WO2013116716A1

WO2013116716A1 - Multi-deck vibratory separator with series and parallel fluid processing capabilities

Info

Publication number: WO2013116716A1
Application number: PCT/US2013/024432
Authority: WO
Inventors: Benjamin Lanning HOLTON
Original assignee: M-I L.L.C.
Priority date: 2012-02-03
Filing date: 2013-02-01
Publication date: 2013-08-08
Also published as: NO20141053A1

Abstract

An adapter assembly for a vibratory separator, the adapter assembly including a flow director having a first side wall, a second side wall disposed parallel to and opposite from the first side wall, and a flow directing wall disposed between the first side wall and the second side wall, wherein the flow directing wall is substantially perpendicular to the first side wall and the second side wall. A method of converting a vibratory separator from a parallel flow configuration to a series flow configuration, the method including accessing a first adapter assembly, and moving a first flow directing wall from a second position, in which a first opening disposed in a first base is exposed, to a first position, in which the first opening disposed in the first base is obstructed.

Description

MULTI-DECK VIBRATORY SEPARATOR WITH SERIES AND PARALLEL FLUID PROCESSING CAPABILITIES

BACKGROUND

[0001] Oilfield drilling fluid, often called "mud," serves multiple purposes in the industry. Among its many functions, the drilling mud acts as a lubricant to cool rotary drill bits and facilitate faster cutting rates. Typically, the mud is mixed at the surface and pumped downhole at high pressure to the drill bit through a bore of the drillstring. Once the mud reaches the drill bit, it exits through various nozzles and ports where it lubricates and cools the drill bit. After exiting through the nozzles, the "spent" fluid returns to the surface through an annulus formed between the drillstring and the drilled wellbore.

[0002] Furthermore, drilling mud provides a column of hydrostatic pressure, or head, to prevent "blow out" of the well being drilled. This hydrostatic pressure offsets formation pressures thereby preventing fluids from blowing out if pressurized deposits in the formation are breeched. Two factors contributing to the hydrostatic pressure of the drilling mud column are the height (or depth) of the column (i.e., the vertical distance from the surface to the bottom of the wellbore) itself and the density (or its inverse, specific gravity) of the fluid used. Depending on the type and construction of the formation to be drilled, various weighting and lubrication agents are mixed into the drilling mud to obtain the right mixture. Typically, drilling mud weight is reported in "pounds," short for pounds per gallon. Generally, increasing the amount of weighting agent solute dissolved in the mud base will create a heavier drilling mud. Drilling mud that is too light may not protect the formation from blow outs, and drilling mud that is too heavy may over invade the formation. Therefore, much time and consideration is spent to ensure the mud mixture is optimal. Because the mud evaluation and mixture process is time consuming and expensive, drillers and service companies may reclaim the returned drilling mud and recycle it for continued use.

[0003] Another significant purpose of the drilling mud is to carry the cuttings away from the drill bit at the bottom of the borehole to the surface. As a drill bit pulverizes or scrapes the rock formation at the bottom of the borehole, small pieces of solid material are left behind. The drilling fluid exiting the nozzles at the bit acts to stir-up and carry the solid particles of rock and formation to the surface within the annulus between the drillstring and the borehole. Therefore, the fluid exiting the borehole from the annulus is a slurry of formation cuttings in drilling mud. Before the mud can be recycled and re-pumped down through nozzles of the drill bit, the cutting particulates are removed.

[0004] Apparatus in use today to remove cuttings and other solid particulates from drilling fluid are commonly referred to in the industry as shale shakers or vibratory separators. A vibratory separator is a vibrating sieve-like table upon which returning solids laden drilling fluid is deposited, and through which clean drilling fluid emerges. Typically, the vibratory separator is an angled table with a generally perforated filter screen bottom. Returning drilling fluid is deposited at a feed end of the vibratory separator. 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 vibratory separator table conveys solid particles left behind until they fall off the discharge end of the separator table. The above described apparatus is illustrative of one type of vibratory separator known to those of ordinary skill in the art. In other vibratory separators, the top edge of the separator may be relatively closer to the ground than the lower end. In such vibratory separators, the movement of particulates may be in a generally upward direction. In still other vibratory separators, the table may not be angled, thus the vibrating action of the separator alone may enable particle/fluid separation. Regardless, table inclination and/or design variations of existing vibratory separators should not be considered a limitation of the present disclosure.

[0005] The amount of vibration and the angle of inclination of the vibratory separator table are adjustable to accommodate various drilling fluid flow rates and particulate percentages in the drilling fluid. After the fluid passes through the perforated bottom of the vibratory separator, it can either return to service in the borehole immediately, be stored for measurement and evaluation, or pass through an additional piece of equipment (e.g. , a drying shaker, centrifuge, or a smaller sized shale shaker) to further remove smaller cuttings. [0006] A typical vibratory separator includes an elongated, box-like, rigid bed, and a screen attached to, and extending across, the bed. The bed is vibrated as the material to be separated is introduced to the screen. The vibrations, often in conjunction with gravity, move the relatively large size material along the screen and off the end of the bed. Liquid and/or relatively small sized material passes through the screen into a pan. The bed is typically vibrated by pneumatic, hydraulic, or rotary vibrators, in a conventional manner.

[0007] In certain vibratory separators, multiple stages of screening may be required to refine the solids laden fluid to a desired purity. In order to reduce space requirements, multiple screen decks may be disposed in a single vibratory separator basket. For example, in the MD-3 shale shaker, commercially available from M-I L.L.C. of Houston, Texas, includes 3 screen decks.

[0008] Referring to Figure 1 , a perspective view of a multi-deck vibratory separator

100 is shown. Multi-deck vibratory separator 100 includes a top screen deck 102, a middle screen deck 104, and a bottom screen deck 106. Solid laden fluid is introduced to multi-deck vibratory separator 100 on top screen deck 102. Fluid and solids smaller than the top screen mesh pass through top screen deck 102, while solids larger than the top screen mesh remain on top screen deck 102 and are removed from multi-deck vibratory separator 100.

[0009] In a series configuration, effluent from top screen deck 102 is directed to middle screen deck 104 by a first flowback pan (not shown) disposed below top screen deck 102. Solids larger than the mesh of middle screen deck 104 do not pass through middle screen deck 104 and are discarded from the separator, while effluent from middle screen deck 104 is directed to bottom screen deck 106. Effluent from bottom screen deck 106 may be collected in a sump, while solids too large to pass through bottom screen deck 106 are removed from the separator and are discarded. Thus, in series operation, fluid is processed by top screen deck 102, middle screen deck 104, and bottom screen deck 106 in order. A multi-deck vibratory separator configured to process fluid in series may remove more solids from the fluid being processed and may be used in selective screening applications where specific solids are recovered for re-use. [0010] A parallel fluid processing configuration may be used instead of the series configuration, described above. In a parallel configuration, effluent from top screen deck 102 is divided into two streams by a first flowback pan (not shown). One of the streams is directed to middle screen deck 104, while the other stream is directed to bottom screen deck 106. Effluent passing through middle screen deck 104 and bottom screen deck 106 may then be collected in a sump for re-use. A multi-deck vibratory separator configured to process fluid in parallel may have a higher fluid capacity for a given mesh size of screen decks 102, 104, and 106, and thus, may process more fluid in a given time than a separator configured to process fluid in series.

BRIEF DESCRIPTION OF DRAWINGS

[0011] Figure 1 is a perspective view of a vibratory separator.

[0012] Figure 2 is a section view of a vibratory separator disposed in a series configuration, in accordance with embodiments disclosed herein.

[0013] Figures 3a and 3b are perspective views of adapter assemblies disposed in a series configuration, in accordance with embodiments disclosed herein.

[0014] Figure 4 is a perspective view of an adapter assembly disposed in a series configuration, in accordance with embodiments disclosed herein.

[0015] Figure 5 is a section view of a vibratory separator disposed in a parallel configuration, in accordance with embodiments disclosed herein.

[0016] Figures 6a, 6b, and 6c are perspective views of adapter assemblies disposed in a parallel configuration, in accordance with embodiments disclosed herein.

[0017] Figure 7 is a perspective view of an adapter assembly disposed in a parallel configuration, in accordance with embodiments disclosed herein.

[0018] Figures 8a, 8b, and 8c are perspective views of an adapter assembly in accordance with embodiments disclosed herein.

[0019] Figures 9a and 9b are perspective views of an adapter assembly in accordance with embodiments disclosed herein. [0020] Figure 9c is a top view of the adapter assembly of Figures 9b.

DETAILED DESCRIPTION

[0021] In one aspect, embodiments disclosed herein generally relate to a vibratory separator for separating solids from fluid. Specifically, embodiments disclosed herein relate to an adapter assembly for a multi-deck vibratory separator. Embodiments disclosed herein relate to an adapter assembly configured to allow a single multi-deck vibratory separator to function in either a parallel operating mode or a series operating mode. In particular, embodiments disclosed herein relate to a vibratory separator having an adapter assembly, wherein the adapter assembly is selectively movable between a first position configured to allow processing of fluid in series over at least two screens, and a second position configured to allow processing of fluid in parallel over at least two screens.

[0022] Referring initially to Figure 2, a multi-deck vibratory separator 300 is shown in series mode. When configured to operate in series mode, the solid-laden fluid introduced to the multi-deck vibratory separator is processed first by a top screen deck 302, then by a middle screen deck 304, and finally by a bottom screen deck 306. The positions of a first adapter assembly 308 and a second adapter assembly 310 allow vibratory separator 300 to process fluid in series, as described.

[0023] During series operation, a solid-laden fluid may be introduced to a top screen deck 302 of multi-deck vibratory separator 300. Fluid and solid particles smaller than openings on top screen deck 302 may pass through top screen deck 302 as a first effluent, while solids too large to pass through are discarded from the multi-deck vibratory separator 300. The first effluent may be collected by a first flowback pan 312, and a flow divider 316 disposed on first flowback pan 312 may divide the first effluent into a first stream and a second stream. In certain embodiments, flow divider 316 may include a solid wall extending upwardly from first flowback pan 312, and extending across the length of flowback pan 312 in a direction parallel to the flow of the first effluent toward a first baffle 318, as shown. Although flow divider 316 is shown dividing first flowback pan 312 into two equal areas, those of ordinary skill in the art will appreciate that flow divider 316 may be offset toward first side 326 or toward second side 328 in order to adjust the amount of effluent in the first and second streams.

[0024] First baffle 318 may direct a first stream of effluent to middle screen deck 304, while directing a second stream of effluent to first adapter assembly 308. First baffle 318 may include a central flow separator 319 which abuts flow divider 316 on first flowback pan 312 to form a continuous wall between the first and second streams of the first effluent. On a first side 326 of central flow separator 319 on first baffle 318, a gap 323 is formed between a substantially vertically-oriented deflecting wall 321 on first baffle 318 and first flowback pan 312. The first stream of effluent on the first side 326 of central flow separator 319 on flowback pan 312 may fall through gap 323 onto middle screen deck 304. In such a configuration, the first stream of effluent may not reach first baffle 318.

[0025] On a second side 328 of central flow separator 319, a bridge 317 of first baffle

318 provides a lower surface across which the second stream of effluent may travel from first flowback pan 312 to first adapter assembly 308. As such, there is no gap on second side 328 of central flow separator 319 through which the second stream of effluent may pass through to land directly on middle screen deck 304. Rather, the second stream of effluent on second side 328 of central flow separator 319 is directed by bridge 317 to a first adapter assembly 308. The configuration of first adapter assembly 308 determines the subsequent flow path of the second stream of effluent.

[0026] In a series configuration, adapter assembly 308 may collect the second stream of effluent from top screen deck 302 and direct the second stream to middle screen deck 304, where the second stream of effluent rejoins the first stream. Referring to Figure 3a, an adapter assembly 308 is shown in a series configuration. Adapter assembly 308 may include a flow director 401 and a base 408 having an opening 410. Flow director 401 may include a first side wall 404a and a second side wall 404b disposed parallel to and opposite first side wall 404a. First and second side walls 404a, 404b may be connected by a flow directing wall 402, and in certain embodiments, flow directing wall 402 may be substantially perpendicular to first and second side walls 404a, 404b. First and second side walls 404a, 404b may be integrally formed with flow directing wall 402, or alternatively, flow directing wall 402 may be selectively movable with respect to first side wall 404a and second side wall 404b. Specifically, flow directing wall 402 may be at least one of removable from and/or rotatable with respect to first and second side walls 404a, 404b, so as to allow the multi-deck vibratory separator to be interchangeable between a series and a parallel operation mode.

[0027] Flow director 401 may be positioned on base 408 using a releasable coupling.

For example, a plurality of tabs 414a may engage base 408 in an interference fit, as shown. Alternatively, clamps, screws, Velcro™, or other releasable couplings known in the art may be used without departing from the scope of the present application. The adapter assembly 308 may be coupled to a screen for placement in a vibratory separator, as discussed in more detail below. The adapter assembly and screen may be held in place in the vibratory separator by a pneumatic bladder, clamp, or other locking mechanisms known in the art for securing a screen in a vibratory separator.

[0028] In a series configuration, flow directing wall 402 obstructs opening 410 of base 408, thereby preventing fluid from flowing through opening 410. In certain embodiments, as shown in Figure 3b, a back wall 406 may be disposed on flow director 401 at approximately 90 degrees from flow directing wall 402 to prevent effluent from flowing away from a screen deck. Thus, in a series configuration, flow directing wall 402 and back wall 406 of first adapter assembly 308 may direct the second stream of effluent from first flowback pan 312 onto middle screen deck 304.

[0029] Referring to Figure 4, a multi-deck vibratory separator 300 configured in series mode is shown. Effluent passing through middle screen deck 304 may be deposited on a second flowback pan 314 and may flow on second flowback pan 314 to a second adapter assembly 310. When multi-deck vibratory separator 300 is configured in series mode, second adapter assembly 310 is configured to direct flow from second flowback pan 314 to bottom screen deck 306. Second adapter assembly 310 may include a flow director similar to flow director 401 of first adapter assembly 308. The flow director of second adapter assembly 310 may include first and second side walls with a flow directing wall disposed therebetween. When assembled in series mode, the flow directing wall of second adapter assembly 310 obstructs an opening in a base, thereby guiding the effluent from middle screen deck 304 toward bottom screen deck 306. As discussed above, a back wall may be used to prevent effluent from flowing away from bottom screen deck 306. From second adapter assembly 310, effluent flows onto bottom screen deck 306 where a third stage of separation may occur. A third effluent from bottom screen deck 306 may be collected in a sump (not shown) or may be re-introduced into an active mud system.

[0030] Those of ordinary skill in the art will appreciate that additional screen decks may be used to further separate the effluent from bottom screen deck 306. For example, while three screen decks are shown in Figures 2 and 4, four, five, or more screen decks may be used in a vibratory separator without departing from the scope of the present application. Four, five, or more adapter assemblies may be used in vibratory separators having four, five, or more screen decks, respectively. Each screen disposed in a vibratory separator may be coupled to a separate adapter assembly. In some embodiments, a vibratory separator may include two screens per deck. In such embodiment, an adapter assembly is coupled to each screen. Therefore, each deck of the vibratory separator may include two adapter assemblies. For example, a three deck vibratory separator as shown in Figures 1 and 2 may include six screens (two screens per each deck). The widths of the screens are approximately half the width of the basket of the vibratory separator. The three deck vibratory separator may, therefore, include four adapter assemblies. Two adapter assemblies are coupled to the two screens on the middle deck to direct the fluid flow between the top and middle deck, and two adapter assemblies are coupled to the two screens on the bottom deck to direct the fluid flow between the middle and bottom deck. The adapter assemblies may be slid into screen tracks of the vibratory separator basket. Each adapter assembly may be configured to operate in series mode, as discussed above, or in parallel mode, as will be discussed later in the application.

[0031] Referring to Figure 5, a multi-deck vibratory separator 600 is shown in parallel mode. Solid-laden fluids may be introduced to a top screen deck 602 of multi-deck vibratory separator 600, and fluid and solid particles smaller than openings on top screen deck 602 may pass through top screen deck 602 as a first effluent, while solids too large to pass are discarded from multi-deck vibratory separator 600. The first effluent may be collected by a first flowback pan 612 disposed below top screen deck 602. In certain embodiments, at least a portion of first flowback pan 612 may be sloped downward toward a first adapter assembly 608 to direct the first effluent toward first adapter assembly 608. Additionally, flowback pan 612 may include a flow divider 616 that extends upward from second flowback pan 612 toward top screen deck 602 and extends along the length of flowback pan 612 in a direction parallel to the flow of the first effluent. Flow divider 616 separates the first effluent into a first stream and a second stream, and both the first and second streams flow toward first adapter assembly 608. Those of ordinary skill in the art will appreciate that any means of separating a volume of fluid into two separate streams may be used.

[0032] Similar to the series embodiment discussed above, a first stream of effluent on a first side 624 of central flow separator 616 may pass through a gap 623 between first flowback pan 612 and deflecting wall 621 of first baffle 618. Middle screen deck 604 disposed below gap 623 may receive the first stream of effluent. Additionally, a second stream of effluent on a second side 626 of central flow separator 616 may pass across a bridge 617 on first baffle 618 and may contact a first adapter assembly 608 disposed in a parallel operation configuration.

[0033] Referring to Figures 6a and 6b, in a parallel configuration, first adapter assembly 608 may be configured to expose an opening 710 in base 708. As shown, a flow director 701 having first and second side walls 704a, 704b connected by flow directing wall 702 may be re-arranged from the series configuration (Figure 3 a) such that flow directing wall 702 exposes opening 710 in base 708. Simultaneously, flow directing wall 702 may prevent the second stream of effluent from flowing onto middle screen deck 604. In certain embodiments, as shown in Figure 6c, a back wall 706 may be disposed substantially parallel to and opposite flow directing wall 702 to help direct fluid through opening 710 in base 708.

[0034] Referring back to Figure 5, fluid from first adapter assembly 608 may flow through opening 710 (Figure 6a) in base 708 (Figure 6a) and may be directed onto a bottom screen deck 608 by a second baffle 620, where further processing of the second stream of the first effluent occurs. Thus, the second stream of effluent is processed by bottom screen deck 606 while the first stream of effluent is processed by middle screen deck 604. Effluent produced by middle screen deck 604 may fall onto a second flowback pan 614 which may direct the effluent produced by middle screen deck 604 to a second adapter assembly 610 disposed in a parallel configuration. Thus, the effluent produced by middle screen deck 604 may pass through an opening in a base of second adapter assembly 610. In certain embodiments, second adapter assembly 610 is substantially the same as first adapter assembly 608. Effluent from middle screen deck 604 may then be collected. Effluent produced by bottom screen deck 606 may be collected separately, or may be collected by the same collection sump used to hold the effluent from middle screen deck 604.

[0035] Figures 3 a, 3b, 6a, 6b, 6c show embodiments in accordance with the present disclosure are shown with first adapter assemblies 308, 608 and second adapter assemblies 310, 610 having flow directors 401, 701 which are removable from bases 408, 708, respectively, and may be rotated to alternate between series and parallel configurations. However, those of ordinary skill in the art will appreciate that other means for switching the operation modes of multi-deck vibratory separators 300, 600 may be used.

[0036] Referring to Figures 8a, 8b, and 8c, an adapter assembly 808 is shown.

Adapter assembly 808 may have a first side wall 804a disposed substantially parallel to an opposing second side wall 804b, with a flow directing wall 802 disposed between first side wall 804a and second side wall 804b. Flow directing wall 802 may be selectively movable with respect to the first and second side walls 804a, 804b. In certain embodiments, flow directing wall 802 may be rotated with respect to side walls 804a, 804b between a series operating position and a parallel operating position. Referring to Figure 8a, adapter assembly 808 is shown in a series configuration with flow directing wall 802 covering an opening 810 in base 812. In this embodiment, flow directing wall 802 may be coupled to base 812 with a hinge-like coupling to allow at least 90 degrees of rotation about the coupling. Referring to Figure 8b, adapter assembly 808 is shown with flow deflecting wall 802 in the middle of a rotation between the series configuration of Figure 8a, and the parallel configuration of Figure 8c. Referring now to Figure 8c, adapter assembly 808 is configured to operate in parallel mode with flow directing wall 802 substantially perpendicular to base 812, and with the opening (not shown) in base 812 exposed. [0037] Referring to Figures 9a, 9b, and 9c, an adapter assembly 908 is shown.

Adapter assembly 908 includes a first side wall 904a disposed substantially parallel to an opposing second side wall 904b, with a flow directing wall 902 disposed between first side wall 904a and second side wall 904b. In this embodiment, flow directing wall 902 is selectively movable with respect to the first and second side walls 904a, 904b. Specifically, flow directing wall 902 is slidable with respect to first and second side wall 904a, 904b. When flow directing wall 902 is in a first position, as shown in Figures 9b and 9c, the opening 910 in base 912 is open or exposed for parallel flow. The flow directing wall 902 may then be slid back to a second position, shown in Figure 9a, in which the flow directing wall 902 covers the opening 910 in the base 912, so as to provide series flow.

[0038] As shown in Figures 9a and 9b the flow directing wall 902 may be shaped such that a bottom portion of the flow directing wall 902 may cover the opening 910 when the flow directing wall 902 is moved into the second position (Figure 9a). For example, the flow directing wall 902 may be L-shaped. In other words, the flow directing wall 902 may include a horizontal portion 903 and a vertical portion 905 joined together. In one embodiment, the movable flow directing wall 902 may include a notch or protrusion (not shown) configured to engage a track formed on an inner surface of one or both of the first and second side walls 904a, 904b. When the protrusion is engaged with the track, the flow directing wall 902 may be moved (i.e., slid) forwards or backwards. In another embodiment, the flow directing wall 902 may include an arm or extension (not shown) proximate a top side of the flow directing wall 902 that is configured to engage a top surface of one or both of the first and second side walls 904a, 904b, so that the flow directing wall 902 may be moved (i.e., slid) forwards or backwards. In some embodiments, the arm or extension may include a groove configured to engage the first and/or second side wall 904a, 904b.

[0039] In yet other embodiments, as shown in Figure 9b, the first side wall 904a may include a first stop 907a and a second stop 909b and the second side wall 904b may include a first stop 907b and second stop 909b. The flow directing wall 902 is configured to slide along base 912 within the first stops 907a, 907b and the second stops 909a, 909b. The first and second stops 907, 909 may be configured as inwardly protruding walls extending from a first end and a second end of the first and second side walls 904a, 904b. The flow directing wall 902 may be moved forward to open or reveal opening 910 (Figure 9c) until the flow directing wall 902 (e.g., the vertical portion 905) contacts or abuts the first stops 907a, 907b. The flow directing wall 902 may be moved backward to cover the opening 910 (Figure 9c) until the flow directing wall 902 contacts or abuts the second stops 909a, 909b. One of ordinary skill in the art will appreciate that other configurations of side walls, bases, and flow directing walls may be used to allow the flow directing wall to move to allow opening 910 to be opened or closed and to stop the flow directing wall at a first position and a second position. Additionally, a locking mechanism may be used to' secure the flow directing wall in the first and/or second position. For example, a latch, screw, bolt, key, or other known mechanical locking mechanisms may be used to secure the flow directing wall 902 in a particular position.

[0040] In another embodiment, a first adapter assembly may have a first side wall disposed substantially parallel and opposite to a second side wall. A flow directing wall may be disposed between the first and second side walls such that the flow directing wall is selectively removable with respect to the first and second side walls. In such an embodiment, the flow directing wall may be removed from a first position, such as a series position, and may be re-inserted into the multi-deck vibratory separator in a second position, such as a parallel position.

[0041] Similarly, a second adapter assembly may have a first side wall disposed substantially parallel and opposite to a second side wall. A flow directing wall may be disposed between the first and second side walls of the second adapter assembly such that the flow directing wall is selectively removable with respect to the first and second side walls. Such a flow directing wall on a second adapter assembly may be moved from a third position, such as a series position in which an opening is obstructed, to a fourth position, such as a parallel position in which an opening is exposed. Those of ordinary skill in the art will appreciate that the flow directing walls of the first and second adapters may also be moved from a parallel position to a series position.

[0042] In yet other embodiments, an adapter assembly may include a parallel flow director and a series flow director. In such an embodiment, if it is determined to assemble the multi-deck vibratory separator in a parallel operating mode, the parallel flow director may be positioned removable within the base, while the series flow director is stored outside of the multi-deck vibratory separator. To change to a series operating mode, the parallel flow director may be removed from the base in the multi- deck vibratory separator and may be stored for later use. The series flow director may then be installed in the base to provide series flow of fluid through the multi-deck vibratory separator. Similar to the previously described embodiments, the parallel flow director may expose an opening in the base while the series flow director may obstruct the opening. Each adapter assembly as described above may be integrally formed. For example, a flow directing wall having a first side wall, a second side wall disposed parallel to and opposite from the first side wall, and a flow directing wall disposed between the first side wall and the second side wall may be integrally formed. In another example, the parallel flow director may be integrally formed and a series flow director may be integrally formed. Thus, a series adapter may be formed having a base, a first side wall, a second side wall, and a flow director wall with no opening in the bottom of the base. Therefore, flow to the lower decks would be blocked or prevented. A parallel adapter may be formed having a base, a first side wall, a second side wall, a flow directing wall, and an opening formed in the base or adapter assembly to allow fluid to pass below to a lower deck. For example, the adapter assembly shown in Figure 8a may be formed as a single series adapter and the adapter assembly shown in Figure 8c may be formed as a single parallel adapter. As such, the series and parallel adapters may be used interchangeably on a multi-deck vibratory separator. In such an embodiment, if it is determined to assemble the multi-deck vibratory separator in a parallel operating mode, the parallel flow adapter assembly may be positioned adjacent an end of at least one screen of the vibratory separator. If it is determined to assemble the multi-deck vibratory separator in a series operating mode, the series flow adapter assembly may be positioned adjacent an end of at least one screen of the vibratory separator. As used herein, integrally formed refers to molding as a single piece, co-molding, or manufacturing as a single component, for example, welding, soldering joining metal, etc. In this embodiment, each of the series and parallel adapters may be assembled to and removed from the vibratory separator as discussed above with respect to other embodiments disclosed.

[0044] Using any of the previously described adapter assembly embodiments, a multi-deck vibratory separator may be alternated between a series operating mode and a parallel operating mode by reconfiguring the adapter assembly to obstruct or expose an opening in the adapter assembly base, respectively. In certain multi-deck vibratory separators, the screen adjacent the adapter assembly may be removed in order to access the adapter assembly for reconfiguration, as the adapter assembly may be coupled to the adjacent screen. The coupling may be substantially permanent and may be accomplished using, for example, adhesives, welding, and/or mechanical fasteners; alternatively, the coupling may be selectively removable and may be achieved using, for example, removable mechanical fasteners, such as screws or bolts, clips, interference fits, and/or magnets.

[0045] Embodiments disclosed herein relate to an adapter assembly for a vibratory separator, the adapter assembly including a flow director having a first side wall, a second side wall disposed parallel to and opposite from the first side wall, and a flow directing wall disposed between the first side wall and the second side wall. The flow directing wall is substantially perpendicular to the first side wall and the second side wall. In some embodiments, the first side wall, the second side wall, and the flow directing wall are integrally formed. In some embodiments, the flow directing wall is selectively movable with respect to the first side wall and the second side wall. In some embodiments, the flow directing wall is selectively movable with respect to a base, the first side wall, and the second side wall. Accessing the first adapter assembly may include removing a first screen and the first adapter assembly from the vibratory separator, wherein the first adapter assembly is coupled to the first screen. Converting the vibratory separator from a series flow configuration to a parallel flow configuration may include removing a series adapter from a first screen and coupling a parallel adapter to the first screen.

[0046] In another aspect, embodiments disclosed herein relate to an adapter assembly for a vibratory separator, the adapter assembly including a parallel flow director having a set of two side walls and a flow directing wall disposed between the two side walls, and a series flow director having a set of two side walls and a flow directing wall disposed between the two side walls. The adapter assembly further includes a base having an opening, wherein the base is configured to receive one of the parallel flow director and the series flow director. The flow directing wall of the parallel flow director is configured to expose the opening in the base. The flow directing wall of the series flow director is configured to obstruct the opening in the base.

[0047] In yet another aspect, embodiments disclosed herein relate to a vibratory separator including a shaker basket, a plurality of screens disposed on a plurality of decks, and at least one adapter assembly. The at least, one adapter assembly includes a flow director having a first side wall, a second side wall, and a flow directing wall disposed between the first side wall and the second side wall, and a base having an opening. The base is configured to receive the flow director, and the flow directing wall is movable with respect to the base between a first position and a second position. The at least one adapter assembly is disposed adjacent an end of at least one of the plurality of screens. In some embodiments, the vibratory separator may include a top screen, a middle screen, and a bottom screen. The vibratory separator may include a first adapter assembly coupled to the top screen and a second adapter assembly coupled to the middle screen.

[0048] In still another aspect, embodiments disclosed herein relate to a method of converting a vibratory separator from a series flow configuration to a parallel flow configuration, the method including accessing a first adapter assembly, and moving a first flow directing wall from a first position, in which a first opening disposed in a first base is obstructed, to a second position, in which the first opening disposed in the first base is exposed. The method may include moving the first flow directing wall from the first position to the second position comprises moving the first flow directing wall from a substantially horizontal position to a substantially vertical position.

[0049] In another aspect, embodiments disclosed herein relate to a method of converting a vibratory separator from a parallel flow configuration to a series flow configuration, the method including accessing a first adapter assembly, and moving a first flow directing wall from a second position, in which a first opening disposed in a first base is exposed, to a first position, in which the first opening disposed in the first base is obstructed. The method may include moving the first flow directing wall from the second position to the first position comprises moving the first flow directing wall from a substantially vertical position to a substantially horizontal position.

[0050] In another aspect, embodiments disclosed herein relate to a method of converting a vibratory separator between a series flow configuration and a parallel flow configuration, the method including accessing a first adapter assembly. The method further includes converting the vibratory separator from a series flow configuration to a parallel flow configuration and/or converting the vibratory separator from a parallel flow configuration to a series flow configuration.

[0051] Embodiments disclosed herein provide for a multi-deck vibratory separator that may operate in either series or parallel mode. The ability to alternate a single vibratory separator between a series mode and a parallel mode may provide a cost effective way for an operator to control the amount of processing performed on a solid-laden fluid. For example, a separator operating in parallel mode may have a higher fluid capacity for a given mesh size of the screens than a separator operating in series mode. However, a series shaker may be able to remove more solids from the solid-laden fluid than a parallel shaker by using screens with progressively smaller mesh sizes. Additionally, a shaker configured in series may allow operators to separate specific solids, such as mud additives, from the solid-laden fluid. These solids may then be stored or reused.

[0052] Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from a multi-deck vibratory separator with series and parallel fluid processing capabilities. Accordingly, all such modifications are intended to be included within the scope of this disclosure. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 1 12, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words 'means for' together with an associated function.

Claims

CLAIMS What is claimed:

1. An adapter assembly comprising:

a flow director comprising:

a first side wall;

a second side wall disposed parallel to and opposite from the first side wall; and

a flow directing wall disposed between the first side wall and the second side wall, wherein the flow directing wall is substantially perpendicular to the first side wall and the second side wall.

2. The adapter assembly of claim 1, further comprising:

a base configured to receive the flow director, wherein the base comprises an opening.

3. The adapter assembly of claim 2, wherein the flow directing wall is movable with respect to the base, the first side wall, and the second side wall, and wherein the flow directing wall is movable between a first position and a second position.

4. The adapter assembly of claim 3, wherein the flow directing wall obstructs the opening of the base in the first position, and wherein the flow directing wall exposes the opening of the base in the second position.

5. The adapter assembly of any preceding claim, wherein the flow directing wall is selectively movable with respect to the first side wall and the second side wall.

6. The adapter assembly of any preceding claim, wherein the flow directing wall is at least one of removable and rotatable with respect, the first side wall, and the second side wall.

7. The adapter assembly of claim 1, further comprising a second flow director comprising:

a set of two side walls; and a flow directing wall disposed between the two side walls; and

a base having an opening, wherein the base is configured to receive one of the flow director and the second flow director,

wherein the flow director is a parallel flow director and the second flow director is a series flow director.

8. A vibratory separator comprising:

a plurality of screens disposed on a plurality of decks; and

at least one adapter assembly comprising:

a flow director having a first side wall, a second side wall, and a flow directing wall disposed between the first side wall and the second side wall; and a base having an opening,

wherein the base is configured to receive the flow director, and

wherein the flow directing wall is movable with respect to the base between a first position and a second position,

wherein the at least one adapter assembly is disposed adjacent an end of at least one of the plurality of screens.

9. The vibratory separator of claim 8, wherein the flow directing wall obstructs the opening of the base in the first position to direct fluid to an upper screen, and wherein the flow directing wall exposes the opening of the base in the second position to direct fluid to a lower screen, wherein the lower screen is disposed below the upper screen.

10. The vibratory separator of claim 8, wherein the first side wall, the second side wall, and the flow directing wall are integrally formed, and wherein the integrally formed first side wall, second side wall, and flow directing wall are movable with respect to the base.

1 1. The vibratory separator of claim 8, further comprising:

a first screen and a first adapter assembly disposed in a middle deck; and

a second screen and a second adapter assembly disposed in a bottom deck, wherein the first screen is disposed above the second screen.

12. The vibratory separator of claim 11, wherein when the first adapter and the second adapter are disposed in the first position, the first adapter obstructs a first opening of the first adapter and the second adapter obstructs a second opening of the second adapter.

13. The vibratory separator of claim 11, wherein when the first adapter and the second adapter are disposed in the second position, the first adapter exposes a first opening of the first adapter and the second adapter exposes a second opening of the second adapter.

14. A method of converting a vibratory separator between a series flow configuration and a parallel flow configuration, the method comprising:

accessing a first adapter assembly; and

at least one selected from a group consisting of converting the vibratory separator from a series flow configuration to a parallel flow configuration and converting the vibratory separator from a parallel flow configuration to a series flow configuration.

15. The method of claim 14, wherein converting the vibratory separator from a series flow configuration to a parallel flow configuration comprises:

moving a first flow directing wall from a first position, in which a first opening disposed in a first base is obstructed, to a second position, in which the first opening disposed in the first base is exposed.

16. The method of claim 15, wherein converting the vibratory separator from a series flow configuration to a parallel flow configuration further comprises:

accessing a second adapter assembly; and

moving a second flow directing wall from a third position, in which a second opening disposed in a second base is obstructed, to a fourth position, in which the second opening disposed in the second base is exposed.

17. The method of claim 14, wherein converting the vibratory separator from a parallel flow configuration to a series flow configuration comprises: moving a first flow directing wall from a second position, in which a first opening disposed in a first base is exposed, to a first position, in which the first opening disposed in the first base is obstructed.

18. The method of claim 17, wherein converting the vibratory separator from a parallel flow configuration to a series flow configuration further comprises:

accessing a second adapter assembly; and

moving a second flow direction wall from a fourth position, in which a second opening disposed in a second base is exposed, to a third position, in which the second opening disposed in the second base is obstructed.

19. The method of claim 15, wherein moving the first flow directing wall from the first position to the second position comprises moving the first flow directing wall from a substantially horizontal position to a substantially vertical position.

20. The method of claim 14, wherein converting the vibratory separator from a series flow configuration to a parallel flow configuration comprises:

removing a series adapter from a first screen; and

coupling a parallel adapter to the first screen