Optical Volume Flow Measurement on Vibratory Shaker Screen Deck
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Solution Overview
Problem
Current methods for measuring volume flow in the oil and gas drilling industry, particularly in shale shakers, are inadequate for accurately determining material flow rates, leading to potential downhole problems and equipment damage due to lack of real-time monitoring and calibration issues.
Innovation Solution
A system comprising an imaging receiver and illumination device, mounted in a fixed position relative to the shale shaker screen deck, uses high-frame-rate imaging and a line of light to calculate volume flow by detecting material height and velocity, with adjustable components for tilt compensation and recalibration, ensuring accurate and continuous monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow measurement methods are used in shale shakers, then the system is simpler and cheaper, but measurement precision and reliability are insufficient leading to inaccurate volume flow determination
Solution Approach 1:
The patent replaces traditional mechanical flow measurement devices with an optical measurement system consisting of an imaging receiver (camera) and illumination device. This substitution enables non-contact, high-precision volume flow measurement by capturing images of material on the screen deck and calculating flow parameters from image analysis, thereby improving measurement precision while avoiding complex mechanical components
Solution Approach 2:
The imaging receiver creates optical copies (images) of the material on the screen deck, allowing virtual measurement of volume flow without physical contact. The system captures visual information and processes it to determine flow rates, replacing the need for direct mechanical interaction with the material while maintaining high measurement accuracy
2Reliability
If real-time volume flow monitoring is implemented, then drilling process safety and efficiency improve, but device complexity and cost increase
Solution Approach 1:
The imaging receiver serves multiple functions: it captures images for volume flow measurement, monitors material characteristics, and provides real-time drilling process information. This multi-functionality enables comprehensive monitoring and reliability improvement while avoiding the need for separate dedicated devices for each function, thereby limiting the increase in system complexity
3Adaptability or versatility
If the imaging receiver and illumination device are mounted on the moving shaker, then they can track material flow, but measurement stability and precision decrease due to vibration and movement
Solution Approach 1:
The mounting bracket is designed to counteract the effects of shaker vibration and movement on the imaging receiver and illumination device. By providing stable mechanical support that compensates for platform instability, the system maintains measurement precision despite the moving and vibrating environment, allowing the devices to remain mounted on the shaker while achieving stable measurements
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 solution provides a modular and economical means to efficiently calculate and monitor material flow, reducing the risk of downhole issues by offering real-time, accurate volume flow measurements that adapt to changing conditions and equipment tilt, thereby enhancing drilling process efficiency and safety.
Implementation Method 1
at least one illumination device configured to project a line of light onto the screen deck
Implementation Method 2
an imaging receiver configured to receive images of a screen deck of a vibratory shaker
Data Source
AI summary
A system for measuring volume flow of a material includes: an imaging receiver for receiving images of a screen deck of a vibratory shaker from an overhead position; at least one illumination device for projecting a line of light onto the screen deck from an angle different than a viewing angle of the imaging receiver to the screen deck; and a mounting bracket for holding the imaging receiver and the at least one illumination device in a substantially fixed relative position to one another and to the screen deck. The system is determines the volume flow of the material based on the images of the screen deck.