Modular Repair Plugs for Shale Shaker Screen Maintenance
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Solution Overview
Problem
Shale shaker screens in oilfield drilling operations frequently experience damage due to vibrational wear, leading to costly replacement of entire screens rather than just repairing damaged sections, as existing methods lack efficient solutions for plugging or repairing tears in the mesh.
Innovation Solution
A modular repair plug system is introduced, featuring securing mechanisms that allow the plug to expand and conform to different cell sizes on the screen grid, securely attaching to the grid to block damaged areas and prevent fluid or solids from passing through, thus extending the screen's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire screen is replaced when damaged, then the separation efficiency is maintained, but the cost and time for replacement increase significantly
Solution Approach 1:
The screen is divided into modular cells that can be independently repaired. When damage occurs in one cell, only that specific cell needs to be replaced rather than the entire screen, allowing the separation efficiency to be maintained while reducing replacement time and cost.
Solution Approach 2:
Damaged cells are removed and replaced while the remaining undamaged cells are recovered and reused. This selective replacement approach maintains the screen's separation efficiency while minimizing the loss of functional components.
2Reliability
If the entire screen is replaced when damaged, then the separation efficiency is maintained, but the cost increases significantly
Solution Approach 1:
The screen is divided into modular cells that can be independently replaced. This segmentation allows only the damaged portion to be replaced rather than the entire screen, significantly reducing material costs while maintaining separation efficiency.
Solution Approach 2:
The undamaged cells are recovered and reused, minimizing material waste. Only the damaged cells are discarded and replaced, which reduces the overall material cost compared to replacing the entire screen.
3Ease of repair
If modular repair plugs are used, then repair cost and time are reduced, but the device complexity increases
Solution Approach 1:
The repair system is segmented into standardized modular plugs that fit into specific cell patterns. This segmentation simplifies the repair process by providing pre-fabricated replacement units, making repair easier while keeping the overall system manageable through standardization.
Solution Approach 2:
The modular plugs are designed with universal compatibility to fit different cell sizes and screen configurations. This multi-functionality reduces the variety of unique components needed, simplifying the overall device complexity while maintaining ease of repair across different applications.
4Duration of action of stationary object
If modular repair plugs are used, then screen lifespan is extended, but the manufacturing precision requirements increase
Solution Approach 1:
The screen lifespan is extended by enabling targeted replacement of damaged cells with modular plugs. The segmentation allows for precise replacement of only the damaged portion, and the standardized nature of the plugs reduces the overall manufacturing precision requirements compared to custom repairs.
Solution Approach 2:
The modular plugs are designed with standardized dimensions and tolerances that can be manufactured using conventional precision manufacturing processes. By establishing standard parameters for plug sizes and attachment mechanisms, the manufacturing precision requirements are controlled and made more manageable, while still achieving extended screen lifespan.
Data Source
AI summary
An apparatus and methods secure modular repair plugs to one another to repair different sized cells of a screen. A modular repair plug is configured to attach to another modular repair plug to create an extended modular repair plug. The modular repair plug can fit within a first, smaller cell, and the extended modular repair plug can fit within a larger second cell.