Master Shaker Module for Drilling Rig Footprint Reduction
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Solution Overview
Problem
Conventional mud circulation systems in drilling rigs have a large footprint and high weight, making them costly and inefficient to assemble and operate, especially in offshore drilling where space and crane capacity are limited.
Innovation Solution
A master shaker module with detachable upper and lower skids that vertically stack mud circulation system components, allowing for reduced footprint and weight, enabling easier handling and assembly, and the ability to isolate shale shakers based on cleaning needs, optimizing equipment usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mud circulation systems are used, then the system can effectively clean mud and remove cuttings, but the system has large footprint and high weight requiring larger cranes and more expensive platforms
Solution Approach 1:
The mud circulation system is divided into separate functional modules (shale shakers, hydrocyclones, degassers, etc.) that can be independently positioned and selectively activated. Each module is mounted on separate skids that can be independently handled and positioned, allowing the system to be assembled in segments rather than as one large heavy unit.
Solution Approach 2:
The system transitions from a horizontal layout to a vertical three-dimensional arrangement. Mud flows vertically through the system via gravity-fed chutes between levels, allowing equipment to be stacked vertically rather than spread horizontally. This reduces the footprint and allows smaller cranes to handle individual components.
2Reliability
If conventional mud circulation systems are used, then the system can effectively clean mud and remove cuttings, but the system has large footprint requiring larger drilling platforms with higher costs
Solution Approach 1:
The mud circulation system is divided into separate functional modules (shale shakers, hydrocyclones, degassers, etc.) that can be independently positioned and selectively activated. Each module is mounted on separate skids that can be independently handled and positioned, allowing the system to be assembled in segments rather than as one large heavy unit.
Solution Approach 2:
The system transitions from a horizontal layout to a vertical three-dimensional arrangement. Mud flows vertically through the system via gravity-fed chutes between levels, allowing equipment to be stacked vertically rather than spread horizontally. This reduces the footprint and allows smaller cranes to handle individual components.
3Reliability
If all shale shakers are operated continuously, then thorough mud cleaning is achieved, but equipment wear increases and operational costs rise
Solution Approach 1:
The system allows dynamic selection and activation of specific mud cleaning modules based on real-time drilling conditions and mud contamination levels. Operators can selectively engage or disengage individual shale shakers, hydrocyclones, or degassers as needed, rather than running all equipment continuously. This dynamic operation reduces unnecessary equipment wear and energy consumption while maintaining adequate cleaning performance.
Solution Approach 2:
Different mud cleaning modules are positioned at different locations in the flow path, allowing selective activation of specific modules based on local cleaning needs. For example, if cuttings are primarily removed early in the process, later modules can be deactivated. Each module performs its specific cleaning function locally rather than requiring all modules to operate uniformly.
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 solution reduces the footprint and weight of the mud circulation system, allowing for efficient assembly and operation with smaller cranes, while minimizing the use of shale shakers only when necessary, thereby reducing costs and extending equipment life.
Implementation Method 1
The upper master skid and the lower master skid are coupled together
Data Source
AI summary
An apparatus that includes an upper skid including a first floor supporting a first plurality of mud circulation components; a first storage structure disposed below the first floor that receives a fluid exiting the first plurality of components; and a first plurality of fasteners carried on the upper skid. The apparatus also includes a lower skid that includes a second floor supports a second plurality of mud circulation components; a second storage structure disposed below the second floor that receives a fluid exiting the second plurality of components; and a second plurality of fasteners carried on the support structure that correspond to the first plurality of fasteners to couple the upper skid over the lower skid. In an exemplary embodiment, the upper skid is selectively detachable from the lower skid.