Automated Cuttings Sampling With Probe Self-Cleaning and Rock Analysis
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Solution Overview
Problem
The existing mud-logging process is hindered by the difficulty in performing quick and repeated analyses of drilling mud cuttings, which relies heavily on human operators, leading to inefficiencies and increased costs due to the need for additional personnel.
Innovation Solution
An intelligent cuttings sampler that automates the sampling, cleaning, analysis, and packaging of drilling mud cuttings, utilizing a probe for extraction, a cleaning system, an analysis system, and a packaging system, controlled by a main controller to ensure precise and safe operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If human operators perform manual sampling and analysis of drilling mud cuttings, then the process can be carried out with existing equipment, but the speed and frequency of sampling are limited and additional personnel are required to improve sampling rate
Solution Approach 1:
The system performs self-cleaning of the probe through vibration and reverse flow mechanisms, eliminating the need for manual intervention and maintenance. The automated sampling system serves itself by continuously cleaning its own components, thereby maintaining high productivity without requiring additional operational complexity
Solution Approach 2:
Manual mechanical sampling operations are replaced with an automated system that uses probes, pumps, and vibration mechanisms. The mechanical system substitutes human operators while maintaining sampling capability, resolving the contradiction between productivity improvement and system complexity
2Speed
If the probe openings are made larger to allow faster passage of drilling mud and cuttings, then the sampling speed increases, but the probe becomes more prone to obstructions and clogging
Solution Approach 1:
The probe is equipped with vibration mechanisms that continuously oscillate the probe body and openings. This vibration prevents cuttings and debris from accumulating and blocking the openings, allowing the probe to maintain larger opening sizes for higher flow rates while preventing obstructions through continuous mechanical agitation
Solution Approach 2:
The system implements periodic reverse flow cycles where the pump temporarily reverses direction to clear any potential obstructions from the probe openings. This periodic action prevents clogging while maintaining high flow rates during normal operation, resolving the contradiction between speed and reliability
3Productivity
If multiple personnel are employed to improve sampling analysis capability, then the quality and frequency of analysis improve, but the operational cost increases prohibitively
Solution Approach 1:
Human operators are replaced with an automated system comprising probes, pumps, cleaning mechanisms, and packaging systems. This mechanical substitution eliminates the need for multiple personnel while maintaining or improving analysis capability, thereby reducing operational costs without sacrificing productivity
Solution Approach 2:
The system extracts and automates the specific sampling and analysis functions that previously required human operators. By isolating and automating these critical functions, the system achieves improved analysis capability without the need for additional personnel, thus reducing operational costs
4Measurement precision
If the probe continuously samples drilling mud at high frequency, then the representativeness of the sampled rock formation improves, but the probe becomes more susceptible to clogging from accumulated cuttings
Solution Approach 1:
The vibration mechanism continuously agitates the probe and its openings, preventing cuttings from accumulating and clogging the probe during continuous high-frequency sampling. This allows the system to maintain high sampling rates for improved representativeness without requiring complex cleaning systems
Solution Approach 2:
The cleaning action is continuous rather than periodic, with vibration and reverse flow operating throughout the sampling process. This continuous cleaning enables uninterrupted high-frequency sampling that maintains sample representativeness while preventing clogging, balancing measurement precision with system simplicity
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
The intelligent sampler enhances the precision and safety of mud-logging processes while reducing costs by automating the sampling workflow, enabling efficient and accurate analysis of drilling mud cuttings without the need for additional personnel.
Implementation Method 1
the probe has a plurality of openings. the plurality of openings are sized to allow for the passage of drilling mud containing cuttings
Implementation Method 2
the sample extractor comprises a variable flow mud pump. the main controller is configured to control at least the variable flow mud pump. the control is a function of a rate of penetration of the drilling operation
Implementation Method 3
the cleaning system is configured to accept the drilling mud sample provided by the sample extractor. the cleaning system performs a cleaning action to remove fluid in the drilling mud sample
Implementation Method 4
the imaging system is configured to analyze a cleanliness level of the cutting sample
Implementation Method 5
the gas sensor is configured to send information pertaining to a quantity or concentration of a hazardous gas
Data Source
AI summary
A cuttings sampler for testing of cuttings from a drilling operation includes a sample extractor which extracts a sample of drilling mud from a flow line. The sample extractor includes a probe located inside of the flow line and having a plurality of openings to allow for the passage of drilling mud containing cuttings, and a variable flow mud pump for extracting a drilling mud sample from the mud flow line. The cuttings sampler further includes: a cleaning system that performs a cleaning action to remove fluid in the drilling mud sample resulting in a cutting sample; an analysis system for performing an initial analysis on the cutting sample to classify a type of rock contained in the cutting sample; a packaging system for accepting and placing the cutting sample in a storage container; and a main controller, configured to control at least the variable flow mud pump.