Vibratory Separator Deck Segmentation for Wellbore Material Recovery
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Solution Overview
Problem
Existing vibratory separators fail to effectively recover wellbore strengthening materials during drilling operations, leading to increased costs due to the need for additional materials and inefficient waste remediation processes.
Innovation Solution
A removable collection system for vibratory separators, featuring multiple decks with varying screen perforations and a collection trough that can be secured to specific decks, allowing for the separation and recycling of wellbore strengthening materials back into the drilling fluid system, with the option to remove the collection trough when not needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vibratory separator is used to remove cuttings from drilling fluid, then cuttings are effectively removed, but wellbore strengthening materials are also removed along with the cuttings
Solution Approach 1:
The vibratory separator is divided into multiple decks with different screen aperture sizes. The first deck has larger apertures that allow wellbore strengthening materials to pass through while retaining cuttings, and the second deck has smaller apertures that retain wellbore strengthening materials. This segmentation enables selective separation of different particle sizes, solving the problem of co-removal of valuable materials with cuttings.
Solution Approach 2:
Different regions of the vibratory separator are assigned different functions through varying screen apertures. The first deck is optimized for cuttings removal with larger openings, while the second deck is optimized for wellbore strengthening materials recovery with smaller openings. This local differentiation allows each deck to perform its specific separation function effectively.
2Loss of substance
If wellbore strengthening materials are recovered and reused, then operational costs are reduced, but the device complexity increases
Solution Approach 1:
The vibratory separator is divided into multiple decks with different screen aperture sizes. The first deck has larger apertures that allow wellbore strengthening materials to pass through while retaining cuttings, and the second deck has smaller apertures that retain wellbore strengthening materials. This segmentation enables selective separation of different particle sizes, solving the problem of co-removal of valuable materials with cuttings.
Solution Approach 2:
The collection trough is designed to be removable from the vibratory separator. When wellbore strengthening materials are being recovered, the trough is attached to collect materials from the second deck. When not needed, the trough can be removed, allowing the separator to be used for standard cuttings removal only. This dynamic configuration allows the system to adapt to different operational requirements.
3Loss of substance
If multiple decks with varying screen perforations are added to separate wellbore strengthening materials, then material recovery is improved, but the device complexity increases
Solution Approach 1:
The vibratory separator is divided into multiple decks with different screen aperture sizes. The first deck has larger apertures that allow wellbore strengthening materials to pass through while retaining cuttings, and the second deck has smaller apertures that retain wellbore strengthening materials. This segmentation enables selective separation of different particle sizes, solving the problem of co-removal of valuable materials with cuttings.
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
Enables the efficient recovery and reuse of wellbore strengthening materials, reducing operational costs and minimizing downtime during drilling operations by allowing the vibratory separator to be reused without the collection system when not required.
Implementation Method 1
The shale shaker may be angled table with a generally perforated filter screen bottom. Returning drilling fluid is deposited at the feed end of the shale shaker. As the drilling fluid travels down length of the vibrating table, the fluid falls through the perforations to a reservoir below leaving the solid particulate material behind. The vibrating action of the shale shaker table conveys solid particles left behind until they fall off the discharge end of the shaker table.
Data Source
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AI summary
A wellbore strengthening material collection system including a vibratory separator having a top deck, a middle deck, and a bottom deck, and also including a collection trough coupled to at least one of the decks and configured to receive wellbore strengthening materials from the at least one of the decks. Additionally, a collection trough including a body having an inlet and an outlet, an angled surface disposed within the body and at least on extension surface extending form the body and configured to secure the collection trough to a vibratory separator.