Screen Break Detector Using Sample Screen Pressure Monitoring
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Solution Overview
Problem
Conventional screening technologies in oil field services face breakdowns due to faulty shakers or broken screens, leading to oversized particles passing through, which can damage drilling components and disrupt operations, necessitating a method to monitor screen conditions effectively.
Innovation Solution
A screen break detection system that includes a sample screen and pressure detector to monitor fluid pressure and detect conditions based on pressure thresholds, providing notifications for potential screen failures, allowing for timely maintenance and preventing equipment damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screening technology is used without monitoring, then equipment simplicity is maintained, but screen break detection capability is insufficient leading to potential equipment damage
Solution Approach 1:
A sample screen is introduced as an intermediary component between the production stream and the detection system. The sample screen collects particles that indicate upstream screen breaks, serving as a mediator that translates hidden screen conditions into detectable physical blockage signals without requiring direct sensing of the actual screens
Solution Approach 2:
The patent replaces direct mechanical inspection of screens with a pressure-based detection system. Instead of mechanically examining screen integrity, the system uses pressure differential measurements across the sample screen to infer screen break conditions, substituting mechanical inspection with a more reliable pressure sensing approach
2Reliability
If screens are monitored continuously, then screen break detection improves, but operational downtime increases due to frequent inspections
Solution Approach 1:
The detection system operates continuously without interrupting the production stream. The sample screen and pressure sensor work together to provide ongoing monitoring, eliminating the need to stop operations for inspections while maintaining constant awareness of screen condition
Solution Approach 2:
The system uses the production stream itself to feed particles onto the sample screen, which then automatically triggers detection when blocked. This self-service mechanism requires no external intervention or operational interruption, as the system monitors itself using the existing process flow
3Object-affected harmful factors
If screen break detection is implemented, then equipment protection improves, but system complexity and cost increase
Solution Approach 1:
The sample screen acts as a sacrificial intermediary that collects particles indicating upstream screen breaks. This mediator approach protects the actual screens and downstream equipment by providing early warning, while keeping the detection system simple and inexpensive
Solution Approach 2:
The sample screen is designed as a disposable or easily replaceable component that can be sacrificed to protect more valuable equipment. By using an inexpensive sample screen that can be quickly replaced, the system avoids the complexity and cost of monitoring expensive, critical components directly
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 system effectively identifies screen breaks and degradation, enabling operators to divert flow to undamaged screens, minimizing downtime and economic impact by allowing for proactive maintenance and ensuring continuous drilling operations.
Implementation Method 1
monitoring a fluid pressure of the fluid stream flowing through the sample screen of the screen break detector and detecting a condition of the at least one screen of the screen system based on the fluid pressure and one or more pressure thresholds
Data Source
AI summary
A method for determining a screen break includes receiving a fluid stream from a screen system of a fluid system into a screen break detector, wherein the screen system comprises at least one screen, and the screen break detector comprises a sample screen. The method also includes monitoring a fluid pressure of the fluid stream flowing through the sample screen of the screen break detector and detecting a condition of the at least one screen of the screen system based on the fluid pressure and one or more pressure thresholds. The method also may include outputting a notification of the condition of the at least one screen of the screen system. A system includes a screen break detector. The screen break detector includes a sample screen configured to receive a fluid stream from a screen system of a fluid system, wherein the screen system includes at least one screen and a pressure detector configured to monitor a fluid pressure of the fluid stream flowing through the sample screen.