Shale Shaker Beach Position Control Using Sensor Feedback
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Solution Overview
Problem
Shale shakers face challenges in maintaining the fluid end point or 'beach' at a consistent level during operation, leading to uneven wear of screens and suboptimal system capacity due to varying fluid volumes and separation efficiency.
Innovation Solution
Implementing sensors and a controller to adjust shaker inclination and fluid flow in real-time based on sensor inputs, using techniques such as motion parameters, motor weight orientation, and high-frequency vibrations to maintain the beach position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual monitoring and adjustment of fluid level is used, then operational flexibility is maintained, but beach position consistency deteriorates leading to uneven screen wear
Solution Approach 1:
The system employs sensors (accelerometers, load cells, or displacement sensors) to continuously monitor the beach position and provides real-time feedback to the controller. The controller processes this feedback signal and automatically adjusts the shaker inclination and/or fluid feed rate to maintain the desired beach position, eliminating the need for manual monitoring and ensuring consistent beach location without excessive complexity
Solution Approach 2:
The control system is designed to autonomously regulate the beach position by integrating sensors, controllers, and actuators into a self-regulating mechanism. The system automatically detects beach position deviations and corrects them through inclination adjustment and/or feed rate modulation, enabling the equipment to self-maintain optimal operating conditions without external intervention
2Productivity
If fixed shaker inclination is used, then operational simplicity is maintained, but fluid load distribution deteriorates leading to suboptimal system capacity
Solution Approach 1:
The shaker inclination is transformed from a fixed parameter to a dynamically adjustable one. The system incorporates an inclination adjustment mechanism (such as a variable inclination frame or adjustable support legs) that allows real-time modification of the shaker's angle relative to horizontal, enabling optimization of fluid load distribution across the screen surface to maximize system capacity
Solution Approach 2:
The system changes the inclination parameter dynamically based on operating conditions. By adjusting the inclination angle and/or fluid feed rate in response to beach position feedback, the system optimizes fluid load distribution across the screen, thereby enhancing overall system capacity and separation efficiency
3Manufacturing precision
If variable fluid feed rate is used, then beach position control is improved, but operational complexity deteriorates
Solution Approach 1:
The system uses sensors to monitor beach position and provides feedback to the controller, which automatically modulates the fluid feed rate to maintain the desired beach position. This closed-loop control eliminates the need for manual adjustment of feed rate, improving beach position control while keeping operation simple through automation
Solution Approach 2:
The system autonomously regulates fluid feed rate based on real-time beach position measurements. The controller automatically adjusts the feed rate without operator intervention, enabling precise beach position control while simplifying operation through self-regulation
4Reliability
If manual adjustment of beach position is used, then system adaptability is limited, but screen wear uniformity deteriorates
Solution Approach 1:
The system implements automatic beach position control through feedback from sensors (accelerometers, load cells, or displacement sensors) that continuously monitor the beach location. The controller processes this feedback and automatically adjusts shaker inclination and/or fluid feed rate to maintain the desired beach position, ensuring uniform screen wear through automated regulation rather than manual adjustment
Solution Approach 2:
The system employs self-regulating control mechanisms that automatically maintain optimal beach position and uniform screen wear. The integrated sensors and controllers enable the equipment to self-correct deviations in beach position, ensuring consistent screen utilization and extended screen life without requiring manual intervention or high levels of operator expertise
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
Enhances screen life by evenly distributing fluid load, optimizing system capacity, and improving overall performance by maintaining the beach at a desired location.
Implementation Method 1
shaker acceleration parameters are acquired by an accelerometer
Implementation Method 2
motor weight orientation, speed, and acceleration parameters are acquired by a proximity sensor and an accelerometer
Implementation Method 3
Vibratory motion of the shaker is responsible, at least in part, for separating the drilling fluid through the screens
Implementation Method 4
The shaker basket holds the fluid during the vibration process and allows filtered fluid to pass through the screen level
Data Source
AI summary
This disclosure relates to shaker adjustments based on sensor measurements for sensors positioned at different locations about the shaker. This disclosure explains techniques to adjust a shale shaker as would be used to separate particulates (cuttings and other solids) from drilling fluid (commonly referred to as “mud”) during a drilling operation. Empirical models have been formulated to provide for programming a controller to calculate run-time adjustments to the shaker to increase efficiency. The controller may control one or more shakers concurrently. Different techniques and measurement types may be used concurrently to achieve desired shaker inclination and maintain a proper beach location during operation. Sensors include accelerometers, proximity sensors, and other types of data acquisition devices that may be used to detect motion parameters of an operational (e.g., in-use and running) shaker.