Coordinated Drilling Fluid Recycling System
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Solution Overview
Problem
Existing drilling fluid recycling systems suffer from suboptimal performance due to the lack of coordinated operation between multiple separation units, leading to inefficiencies in separation efficiency, power consumption, and equipment reliability, primarily because of proprietary technologies that limit integrated management and optimization.
Innovation Solution
A system and method for coordinating the operation of multiple separation units through a user interface module that monitors performance values, adjusts operating parameters, and automates the operation of shakers, desanders, desilters, and centrifuges, enabling situational optimization and improved maintenance scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separation units are combined together with feed tanks, overflow containers, retention pits, augers, pumps, and valves to regulate fluid flow rates, then the system can handle drilling fluid recycling, but the proprietary technology of the various units presents barriers to coordinated operation and limits overall system performance
Solution Approach 1:
The patent combines multiple independently manufactured separation units (shakers, de-sanders, desilters, centrifuges) into a single coordinated system. By integrating these units with common infrastructure (feed tanks, pumps, valves) and implementing unified control software, the system achieves coordinated operation that improves reliability while managing the inherent complexity through modular architecture.
Solution Approach 2:
The control system serves multiple functions: it monitors performance of individual units, coordinates operation across all separation units, optimizes fluid flow rates, and manages maintenance scheduling. This multi-functional control approach allows a single system to address various operational requirements without requiring separate proprietary control systems for each unit.
2Productivity
If multiple separation units are operated independently with proprietary software, then each unit can be optimized by its manufacturer, but the overall system performance is limited due to lack of coordination
Solution Approach 1:
The control system continuously monitors performance metrics from each separation unit and uses this feedback to coordinate their operation. By analyzing real-time data on separation efficiency and power consumption, the system adjusts operating parameters to optimize overall productivity while minimizing energy loss, achieving better performance than independent operation could provide.
Solution Approach 2:
The system dynamically adjusts the operation of each separation unit based on changing drilling conditions and performance requirements. Rather than static independent operation, the coordinated system can adapt flow rates, activation sequences, and operational parameters in real-time to maximize separation efficiency while minimizing power consumption across the entire system.
3Adaptability or versatility
If units are selected and assembled for static operation in a wide variety of conditions, then the system can adapt to different drilling scenarios, but the overall performance is necessarily limited
Solution Approach 1:
The system transitions from static pre-configured operation to dynamic coordinated control. The control software enables real-time adjustment of operational parameters and coordination strategies based on actual drilling conditions, allowing the system to adapt to various scenarios while maintaining optimized performance and reliability that static configurations cannot achieve.
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 approach enhances separation efficiency, reduces power consumption, improves equipment reliability, and optimizes maintenance programs, leading to improved overall system performance and reduced environmental impact by facilitating the reuse of drilling fluids.
Implementation Method 1
shakers
Implementation Method 2
centrifuges
Data Source
AI summary
One system embodiment includes: an inlet sensor that measures a fluid quality of an input fluid stream; an arrangement of separation units operating to extract contaminants from the fluid stream; and a user interface (UI). Each separation unit produces a respective output fluid stream, exhibiting a performance that is impacted by a respective operating parameter, and has an outlet sensor that measures an output fluid stream quality. The UI receives fluid quality measurements from the inlet and the outlet sensors, responsively derives a performance value for each separation unit and an overall performance value for the arrangement, and displays each of the performance values. The UI may further set the operating parameter values to automate and optimize the operation of the arrangement for different drilling conditions. The fluid quality measurements may indicate contaminant concentrations, and the performance values may account for separation efficiency, energy consumption, reliability, and next service date.