The solids testing system of claim 1, wherein the one or more characteristics comprise a particle size, a type, a concentration, or any combination thereof.

15. The solids testing system of claim 1, comprising a vibration device to vibrate the screen to facilitate the separation of the large solids fraction from the first fluid flow.

16. The solids testing system of claim 1, wherein the container comprises a housing, and the screen is rotatable within the housing.

17. The solids testing system of claim 1, comprising a washing system configured to deliver a cleaning fluid, compressed air, or both to facilitate the separation of the large solids fraction from the first fluid flow.

18. The solids testing system of claim 1, comprising a vacuum system configured to apply vacuum pressure on the second side of the screen to facilitate the separation of the large solids fraction from the first fluid flow.

19. The solids testing system of claim 1, comprising a collection bin to collect the large solids fraction for return to a first source.

20. The solids testing system of claim 1, wherein the controller is configured to generate three-dimensional (3D) images of the large solids fraction based on the imagery.

21. The solids testing system of claim 1, wherein the controller is configured to perform a calibration based on color, particle size, or both.

22. The solids testing system of claim 1, wherein the large solids fraction comprises a particle size of less than 5 millimeters.PATENT Docket No. IS22.0296-WO-PCT 23. The solids testing system of claim 1, comprising an additional container, wherein the container is configured to receive the first fluid flow and a cleaning fluid to facilitate the separation of the large solids fraction from the first fluid flow, and the additional container supports the imaging device and a light source to facilitate capturing the imagery of the large solids fraction.

24. The solids testing system of claim 23, wherein the screen is configured to slide along a track between the container and the additional container.

25. The solids testing system of claim 23, wherein the screen is coupled to a calibration plate, such that while the screen is positioned at the container, the calibration plate is positioned at the additional container.

26. The solids testing system of claim 23, comprising a calibration plate cover adjacent to the additional container, such that while the screen is positioned at the additional container, the calibration plate is positioned at the calibration plate cover.

27. A method, comprising: controlling, using one or more processors, a solids / liquid separator to facilitate separation of a large solids fraction from a first fluid flow; controlling, using the one or more processors, an imaging device to capture imagery of the large solids fraction remaining on a first side of a screen after the separation of the large solids fraction from the first fluid flow; and analyzing, using the one or more processors, the imagery to identify one or more characteristics of the large solids fraction remaining on the first side of the screen after the separation of the large solids from the first fluid flow.

28. The method claim 27, comprising: controlling, using the one or more processors, an additional imaging device to capture additional imagery of a small solids fraction contained in a part ofPATENT Docket No. IS22.0296-WO-PCT the first fluid flow that passes through the screen to a second side of the screen; and analyzing, using the one or more processors, the additional imagery to identify one or more respective characteristics of the small solids fraction contained in the part of the first fluid flow that passes through the screen to the second side of the screen.

29. A system, comprising: a processing system comprising one or more processors; and memory storing instructions that, when executed by the processing system, cause the processing system to perform operations comprising: analyze imagery to identify one or more characteristics of a large solids fraction supported on a screen after separation of the large solids fraction from a drilling fluid by the screen; analyze additional imagery to identify one or more additional characteristics of a small solids fraction retained within the drilling fluid through the screen; and log the one or more characteristics of the large solids fraction and the one or more additional characteristics of the small solids fraction in a well log.

30. The system of claim 29, wherein the one or more characteristics and the one or more additional characteristics comprise particle type.

Images