GB2458114A

GB2458114A - A vacuum pumping system for drill cuttings

Info

Publication number: GB2458114A
Application number: GB0803957A
Authority: GB
Inventors: Michael H James
Original assignee: Triton Industries LLC
Current assignee: Triton Industries LLC
Priority date: 2008-03-03
Filing date: 2008-03-03
Publication date: 2009-09-09
Anticipated expiration: 2028-03-03
Also published as: GB0803957D0; GB2458114B

Abstract

A drill cuttings handling system apparatus 10 for use on an oil and gas drilling rig. The drill cuttings handling system is comprised of a portable hopper 20, a vacuum pump 26, for creating a vacuum in the hopper and thereby drawing the cuttings through an inlet 38 into the hopper, and a solids pump 42 attached to an outlet for the hopper for removing the drill cuttings from the hopper. A control means 32 for detecting the level of cuttings in the system and remotely controlling the flow of cuttings into and out of the hopper 20 by remote control of valves, and/or pumps is utilized. A vacuum relief valve 34 may be regulated by the control system

Description

DRILL CUTTINGS HANDLING APPARATUS

This invention relates to a method and apparatus incorporating a portable vacuum and pumping system to monitor and control the handling of materials such as drill cuttings produced during the drilling of oil and gas wells.

In the drilling of oil and gas wells, whether offshore or onshore, rotary drilling techniques require the use of drilling mud circulated through the borehole during the drilling process.

Typically, the drilling mud is pumped from a mud holding tank, through mud supply lines, down through the borehole and returned to the surface of the borehole. The circulating drilling mud, as it is returned to the surface of the borehole, is used to carry the drill cuttings produced from the bottom of the advancing borehole to the surface for disposal.

The drilling mud that is returned to the surface, along with the carried drill cuttings, is typically transferred to a shaker or sieving device that is utilized to remove the carried drill cuttings drilling mud. The drilling mud, absent the removed drill cuttings, is re-circulated to the borehole and the drill cuttings, removed by the shaker, are typically collected in a drill cuttings collection trough that is in communication with the shaker and conveyed to dryers for further processing on the rig or to storage boxes or containers for treatment and disposal at a later time.

Various techniques are currently utilized to convey the drill cuttings from the drill cuttings collection trough. These techniques include the use of conveyors, chutes, and suction lines. These techniques, whether the incorporate coriveyors, chutes, suction lines or combinations thereof, typically require elaborate networks of conveyors, hoses, chutes, and tanks that take up valuable rig space. These systems typically require substantial amounts of time to set up and take down which can have a negative impact on the time associated with the drilling process.

The present invention seeks to provide for improved handling of drill cuttings and other such small particles.

The preferred embodiments of the present invention are designed to provide a portable vacuum and pumping apparatus and system to handle drill cuttings that may be brought to the well location in single a unit. The unit is easily set up for use and is easily removed from the well location. The unit is easy to operate and maintain, provides a method and means to monitor and control the flow of cuttings through the unit and thus eliminates many of the problems associated with conventional drill cuttings systems. All of the components of the system may be incorporated onto a transportable skid for easy transportation to and from a drill site.

According to an aspect of the present invention, there is provided a material handling apparatus as specified in claim I. According to another aspect of the present invention, there is provided apparatus for transporting a material slurry as specified in claim 9.

The preferred embodiment of the present invention provides a portable vacuum and pumping apparatus and system for handling slurries of solids such as the slurry comprised of drill cuttings produced during the drilling of oil and gas wells. The components of the preferred embodiments can be easily transported and setup on ajob location. Due to such portability, ease of assembly, and small footprint, the system it is particularly suitable for use on oil and gas drilling platforms.

All of the relevant components of the drill cuttings handling apparatus may also be arranged and housed as a unit on a transportable skid to minimize the amount of platform deck space utilized by the unit. The transportable skid may be equipped with removable lifting lugs to facilitate its transport to and from the drilling platform or well location.

The preferred embodiment provides a cyclone cuttings hopper, a device for detecting the level of cuttings and other materials contained in the cuttings hopper, a vacuum pump for creating suction in the cuttings hopper, a hopper vacuum relief valve, a solids pump, engine means for operating the vacuum pump and the solids pump, inlet and outlet valves and piping, and means for delivering the detected levels to a control mechanism for regulating the flow of drill cuttings into and out of the cuttings hopper. In operation, at least one vacuum line is placed in the cuttings trough and connected to an inlet in the cuttings hopper. A cuttings discharge line is then attached to the outlet of the solids pump and directed to a cuttings dryer, a cuttings storage box, or other interim storage location.

With the hopper vacuum relief valve closed, and the vacuum pump in operation, drill cuttings are drawn from the cuttings trough through the vacuum lines and in to the cuttings hopper by means of a vacuum created in the cuttings hopper by means of the vacuum pump.

Drill cuttings accumulated in the cuttings hopper are discharged to the solids pump by gravity means and then pumped by the solids pump to a cuttings dryer, to cuttings storage boxes, or to other desired destinations via the cuttings discharge line.

The level or volume of cuttings retained in the cuttings hopper may be monitored by a monitoring device, such as an ultrasonic or sonar sensor and system or a by a photoelectric sensor and system, to deliver and receive signals to detect the level of drill cuttings in the hopper and transmit the signals to a control system. The control system can then generate desired signals to regulate the hopper vacuum relief to control the vacuum maintained in the hopper so as to keep an efficient flow of cuttings in to and out of the cuttings hopper. The system, if desired, may also be used to generate a control signal, based upon the detected level of cuttings in the cuttings hopper, to regulate the concrete pump and thereby the flow of cuttings from the system.

The components of the system may be easily transported to and from a well location by trucking or other means. The components may be arranged an mounted on a skid to facilitate transportation of the system. When mounted on a skid, all of the essential components of the apparatus may be contained and incorporated into a single unit. Such a unit may be easily added to or removed from a drilling mud system of a drilling rig assembly. The ease of addition and removal of a unit allows for the ready addition or replacement of a unit in the event of capacity requirements or unit malfunction. Maintenance on the replaced apparatus can then be conducted with little impact on the drilling operation.

According to an aspect of the present invention, there is provided a method of handling drill cuttings as specified in claim 14.

According to another aspect of the present invention, there is provided apparatus for handling drill cuttings as specified in claim 23.

Embodiments of the present invention are described below, by way of example only, with reference to the accompanying drawings, in which: Fig. I is a schematic diagram of an embodiment of apparatus and method of applicant's invention; Fig. 2 is a schematic sectional view of the apparatus of Fig. 1.

Referring now to the drawings and more particularly to Fig. I there is shown a schematic diagram of the proposed materials handling system 10 to be used as a means for handling slurries of solids such as the slurry comprised of drill cuttings produced during the drilling of oil and gas wells. The system 10 is comprised of a slurry collection tank such as a cyclone cuttings hopper 20, a vacuum system 30, at least one Suction line 22, a cuttings discharge system 40, and a control system 50.

The vacuum system 30 includes a vacuum line 24, a vacuum pump 26, with associated valves and fittings, and a power means 28. It is thought that the power means 28 would be a diesel engine having a horsepower rating sufficient for operating the vacuum pump 26 at a pressure level in the cuttings hopper 20, via vacuum line 24, sufficient to create a desired vacuum or Suction level though power means of equivalent power ratings such as electric engines could also be utilized.

The cuttings hopper 20 has a vacuum line inlet 36 in communication with the vacuum line 24, which is in turn in communication with a vacuum pump 26. The hopper 20 is also provided with at least one suction inlet 38 that is in communication with a Suction line 22. A vacuum relief valve 34 is mounted to cuttings hopper 20 to regulate the vacuum level generated in the hopper 20. In an embodiment, the transition between the cuttings hopper 20 and the vacuum relief valve 34 is an atmospheric conduit.

Mounted at the base of the cuttings hopper 20 is the cuttings discharge system 40. The discharge system 40 is comprised of a hopper outlet 21 in communication with the hopper 20, a solids pump 42 having an inlet to receive a flow of cuttings from the hopper outlet 21, power means 44 for operating the solids pump 42, and a discharge line 46 in communication with the solids pump 42 for delivering a flow of cuttings and other material from the solids pump 42. It is thought that the solids pump 42 will be a concrete pump having an operating lift and pressure sufficient to convey drill cuttings as described herein though other types of solids pump and motor combinations might also be utilized. Solids pumps such as those manufactured by REED�, 13822 Oaks Avenue, Chino, CA, 91710, USA are thought to be a suitable solids pump 42, in particular, the pumps utilized in the REED� Model A30 and A3OHP "Rockmaster" or the REED� C Series Concrete pumps are thought suitable for use with Applicant's system, though pumps of other models and manufacturers may also be used.

Mounted within the cuttings hopper 20 is a means 32 for continuously detecting the level of drill cuttings and other materials contained in the cuttings hopper 20. The means 32 for continuously detecting the level of drill cuttings may be a monitoring device, such as an ultrasonic or sonar sensor arid system or a by a photoelectric sensor and system. A suitable means 32 for continuously detecting the level of drill cuttings would be those manufactured by the Madison� Company, 27 Business Park Dr., Branford, CT 06405, USA. In particular, the Madison� Model U3/U4 ultrasound level sensors and the Madison� R3/R4 radar level sensors are thought suitable for use with Applicant's system, though sensors of other models and manufacturers may also be used.

The means 32 for continuously detecting the level of drill cuttings includes means 52 for delivering or transmitting the signals so detected to a control system 50. The control system 50 maybe be calibrated by computer means or otherwise to then generate desired control signals via vacuum control signal means 54 to regulate the hopper vacuum relief valve 34 to control the vacuum pressure maintained in the cuttings hopper 20 so as to keep an efficient flow of cuttings in to and out of the cuttings hopper 20. Such control systems are thought to be generally well known. The control system 50, if desired, may also be used to generate a control signal, via control signal means 56, based upon the detected level of cuttings in the cuttings hopper 20 from the detecting means 32, to regulate the concrete pump 42 and thereby the flow of cuttings to and from the cuttings discharge line 46.

In operation, as shown in schematic drawing Fig. I, the system 10 comprised of the cuttings hopper 20 its other component parts is mounted on a platform 23 such as the bed of a truck or on a skid where it may be readily transported to a drill location. The system 10 may also be assembled directly on the ground or the floor or work area where it is to be utilized.

Assembly includes attaching the cuttings suction line 22 to the cuttings inlet 38 of the cuttings hopper 20 and running the cuttings suction line 22, so attached, to a cuttings trough 15 of a drilling rig system and attaching the cuttings discharge line 46 to the solids pump 42 and extending the discharge line 46 to a desired cuttings collection location 48 such as a cuttings storage box or a cuttings dryer.

Once assembled, the cuttings 18 and any associated liquids are drawn from the cuttings trough 15 via at least one cuttings vacuum line 22 by means of a vacuum or negative pressure created in the cuttings hopper 20 by the vacuum line 24, with associated valves and fittings, by means of the vacuum pump 26 powered by the engine 28. Cuttings 1 8 drawn into the cuttings hopper 20 via cuttings inlet 38 are discharged from hopper 20 to the hopper outlet 21 via gravity means to the inlet of the solids pump 42 powered by the engine 44. Cuttings 18 are then pumped via the solids pump 42 though the cuttings discharge line 46 to a desired destination 48 such as a cuttings box or a cutting dryer.

As shown in Fig. 2, showing a cross-sectional schematic of the hopper 20, the means 32 for continuously detecting the level of drill cuttings and other materials monitors the level of drill cuttings and other materials drawn into the cuttings hopper 20 via the suction line 22 during operation of the system 10. This means 32 for level detection, thought to be an ultrasonic transducer and sensor system, generates and detects signals to determine the cuttings level in the hopper 20 and delivers the detected signals to the control system 50 via signal transmitting means 54.

For example, when the cuttings level in the hopper 20 is at a desired level designated as "A" in Fig. 2, a signal is delivered from the detection means 32 to the control system 50 might be processed to generate a signal from the control system 50 to the vacuum relief valve 34. The signal so generated may be used to open or close the relief valve 34 and thereby reduce or increase the vacuum pressure in the hopper 20 and, consequently, the flow of cuttings 18 from the cuttings trough 15 to the hopper 20.

Similarly, when the cuttings level in the hopper 20 is at a desired level designated as "B" in Fig. 2, a signal is delivered from the detection means 32 to the control system 50 might be processed to generate a signal from the control system 50 to the discharge system 40. The signal so generated may be used to regulate the solids pump 42 and thereby shutoff or continue the discharge of cuttings 18 from the system 10. Various types of control systems and valve arrangements may be utilized to control the cuttings collection system from the control system based upon the level of cuttings detected in the hopper 20 by the means for level detection 32 and thus the flow of drill cuttings into and from the cuttings hopper and the solids pump.

The control system 50 may be utilized to control the operations of the various engines, the pumps, and any attendant valves and it is thought that various types of control means are well known and might be adapted for such use including hydraulic, electric or pneumatic control systems.

When the cyclone cuttings hopper 20, the vacuum pump 26, the engines 28, 44, and the solids pump 42 are positioned on and mounted to a base or skid 23 they may be positioned in such a fashion so as keep the overall dimension of the base or skid 23 to a minimum. Lifting Jugs may be attached to the base 23 so as to provide a means for securing lifting lines to facilitate moving the system JO as desired. In certain configurations, a single engine 28, 44 might be used to operate both the vacuum pump 26 and the solids pump 42 so as to further reduce the minimum surface area required for the system.

It is thought that the material handling system presented herein and many of its attendant advantages will be understood from the foregoing description. It is also thought that it will be apparent that various changes may be make in the form, construction and arrangement of the parts the system without departing from the scope of the invention or sacrificing all of its material advantages.

Claims

CLAIMSMaterial handling apparatus including: a) a portable container; b) means for creating a vacuum in said portable container and thereby drawing material into said portable container; c) means for discharging material from said portable container to a desired location; d) means for continuously detecting and transmitting the level of material located in said portable container; and e) a control mechanism, operable in cooperation with said means for continuously detecting and transmitting the level of material drawn into said portable container and thereby for controlling said level of material located in said portable container.
2. Apparatus according to claim I, wherein said control mechanism includes: a) a vacuum relief valve, in communication with said portable container; and b) means for regulating said vacuum relief valve and for generating a control signal, said means being in cooperation with said vacuum relief valve.
3. Apparatus according to claim 2, wherein: a) said portable container includes at least one vacuum conduit, at least one inlet conduit, at least one atmospheric conduit, and at least one outlet conduit, said atmospheric conduit being in communication with said vacuum relief valve; b) said means for creating a vacuum includes at least one vacuum pump, at least one vacuum line, and means for operating said vacuum pump; said vacuum line being in cooperation with said vacuum pump and said inlet conduit; and c) said means for discharging material includes at least one solids pump; at least one discharge line, and means for operating said solids pump; said solids pump being in communication with said outlet conduit, and said discharge line being in communication with said solids pump.
4. Apparatus according to claim 3, wherein said means for regulating said vacuum relief valve and generating a control signal includes a computer.
5. Apparatus according to any preceding claim, wherein said means for continuously detecting and transmitting the level of material located in said portable container is an ultrasonic sensor.
6. Apparatus according to any one of claims I to 4, wherein said means for continuously detecting and transmitting the level of material located in said portable container is a sonar sensor.
7. Apparatus according to any one of claims I to 4, wherein said means for continuously detecting and transmitting the level of material located in said portable container is a photoelectric sensor.
8. Apparatus according to any one of claims I to 4, wherein said means for continuously detecting and transmitting the level of material located in said portable container is a radar sensor.
9. Apparatus for transporting material slurries such as drill cuttings, including: a) a portable hopper, provided with at least one vacuum conduit, at least one inlet conduit, at least one atmospheric conduit; and at least one outlet conduit; b) means for drawing a material slurry into said hopper, said means including at least one vacuum pump, at least one vacuum line, and means for operating said vacuum pump; said vacuum line being in cooperation with said vacuum pump and said inlet conduit; c) means for discharging said material slurry from said portable hopper including at least one solids pump; at least one discharge line, and means for operating said solids pump; said solids pump being in cooperation with said outlet conduit and said discharge line; d) a vacuum relief valve in cooperation with said atmospheric conduit; e) a control mechanism comprising means for regulating said vacuum relief valve and generating a control signal; and means for continuously detecting and transmitting the level of said material slurry located in said portable hopper, said means being in cooperation with said control mechanism.
10. Apparatus according to claim 9, wherein said means for continuously detecting and transmitting the level of material located in said portable hopper is an ultrasonic sensor.
II. Apparatus according to claim 9, wherein said means for continuously detecting and transmitting the level of material located in said portable hopper is a sonar sensor.
12. Apparatus according to claim 9, wherein said means for continuously detecting and transmitting the level of material located in said portable hopper is a photoelectric sensor.
13. Apparatus according to any one of claims 9 to 12, wherein said solids pump is a concrete pump.
14. A method of handling drill cuttings including the steps of: a) transporting cuttings and any associated liquids from a predetermined location into a portable hopper; b) activating a monitoring means for continuously detecting and transmitting the level of drill cuttings and other materials drawn into said portable hopper; c) controlling the level of said cuttings and associated liquids by a control mechanism in communication with said monitoring means; and d) discharging said cuttings from the portable hopper to a desired destination.
15. A method according to claim 14, wherein said step of transporting cuttings and any associated liquids, includes: a) attaching at least one suction line to at least one inlet conduit of said portable hopper; b) attaching said suction line to a cuttings trough; c) attaching at least one vacuum line to at least one vacuum conduit located on saidportable hopper;d) attaching said vacuum line to vacuum pump; and e) activating said vacuum pump.
16. A method according to claim 14 or 15, wherein said step of discharging said cuttings to a desired location, includes: a) attaching a solids pump to at least one outlet conduit of said portable hopper; b) attaching at least one discharge line to said solids pump; c) extending said discharge line to a desired cuttings collection location; and d) activating said solids pump.
17. A method according to any one of claims 14 to 16, wherein said monitoring means for continuously detecting and transmitting the level of drill cuttings and other materials drawn into said portable hopper is an ultrasonic sensor.
1 8. A method according to any one of claims 14 to 16, wherein said monitoring means for continuously detecting and transmitting the level of drill cuttings and other materials drawn into said portable hopper is a sonar sensor.
19. A method according to any one of claims 14 to 16, wherein said monitoring means for continuously detecting and transmitting the level of drill cuttings and other materials drawn into said portable hopper is a photoelectric sensor.
20. A method according to any one of claims 14 to 16, wherein said monitoring means for continuously detecting and transmitting the level of drill cuttings and other materials drawn into said portable hopper is a radar sensor.
21. A method according to any one of claims 14 to 20, wherein said step of controlling the level of said cuttings and associated liquids includes controlling communication between said portable hopper and the atmosphere.
22. A method according to claim 21, wherein said step of controlling communication between said portable hopper and the atmosphere includes controlling a vacuum relief valve so that communication between said portable hopper and the atmosphere varies with respect to the position of the vacuum relief valve.
23. Apparatus for handling drill cuttings including: a) a container provided with at least one vacuum conduit, at least one inlet conduit, at least one atmospheric conduit, and at least one outlet conduit, said atmospheric conduit being in communication with a vacuum relief valve; b) means for creating a vacuum in said container whereby drill cuttings are drawn into said container through said inlet conduit; c) means for discharging said drill cuttings from said container to a desired location; d) means for continuously detecting and transmitting the level of said drill cuttings located in said container; and e) a control mechanism, in cooperation with said means for continuously detecting and transmitting the level of said drill cuttings drawn into said portable container and said vacuum relief valve, for controlling said level of said drill cuttings located in said portable container.
24. Apparatus according to claim 23, wherein: a) said means for creating a vacuum in said container includes, at least one vacuum pump, at least one vacuum line, and means for operating said vacuum pump; said vacuum line being in cooperation with said vacuum pump and said inlet conduit; and b) said means for discharging said drill cuttings includes, at least one solids pump; at least one discharge line, and means for operating said solids pump; said solids pump being in communication with said outlet conduit, and said discharge line being in communication with said solids pump.
25. Apparatus according to claim 23 or 24, wherein said control mechanism includes: a) means for regulating said vacuum relief valve and generating a control signal, said means for regulating said vacuum relief valve and generating a control signal being in cooperation with said vacuum relief valve.
26. Apparatus according to claim 25, wherein said means for regulating said vacuum relief valve and generating a control signal is a computer.
27. Apparatus according to any one of claims 21 to 26, wherein said means for continuously detecting and transmitting the level of said drill cuttings located in said portable container is an ultrasonic sensor.
28. Apparatus according to any one of claims 21 to 26, wherein said means for continuously detecting and transmitting the level of said drill cuttings located in said portable container is a sonar sensor.
29. Apparatus according to any one of claims 21 to 26, wherein said means for continuously detecting and transmitting the level of said drill cuttings located in said portable container is a photoelectric sensor.
30. Apparatus according to any one of claims 21 to 26, wherein said means for continuously detecting and transmitting the level of said drill cuttings located in said portable container is a radar sensor.
31. Apparatus according to any one of claims 21 to 26, wherein said control mechanism includes: a) means for regulating said solids pump and generating a control signal, said means for regulating said solids pump and generating a control signal being in cooperation with said solids pump.