Image-Based Separator Control for Drilling Fluid Loss Reduction
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Solution Overview
Problem
Existing separators used in drilling operations are inefficient in separating solids from fluids, leading to increased costs due to inconsistent manual adjustments and slow visual inspection, resulting in loss of valuable drilling fluid and additives.
Innovation Solution
Implementing image sensors proximate to separators to capture still and/or video images of the slurry properties, allowing for automated adjustment of separator parameters to optimize the separation process, including closed-loop control of fluid endpoints and solid phase discharge management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual inspection and manual adjustments are used to monitor and control separators, then operational flexibility is maintained, but separation efficiency deteriorates due to inconsistent interpretation and slow response time
Solution Approach 1:
The patent replaces manual visual inspection and mechanical adjustment with an automated optical sensing system. Image sensors capture images of the separator operation, and a control system automatically processes these images to determine separator performance and adjust parameters, eliminating the need for manual observation and adjustment while improving consistency and speed.
Solution Approach 2:
The patent implements a closed-loop feedback system where image sensors continuously monitor separator operation, the control system analyzes the images to assess separation efficiency, and automatic adjustments are made to separator parameters based on the analysis. This continuous feedback loop ensures optimal performance without manual intervention.
2Device complexity
If manual monitoring of separators is performed, then system complexity is minimized, but fluid loss increases due to delayed detection of suboptimal separation
Solution Approach 1:
The patent replaces simple manual monitoring with an automated optical sensing and image processing system. Image sensors continuously capture separator operation, and a control system automatically analyzes these images to detect suboptimal separation conditions, enabling timely intervention to prevent fluid loss while maintaining manageable system complexity through standardized components.
3Productivity
If automated image-based monitoring is implemented, then separation efficiency improves through real-time optimization, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent uses optical sensing and image processing technology to automate separator monitoring and control. Image sensors capture visual information about separator performance, and a control system processes these images to automatically adjust separator parameters, replacing manual operations with automated systems that improve efficiency while keeping complexity manageable through standardized components.
Solution Approach 2:
The patent creates visual copies of the separator operation through image capture. Instead of directly measuring physical parameters, the system uses image sensors to create optical representations of the separator's state, which are then analyzed to determine performance and guide adjustments, simplifying the measurement and control process.
4Device complexity
If manual adjustments are made to separator parameters, then system cost is reduced, but drilling fluid loss increases due to slow response to changing conditions
Solution Approach 1:
The patent implements automated feedback control where image sensors continuously monitor separator performance, the control system analyzes the images to assess separation efficiency, and parameter adjustments are automatically made in real-time. This continuous feedback loop enables rapid response to changing conditions, preventing fluid loss while maintaining cost-effectiveness through automated control.
Solution Approach 2:
The patent replaces manual monitoring and adjustment with automated image-based sensing and control systems. Image sensors capture separator operation continuously, and a control system automatically processes these images and adjusts separator parameters, enabling real-time optimization that prevents fluid loss while keeping operational costs manageable.
Data Source
AI summary
A system for separating solids from fluids, the system including a separator having a deck having a feed inlet and a solids outlet and a plurality of screens disposed on the deck. Also, an image sensor disposed proximate the solids outlet, the image sensor to capture images of the separator, and send the captured mages to a remote location for analysis. Additionally, a method of monitoring a separator, the method including capturing an image of the separator and sending the image of the separator to a control module disposed at a remote location. The method also including analyzing the image with the control module to determine a separation property and modifying the operation of the separator based on the determined separation property.