Adjustable Weir for Drilling Fluid Flow Control
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Solution Overview
Problem
Current separators in the oilfield industry face challenges in achieving increased fluid capacity, flow-through rates, and efficient fluid removal, with a need for better control over fluid flow rates and volumes during the separation of solids from drilling mud.
Innovation Solution
The system incorporates an adjustable weir within the feeder of the separator, which can alter its height and profile to control the flow rate and speed of drilling fluid as it enters the separator, utilizing a distribution manifold and various flow control mechanisms to optimize fluid processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the fluid flow rate into the separator is increased to improve productivity, then the separation efficiency may deteriorate due to excessive fluid volume overwhelming the separator capacity
Solution Approach 1:
The patent applies dynamics by making the weir height adjustable rather than fixed. The adjustment mechanism allows the weir to be dynamically repositioned to different heights along the separator screen, enabling operators to optimize fluid flow control based on varying operational conditions. This dynamic adjustment resolves the contradiction by allowing the system to adapt between high productivity modes (higher weir height for greater flow) and high efficiency modes (lower weir height for better separation).
Solution Approach 2:
The patent implements parameter changes by modifying the weir height parameter to control fluid flow characteristics. By changing this geometric parameter, the system can regulate the volume and velocity of fluid entering the separator, thereby maintaining optimal separation efficiency across different productivity levels. The adjustable weir transforms a static parameter into a controllable variable that directly influences both flow rate and separation quality.
2Quantity of substance
If the weir height is increased to allow greater fluid capacity, then the flow control precision deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the weir structure into multiple discrete height levels or segments along the separator. Rather than a single monolithic weir, the system incorporates several adjustable elements at different positions, each capable of independent adjustment. This segmentation enables precise control over fluid flow at various stages of the separation process, maintaining flow control precision even as overall fluid capacity increases through multiple parallel flow paths.
3Productivity
If the fluid flow velocity is increased to improve throughput, then the wear on separator screens increases
Solution Approach 1:
The patent implements preliminary action by using the adjustable weir to pre-regulate fluid velocity before the fluid reaches the separator screens. By controlling the weir height upstream, the system can moderate the flow velocity to prevent excessive wear on the screens, while still maintaining high throughput through optimized flow distribution. This preliminary velocity control protects the screens from high-velocity impact that would otherwise reduce their operational life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances fluid flow management, allowing for improved separation efficiency, increased fluid capacity, and optimized fluid removal, while minimizing wear on separator screens and extending their operational life.
Implementation Method 1
The system incorporates an adjustable weir within the feeder of the separator, which can alter its height and profile to control the flow rate and speed of drilling fluid as it enters the separator, utilizing a distribution manifold and various flow control mechanisms to optimize fluid processing.
Implementation Method 2
The separating screens are vibrated while the mixture of particles and/or fluids is deposited on an input end of the separator. The vibration improves separation and conveys the remaining particles to a discharge end of the separating screen.
Data Source
AI summary
A system, an apparatus and a method for adjusting a weir control the rate and/or speed at which drilling fluid feeds a separator. Multiple separators are typically used in parallel to process fluid returning from the well. A distribution manifold directs fluid to each separator. The weir is positioned within a feeder on an inlet end of the separator and connects to an attachment plate within the feeder. The distribution manifold or other flow control mechanism operates in combination with the weir. Adjustment apparatuses control the height of the weir to determine the rate the fluid flows onto the separator. The adjustment apparatuses provide mechanical and/or automated operation of the weir. Various profiles of the weir and adjustments of the height of the weir within the feeder increase and/or decrease the speed of the fluid as the fluid spills into the separator.