U.S. patent application number 12/597161 was filed with the patent office on 2010-04-08 for rig storage system.
This patent application is currently assigned to M-I L.L.C.. Invention is credited to Jan Thore Eia, Peter Wright.
Application Number | 20100084190 12/597161 |
Document ID | / |
Family ID | 39875961 |
Filed Date | 2010-04-08 |
United States Patent
Application |
20100084190 |
Kind Code |
A1 |
Eia; Jan Thore ; et
al. |
April 8, 2010 |
RIG STORAGE SYSTEM
Abstract
A system for storing cuttings including a drilling rig having a
deck and at least two support structures, and at least one cuttings
storage vessel disposed in at least one of the at least two support
structures is disclosed. A method of storing cuttings on a drilling
rig including transferring materials from a deck of the drilling
rig to a pressurized vessel dispose din a support structure of the
drilling rig is also disclosed.
Inventors: |
Eia; Jan Thore; (Kvernaland,
NO) ; Wright; Peter; (Hundvag, NO) |
Correspondence
Address: |
OSHA LIANG/MI
TWO HOUSTON CENTER, 909 FANNIN STREET, SUITE 3500
HOUSTON
TX
77010
US
|
Assignee: |
M-I L.L.C.
Houston
TX
|
Family ID: |
39875961 |
Appl. No.: |
12/597161 |
Filed: |
April 22, 2008 |
PCT Filed: |
April 22, 2008 |
PCT NO: |
PCT/US08/61162 |
371 Date: |
December 3, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60913477 |
Apr 23, 2007 |
|
|
|
Current U.S.
Class: |
175/5 ; 175/207;
175/57 |
Current CPC
Class: |
E21B 21/066
20130101 |
Class at
Publication: |
175/5 ; 175/207;
175/57 |
International
Class: |
E21B 21/01 20060101
E21B021/01; E21B 7/12 20060101 E21B007/12 |
Claims
1. A system for storing cuttings comprising: a drilling rig having
a deck and at least two support structures; and at least one
cuttings storage vessel disposed in at least one of the at least
two support structures.
2. The system of claim 1, wherein the cuttings storage vessel
comprises a pressurized vessel.
3. The system of claim 2, further comprising a pneumatic transfer
device operatively connected to the at least one cuttings storage
vessel.
4. The system of claim 1, further comprising a fluid supply line in
fluid communication with the at least one cuttings storage
vessel.
5. The system of claim 1, wherein a plurality of cuttings storage
vessels disposed in at least one of the two support structures is
arranged in a circular configuration.
6. The system of claim 1, further comprising a discharge line
operatively connected to an outlet the at least one cuttings
storage vessel and configured to allow for the transfer of cuttings
from the cuttings storage vessel to an offsite location.
7. The system of claim 6, wherein the offsite location comprises a
transport vehicle.
8. The system of claim 1, wherein the at least one cuttings storage
vessel is disposed above sea level.
9. The system of claim 1, wherein the at least one cuttings storage
vessel is disposed proximate sea level.
10. The system of claim 1, wherein the at least one cuttings
storage vessel comprises an angled lower section.
11. The system of claim 10, wherein the angled lower section of the
at least one cuttings storage vessel comprises a plurality of
angled structures.
12. A system for storing cuttings comprising: a drilling rig having
a deck and at least two support structures; and at least one
pressurized vessel disposed in at least one of the at least two
support structures, wherein the at least one pressurized vessel is
configured to store a material.
13. The system of claim 12, wherein the material comprises one of a
group consisting of a non-free flowing material, a free flowing
material, and combinations thereof.
14. The system of claim 13, wherein the non-free flowing material
comprises cuttings.
15. The system of claim 12, further comprising a pneumatic transfer
device operatively connected to the at least one pressurized
vessel.
16. A method of storing cuttings on a drilling rig comprising:
transferring materials from a deck of the drilling rig to a
pressurized vessel disposed in a support structure of the drilling
rig.
17. The method of claim 16, wherein the transferring comprises
actuating a pneumatic transfer device to provide a flow of the
materials from the pneumatic transfer device to the pressurized
vessel.
18. A method of preparing a drilling rig for cuttings storage
comprising: disposing at least one cuttings storage vessel in at
least one support structure of the drilling rig.
19. The method of claim 18, further comprising cutting an opening
in the at least one support structure of the drilling rig for
installation of a cuttings storage vessel therein.
20. The method of claim 19, further comprising closing a removed
section of the at least one support structure to seal the cuttings
storage vessel within the at least one support structure.
Description
BACKGROUND
[0001] 1. Field
[0002] Embodiments disclosed herein relate generally to a vessel
used for storing and transporting materials on a drilling rig. More
specifically, embodiments disclosed herein relate to use of a
vessel for cuttings storage and/or transport.
[0003] 2. Background Art
[0004] In the drilling of wells, a drill bit is used to dig many
thousands of feet into the earth's crust. Oil rigs typically employ
a derrick that extends above the well drilling platform or deck.
The derrick supports joint after joint of drill pipe connected
end-to-end during the drilling operation. As the drill bit is
pushed further into the earth, additional pipe joints are added to
the ever lengthening "string" or "drill string". Therefore, the
drill string typically includes a plurality of joints of pipe.
[0005] Fluid "drilling mud" is pumped from the well drilling
platform, through the drill string, and to a drill bit supported at
the lower or distal end of the drill string. The drilling mud
lubricates the drill bit and carries away well cuttings generated
by the drill bit as it digs deeper. The cuttings are carried in a
return flow stream of drilling mud through the well annulus and
back to the well drilling platform at the earth's surface. When the
drilling mud reaches the platform, it is contaminated with small
pieces of shale and rock that are known in the industry as well
cuttings or drill cuttings. Once the drill cuttings, drilling mud,
and other waste reach the platform, a "shale shaker" is typically
used to remove the drilling mud from the drill cuttings so that the
drilling mud may be reused. The remaining drill cuttings, waste,
and residual drilling mud are then transferred to a holding trough
or vessel for disposal. The drill cuttings are typically stored in
large tanks or vessels on the drilling rig platform. These vessels
may be large in size, and therefore, may require large spaces on
the drilling rig. In some situations, for example with specific
types of drilling mud, the drilling mud may not be reused and it
must also be disposed. Typically, the non-recycled drilling mud is
disposed of separate from the drill cuttings and other waste by
transporting the drilling mud via a vessel to a disposal site.
[0006] The disposal of the drill cuttings and drilling mud is a
complex environmental problem. Drill cuttings contain not only the
residual drilling mud product that would contaminate the
surrounding environment, but may also contain oil and other waste
that is particularly hazardous to the environment, especially when
drilling in a marine environment.
[0007] In the Gulf of Mexico, for example, there are hundreds of
drilling platforms that drill for oil and gas by drilling into the
subsea floor. These drilling platforms may be used in places where
the depth of the water may be many hundreds of feet. In such a
marine environment, the water is typically filled with marine life
that cannot tolerate the disposal of drill cuttings and other
waste. Therefore, there is a need for a simple, yet workable
solution to the problem of disposing of well drill cuttings,
drilling mud, and/or other waste in offshore marine and other
fragile environments.
[0008] Traditional methods of disposal include dumping, bucket
transport, cumbersome conveyor belts, screw conveyors, and washing
techniques that require large amounts of water. Adding water
creates additional problems such as added volume, bulk, and
transportation. Installing conveyors requires major modification to
the rig area and involves extensive installation hours and
expense.
[0009] Another method of disposal includes returning the drill
cuttings, drilling mud, and/or other waste via injection under high
pressure into an earth formation. Generally, the injection process
involves preparation of a slurry within surface-based equipment and
pumping the slurry into a well that extends relatively deep
underground into a receiving stratum or adequate formation.
Material to be injected back into a formation may be prepared into
a slurry acceptable to high pressure pumps used in pumping material
down a well. The particles are usually not uniform in size and
density, thus making the slurrification process complex. If the
slurry is not the correct density, the slurry often plugs
circulating pumps. The abrasiveness of the material particles may
also abrade or damage the pump impellers causing cracking. Some
centrifugal pumps may be used for grinding the injection particles
by purposely causing pump cavitations.
[0010] The basic steps in the injection process include the
identification of an appropriate stratum or formation for the
injection; preparing an appropriate injection well; formulation of
the slurry, which includes considering such factors as weight,
solids content, pH, gels, etc.; performing the injection
operations, which includes determining and monitoring pump rates
such as volume per unit time and pressure; and capping the
well.
[0011] In some instances, the cuttings, which are still
contaminated with some oil, are transported from a drilling rig to
an offshore rig or ashore in the form of a thick heavy paste for
injection into an earth formation. Typically, the material is
transferred into special skips of about 10 ton capacity which are
loaded by crane from the rig onto supply boats. This is a difficult
and dangerous operation that may be laborious and expensive.
[0012] U.S. Pat. No. 6,179,071 discloses that drill cuttings may be
stored in a holding tank or multiple tanks on a drilling rig. The
holding tank is then connected to a floating work boat with a
discharge flow line. Cuttings may then be transferred to the boat
via the flow line.
[0013] U.S. Pat. No. 6,709,216, and related patent family members,
disclose that cuttings may also be conveyed to and stored in an
enclosed, transportable vessel, where the vessel may then be
transported to a destination, and the drill cuttings may be
withdrawn therefrom. The transportable storage vessel has one or
several lower conical sections structured to achieve mass flow of
the material in the vessel, and withdrawal of the cuttings may
include applying a compressed gas to the cuttings in the vessel.
The transportable vessels are designed to fit within a 20 foot ISO
(International Organization for Standardization) container frame.
These conical vessels will be referred to herein as ISO-vessels.
This patent is herein incorporated by reference in its
entirety.
[0014] As described in U.S. Pat. No. 6,709,216 and family, the
ISO-vessels may be lifted onto a drilling rig by a rig crane and
used to store cuttings. The vessels may then be used to transfer
the cuttings onto a supply boat. The vessels may also serve as
buffer storage while a supply boat is not present. Alternatively,
the storage vessels may be lifted off the rig by cranes and
transported by a supply boat.
[0015] Space on offshore platforms is limited. In addition to the
storage and transfer of cuttings, many additional operations take
place on a drilling rig, including tank cleaning, slurrification
operations, drilling, chemical treatment operations, raw material
storage, mud preparation, mud recycle, mud separations, and many
others.
[0016] Due to the limited space, it is common to modularize these
operations and to swap out modules when not needed or when space is
needed for the equipment. For example, cuttings containers may be
offloaded from the rig to make room for modularized equipment used
for tank cleaning operations. Modularized tank cleaning operations
may include a water recycling unit of an automatic tank cleaning
system, such as described in U.S. Patent Application Publication
No. 20050205477, assigned to the assignee of the present disclosure
and hereby fully incorporated by reference.
[0017] In other drilling operations, cuttings containers may be
offloaded from the rig to make room for environmental and/or
drilling fluid recycling systems. Such systems may include a number
of mixing, flocculating, and storage tanks to clean industrial
wastewater produced during drilling or shipping operations.
Examples of such environmental and drilling fluid recycling methods
and systems are disclosed in U.S. Pat. Nos. 6,881,349 and
6,977,048, assigned to the assignee of the present disclosure, and
hereby incorporated in their entirety.
[0018] Slurrification systems that may be moved onto a rig are
typically large modules that are fully self-contained, receiving
cuttings from a drilling rig's fluid/mud recovery system. For
example, PCT Publication No. WO 99/04134 discloses a process module
containing a first slurry tank, grinding pumps, a shale shaker, a
second slurry tank, and an optional holding tank. The module may be
lifted by a crane on to an offshore drilling platform.
[0019] The lifting operations required to swap modular systems, as
mentioned above, may be difficult, dangerous, and expensive.
Additionally, many of these modularized operations are
self-contained, and therefore include redundant equipment, such as
pumps, valves, and tanks or storage vessels.
[0020] There exists a need for more efficient use of deck space and
equipment. Additionally, there exists a need to minimize the number
or size of lifts to or from a rig. Accordingly, there is a
continuing need for systems and methods for efficiently storing and
transporting materials, including free flowing materials and
non-free flowing materials.
SUMMARY OF INVENTION
[0021] In one aspect, embodiments disclosed herein relate to a
system for storing cuttings including a drilling rig having a deck
and at least two support structures, and a least one cuttings
storage vessel disposed in at least one of the at least two support
structures.
[0022] In another aspect, embodiments disclosed herein relate to a
system for storing cuttings including a drilling rig having a deck
and at least two support structures, and at least one pressurized
vessel disposed in at least one of the at least two support
structures, wherein the at least one pressurized vessel is
configured to store a material.
[0023] In another aspect, embodiments disclosed herein relate to a
method of storing cuttings on a drilling rig including transferring
materials from a deck of the drilling rig to a pressurized vessel
disposed in a support structure of the drilling rig.
[0024] In another aspect, embodiments disclosed herein relate to a
method of preparing a drilling rig for cuttings storage including
disposing at least one cuttings storage vessel in at least one
support structure of the drilling rig.
[0025] Other aspects and advantages of the invention will be
apparent from the following description and the appended
claims.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1A is a front view of a drilling rig in accordance with
embodiments disclosed herein.
[0027] FIG. 1B is a cross-sectional view of a support structure of
a drilling rig in accordance with embodiments disclosed herein.
[0028] FIG. 1C is a perspective view of a storage vessel in
accordance with embodiments disclosed herein.
[0029] FIG. 1D is a partial perspective view of a storage vessel in
accordance with embodiments disclosed herein.
[0030] FIG. 2 shows a top view of a system for transferring
material from an off-shore rig in accordance with an embodiment of
the present disclosure.
[0031] FIG. 3 is a side view of a system illustrating use of
cuttings storage vessels in a cuttings storage/transfer system and
in a module-based system fluidly connected to the cuttings storage
vessels in accordance with an embodiment of the present
disclosure.
[0032] FIG. 4 shows a slurrification system in accordance with
embodiments of the present disclosure.
[0033] FIG. 5 shows a grinding device in accordance with
embodiments of the present disclosure.
[0034] FIG. 6 shows a slurrification system in accordance with
embodiments of the present disclosure.
[0035] FIG. 7 shows a slurrification system in accordance with
embodiments of the present disclosure.
DETAILED DESCRIPTION
[0036] In one aspect, embodiments disclosed herein relate to
systems and methods for storing and transporting non-free flowing
materials, including drill cuttings, and free flowing materials.
Drilling locations may include both on-shore and off-shore drill
sites, such as drilling rigs, platforms, drill-ships, drilling
barges, and the like. In other aspects, embodiments relate to using
pressurized vessels for storage and transportation combined with
drill cuttings slurrification, cuttings processing (mechanical and
thermal drying), tank cleaning, and fluid processing systems.
[0037] FIG. 1A shows a drilling rig 1000 in accordance with
embodiments disclosed herein. In particular, drilling rig 1000
includes a system 1002 for storing and transporting non-free
flowing and/or free flowing materials. As used herein, non-free
flowing materials refer to materials that do not readily flow from
a container, for example, cuttings, powders, and dry materials. As
used herein, free flowing materials refer to materials that may
readily flow from a container, for example, proppants, chemicals,
and liquids. In some embodiments a mixture of non-free flowing and
free-flowing materials, for example, a slurry, may be stored in the
system 1002 of drilling rig 1000.
[0038] As shown in FIG. 1A, the system 1002 for storing and
transporting non-free flowing materials and/or free flowing
material in accordance with embodiments disclosed herein includes
at least one storage vessel 1004 disposed in at least one support
structure 1006 of drilling rig 1000. Drilling rig 1000 may be an
offshore drilling rig having a deck 1005 supported by at least two
support structures 1006, or legs. The at least one support
structure 1006 is coupled to at least one buoyant device 1008, for
example, a pontoon. One of ordinary skill in the art will
appreciate that any number of support structures 1006 or buoyant
devices 1008 may be used without departing from the scope of
embodiments disclosed herein. For example, in one embodiment,
drilling rig 1000 may include three or four support structures
supported by one or more buoyant devices 1008.
[0039] In one embodiment, at least one storage vessel 1004 may be
constructed or installed in at least one support structure 1006
during fabrication or manufacture of the at least one support
structure 1006. Alternatively, a support structure 1006 of a
drilling rig 1000 may be retrofitted to include at least one
storage vessel 1004. For example, in one embodiment, a hole may be
cut in at least one support structure 1006, using any method known
in the art. At least one storage vessel 1004 may be secured in the
support structure 1006 and the cut section from the support
structure 1006 may be sealed and welded back into place on the
support structure 1006. In one embodiment, the at least one storage
vessel 1004 may be fixedly attached within at least one support
structure 1006. As used herein, fixedly attached refers to a
substantially permanent connection by, for example, integrally
forming or welding. In alternate embodiments, the at least one
storage vessel 1004 may be removably disposed in at least one
support structure 1006. For example, storage vessel 1004 may be
bolted, locked, or screwed into place within the at least one
support structure 1006.
[0040] In one embodiment, at least one storage vessel 1004 may be
disposed in at least one support structure 1006 above sea level. In
accordance with certain embodiments, at least one storage vessel
1004 may be disposed in at least one support structure 1006
proximate sea level. Typically, a drilling rig deck 1005 may be
disposed approximately 65 to 100 feet (20-30 m) above sea level.
Thus, in some embodiments, the at least one storage vessel 1004 may
be disposed in at least one support structure 1006 less than 15 ft.
above sea level. In another embodiment, the at least one storage
vessel 1004 may be disposed in at least one support structure 1006
less than 30 ft. above sea level. In yet other embodiments, the at
least one storage vessel 1004 may be disposed in at least one
support structure 1006 less than 50 ft. above sea level. One of
ordinary skill in the art will appreciate that the location of the
at least one storage vessel 1004 above sea level may vary depending
on, for example, the particular drilling rig 1000 being used,
drilling equipment used, or manufacturing limitations, without
departing from the scope of the embodiments disclosed herein.
[0041] As described above, in certain embodiments, only one support
structure 1006 may contain at least one storage vessel 1004 storing
a material therein. Additionally, in certain embodiments, more than
one support structure 1006 may contain at least one storage vessel
1004, but only one or less than all of the storage vessels 1004 may
contain a material. In such embodiments, the stored material may
add additional weight to a given side or area of drilling rig 1000.
However, fluid may be filled into at least one support structure
1006, as known in the art, to counteract or ballast any weight
imbalances due to the distribution of stored material in the
storage vessels 1004 disposed in at least one support structure
1006. Additionally, disposing the storage vessels 1004 proximate
sea level, as discussed above, may also assist in stabilizing
and/or reducing the effect of any imbalanced material weight
distribution of drilling rig 1000.
[0042] As shown in FIG. 1B, in one embodiment, a plurality of
storage vessels 1004a may be disposed in at least one support
structure 1006a in a circular configuration. In such an embodiment,
a staircase, conduit, or other equipment may be disposed in the
space formed 1010 in the center of the circular configuration.
Thus, the plurality of storage vessels 1004a may be arranged within
the at least one support structure 1006a in a manner most
convenient for the construction, modification, and use of support
structure 1006a. For example, the plurality of storage vessels
1004a, disposed in the at least one support structure 1006a, may be
arranged in a grouping towards the center of support structure, in
a square configuration, opposite one another, or stacked on top of
one another. Those of ordinary skill in the art will appreciate
that the configuration of the plurality of storage vessels 1004a
may vary without departing from the scope of embodiments disclosed
herein.
[0043] Referring now to FIG. 1C, in some embodiments, the at least
one storage vessel 1004 has an angled lower section 1012 structured
to achieve mass flow of the material in the storage vessel 1004. In
one embodiment, angled lower section 1012 includes one conical
angle. These conical vessels may be referred to as ISO-vessels.
Exemplary ISO-vessels is an ISO-pump.RTM. commercially available
from M-I, LLC (Houston, Tex.). In alternate embodiments, as shown
in FIG. 1D, the angled lower section 1012 of the at least one
storage vessel 1004 has a plurality of angled structures 1014,
forming, for example, a honeycomb structure, as disclosed in PCT
Publication WO 2007/034215 A1, incorporated by reference
herein.
[0044] Referring generally to FIG. 1A, in one embodiment, material
stored in at least one storage vessel 1004 disposed in at least one
support structure 1006 may be transferred or conveyed to an offsite
location. In this embodiment, a least one discharge line 1016 may
be operatively connected to an outlet (not shown) of storage vessel
1004. A distal end 1020 of discharge line 1016 may be operatively
connected to a transport vessel (not shown) disposed on a transport
vehicle (not shown), for example, a boat or barge. In some
embodiments, as shown in FIG. 1B, material stored in a first
storage vessel 1001a disposed in at least one support structure
1006a may be conveyed via conduit 1003 to a second storage vessel
1001b disposed in the same support structure 1006a.
[0045] To facilitate the transfer of material from a storage vessel
1004 to a transport vessel or between storage vessels 1004 (1001a,
1001b), in one embodiment, the at least one storage vessel 1004 may
be pressurized. In such an embodiment, a pressurized storage vessel
1004 may store non-free flowing material, for example, cuttings. In
this embodiment, a pneumatic transfer device (not shown) may be
coupled to the at least one storage vessel 1004. Pneumatic transfer
device may include, for example, a cuttings blower (not shown) and
pneumatic transfer lines (now shown), such as disclosed in U.S.
Pat. Nos. 6,698,989, 6,702,539, and 6,709,206, and hereby
incorporated by reference herein. However, those of ordinary skill
in the art will appreciate that other methods for transferring
cuttings to storage vessels 1004 may include augers, conveyors,
vacuum suction, and pneumatic blower systems.
[0046] Still referring to FIG. 1A, in one embodiment, the at least
one storage vessel 1004 disposed in at least one support structure
1006 of drilling rig 1000 may store cuttings. In this embodiment, a
pneumatic transfer device (not shown) may be operatively coupled to
the at least one storage vessel. For example, a cuttings blower
(not shown) may be disposed on the deck 1005 of drilling rig 1000
and configured to blow cuttings from, for example, a separatory
device (not shown) disposed on the deck 1005, into at least one
storage vessel 1004 disposed in the at least one support structure
1006. Thus, by placing the storage vessel 1004 in the at least one
support structure 1006 of drilling rig 1000, more space may be made
available for other equipment and/or operations on the deck
1005.
[0047] Cuttings stored in storage vessels 1004 in at least one
support structure 1006 may be conveyed from the storage vessel 1004
to an offsite location. One or more discharge lines 1016 may be
coupled to one or more storage vessels 1004 to provide for
conveyance of the cuttings from storage vessel 1004 to a transport
vehicle (not shown). In this embodiment, storage vessel 1004 may be
pressurized and/or may be operatively coupled to a pneumatic
transfer device to transfer the cuttings through an outlet of the
storage vessel 1004. In one embodiment, cuttings may be transferred
from the at least one storage vessel 1004 to a transport vessel
(not shown) on a transport vehicle (not shown). In another
embodiment, cuttings may be transferred from first storage vessel
(1001a in FIG. 1B) to second storage vessel (1001b in FIG. 1B) via
conduit (1003 in FIG. 1B).
[0048] In one embodiment, as shown in FIG. 2, two discrete streams
of materials may be transferred contemporaneously (i.e., at least
partially during the same time interval) to a transport vehicle,
for example, a supply boat 5. In this embodiment, a first supply
line 20 may transfer a first material from at least a first storage
vessel 21 disposed in at least one support structure 1006 of
drilling rig (not shown) to supply boat 5, and a second supply line
22 may transfer a second material from at least a second storage
vessel 23 disposed in the at least one support structure 1006 to
supply boat 5. The first and second materials may also be
transferred to a cuttings storage assembly 25 disposed on supply
boat 5. Alternatively, the first and second materials may be
transferred to separate storage vessels; for example the first
and/or second material may be transferred to a storage tank (not
shown) disposed on or below the deck of supply boat 5.
[0049] In one embodiment, the first material may include dry
cuttings, while the second material may include a fluid. One of
ordinary skill in the art will appreciate that a fluid may include
a liquid, slurry, or gelatinous material. Additionally, one of
ordinary skill in the art will appreciate that dry cuttings may
include cuttings processed by a separatory or cleaning system, like
mechanical and/or thermal processing, such as Thermomechanical
Cuttings Cleaner (TCC), commercially available from Thermtech
(Bergen, Norway), and VERTI-G.TM. Dryer, commercially available
from M-I LLC (Houston, Tex.). As such, cuttings may include small
amounts of residual fluids, hydrocarbons, and/or other chemical
additives used during the cleaning process. Pumps (not shown) may
be coupled to the storage vessels 21, 23 to facilitate the transfer
of material, including, for example, dry cuttings, a fluid, or a
slurry, from a separatory or cleaning operation on the rig to
supply boat 5. Alternatively, a pneumatic transfer system 26 may be
coupled to the storage vessels 21, 23 to transfer materials,
including dry cuttings, fluids, and slurries, to the supply boat 5.
In one embodiment, the pneumatic transfer system 26 may include a
forced flow pneumatic transfer system as disclosed in U.S. Pat.
Nos. 6,698,989, 6,702,539, and 6,709,216. Providing contemporaneous
transfer of discrete material streams (e.g., dry cuttings, fluids),
may reduce the transportation time between a rig and a transport
vehicle, such as, supply boat 5.
[0050] In one embodiment, cuttings storage assembly 25 may include
at least one cuttings storage vessel 27. As such, the first
material and the second material may be transferred to a single
cuttings storage vessel 27 of cuttings storage assembly 25. In
another embodiment, the first material and the second material may
be transferred to separate cuttings storage vessels 27 of cuttings
storage assembly 25. In one embodiment, a cutting storage vessel 27
disposed on the supply boat 5 may be used in a slurrification
system, as disclosed below with reference to cuttings storage
vessels disposed on a rig. In this embodiment, briefly, a module
(not shown) may be operatively connected to the cuttings storage
assembly 25 to incorporate existing cuttings storage vessels 27
into a slurrification system.
[0051] In contrast to the prior art methods, embodiments disclosed
herein use storage vessels in two or more operations that are
performed on a drilling rig. In one aspect, embodiments disclosed
herein relate to operating a vessel in at least two operations
performed on a rig. In some aspects, embodiments disclosed herein
relate to using a vessel in both cuttings storage/transfer
operations and a second operation. More specifically, embodiments
disclosed herein relate to using a cuttings storage vessel as a
cuttings storage/transfer vessel and as a component in a
slurrification system, such as that disclosed in co-pending U.S.
patent application Ser. No. 60/887,442, hereby incorporated by
reference in its entirety.
[0052] Use of storage vessels and vessel assemblies in each of
these additional systems will be described below. Additionally,
modules that may integrate these vessels and vessel assemblies into
more than one additional system will also be discussed. One of
ordinary skill in the art will appreciate that storage vessels as
described in embodiments disclosed herein may also be used in
recycling systems, such as those disclosed in co-pending
application Ser. No. 60/887,444, tank cleaning systems, such as
those disclosed in co-pending application Ser. No. 60/887,509,
in-transit slurrification systems, such as those disclosed in
co-pending application Ser. No. 60/887,449, and cuttings processing
systems, such as those disclosed in co-pending application Ser. No.
60/887,514, all hereby incorporated by reference in their
entireties.
[0053] Referring back to FIG. 1A, storage vessels 1004 disposed
within at least one support structure 1006 of drilling rig 1000 may
be used in other systems/operations typically performed on the deck
1005. For example, storage vessels 1004 may be used in a
slurrification system as described in further detail below. In this
embodiment, cuttings disposed in at least one storage vessel 1004
may be combined with a fluid provided by a fluid supply line (not
shown) in fluid communication with the at least one storage vessel
1004.
[0054] Referring now to FIG. 3, a rig 40, including a system module
42 according to embodiments of the present disclosure, is shown.
System module 42 may be located anywhere on rig 40, and in some
embodiments is located proximate at least one cuttings storage
vessel 43, or a vessel assembly, disposed in at least one support
structure 41, that may be fluidly connected to system module 42 via
connection lines 44. Cuttings storage vessels 43 may be detachably
connected to a second set of storage vessels 45 located on a supply
boat 46 by a flexible hose 47. System module 42 may include a
slurrification system module.
[0055] In operation, cuttings may be transferred to cuttings
storage vessels 43 via one or more pneumatic transfer devices 48
located on rig 40. The cuttings may be stored in cuttings storage
vessels 43 until they are transferred to supply boat 46 for
disposal thereafter.
[0056] Cuttings transfer systems and slurrification systems, as
described above, are typically independent systems, where the
systems may be located on rig 40 permanently or may be transferred
to rig 40 from supply boat 46 when such operations are required.
However, in embodiments disclosed herein, system module 42 may be
located on rig 40 proximate cuttings storage vessels 43, and
transfer lines 44 may be connected therebetween to enable use of
the cuttings storage vessels 43 with tanks, pumps, grinding pumps,
chemical addition devices, cleaning equipment, water supply tanks,
filter systems, and other components that may be used in other
operations performed at a drilling location, including
slurrification of drill cuttings. Such integrated systems may allow
for existing single use structures (e.g., cuttings storage vessels
43) to be used in multiple operations (e.g., slurrification systems
and cuttings storage/transfer). Thus, when not being used to store
or transport cuttings, vessels 43 may be operated in a tank a
slurrification system.
[0057] Integration of a cuttings storage vessel into a
slurrification system is now described with respect to cuttings
storage vessel(s) disposed in at least one support structure of a
drilling rig. In this embodiment a module may be disposed at the
work site proximate the cuttings storage vessel and operatively
connected to the cuttings storage vessel, thereby converting the
cuttings storage vessel from a vessel for storing cuttings to a
component of a slurrification system.
[0058] As described above, previous fluid slurrification systems
required the conversion of valuable drilling rig space for storing
independent fluid recovery vessels and processing equipment.
However, embodiments disclosed herein allow existing structural
elements (i.e., cuttings storage vessels) to be used in multiple
operations. Modules in accordance with embodiments disclosed herein
are relatively small compared to previous systems, thereby
preserving valuable drill space, and preventing the need for costly
and dangerous lifting operations.
[0059] Referring now to FIG. 4, a slurrification system 300
incorporating a first cuttings storage vessel 302 is illustrated.
Slurrification system 300 includes a module 352, or drive unit,
configured to operatively connect with the first cuttings storage
vessel 302 disposed in at least one support structure (not shown)
of a drilling rig (not shown), and a fluid supply line 378. Module
352 may include a containment unit, a skid, a housing, or a
moveable platform configured to house select slurrification system
components, as described in more detail below.
[0060] In this embodiment, system 300 includes an independent power
source 360 for providing power to components of module 352. Power
source 360 is electrically connected to, for example, grinding
device 354 and/or a programmable logic controller (PLC) 361. Those
of ordinary skill in the art will appreciate that such a power
source may provide primary or auxiliary power for powering
components of module 352. In other embodiments, power source 360
may be merely an electrical conduit for connecting a power source
on a rig (not shown) via an electrical cable 362, to module
352.
[0061] Module 352 includes an inlet connection 370 configured to
connect with outlet 372 of first cuttings storage vessel 302, and
an outlet connection 374 configured to connect with an inlet 376 of
first cuttings storage vessel 302. Inlet connection 370 may be
connected to outlet 372 and outlet connection 374 may be connected
to inlet 376 by fluid transfer lines, for example, flexible hoses
and/or new or existing piping. Module 352 further includes a
grinding device 354 configured to facilitate the transfer of fluids
from the first cuttings storage vessel 302, through the module 352,
and back to the first cuttings storage vessel 302. Grinding device
354 is configured to reduce the particle size of solid materials of
the drill cuttings transferred therethrough.
[0062] In one embodiment, grinding device 354 may include a
grinding pump. The grinding pump may be, for example, a centrifugal
pump, as disclosed in U.S. Pat. No. 5,129,469, and incorporated by
reference herein. As shown in FIG. 5, a centrifugal pump 458,
configured to grind or reduce the particle size of drill cuttings,
may have a generally cylindrical casing 480 with an interior
impeller space 482 formed therein. Centrifugal pump 458 may include
an impeller 484 with backward swept blades with an open face on
both sides, that is, the blades or vanes 485 are swept backward
with respect to a direction of rotation of the impeller and are not
provided with opposed side plates forming a closed channel between
the impeller fluid inlet area 487 and the blade tips. The casing
480 has a tangential discharge passage 488 formed by a casing
portion 490. The concentric casing of centrifugal pump 458 and the
configuration of the impeller blades 485 provide a shearing action
that reduces the particle size of drill cuttings. The blades 485 of
the impeller 484 may be coated with a material, for example,
tungsten carbide, to reduce wear of the blades 485. One of ordinary
skill in the art will appreciate that any grinding pump known in
the art for reducing the size of solids in a slurry may be used
without departing from the scope of embodiments disclosed
herein.
[0063] In an alternative embodiment, as shown in FIG. 6, grinding
device 554 may include a pump 556 and a grinder 557, for example, a
ball mill. In this embodiment, cuttings may be injected into the
grinder 557, wherein the particle size of the solids is reduced.
The pump 556 may then pump the slurry back to first cuttings vessel
502. In one embodiment, the pump may include a grinding pump, as
disclosed above, as a second grinder, for further reduction of the
particle size of solids exiting the grinder 557.
[0064] Referring back to FIG. 4, in one embodiment, slurrification
system 300 further includes a second cuttings storage vessel 390
disposed in the support structure (not shown) of the drilling rig
(not shown). Second cuttings storage vessel 390 may be configured
to supply cuttings to first cuttings storage vessel 302. In one
embodiment, a pump (not shown), as known in the art, may be used to
transfer the cuttings. In another embodiment, a pneumatic transfer
device (not shown), as disclosed above, may be used to transfer the
cuttings to the first cuttings storage vessel 302. One of ordinary
skill in the art will appreciate that any method for transferring
the cuttings to first storage vessel 302 may be used without
departing from the scope of embodiments disclosed herein.
[0065] In one embodiment, module 352 may further include a
pneumatic control device (not shown) to control the flowrate of air
injected into the cuttings storage vessel 302 by a pneumatic
transfer device (not shown). In such an embodiment, an air line
(not shown) from an air compressor (not shown) may be coupled to
the pneumatic control device (not shown) in module 352 to control a
flow of air into first cuttings storage vessel 302.
[0066] In another embodiment, cuttings may be supplied to first
cuttings storage vessel 302 from a classifying shaker (not shown)
or other cuttings separation or cleaning systems disposed on the
drilling rig. Additionally, multiple cuttings storage vessels
disposed in the support structure of the drilling rig may be
connected to and supply cuttings to first cuttings storage vessel
302. In one embodiment, each cuttings storage vessel may be
configured to supply cuttings of predetermined sizes, for example,
coarse cuttings or fines. Cuttings of a selected size may then be
provided to first cuttings storage vessel 302 to form a slurry of a
predetermined density. One of ordinary skill in the art will
appreciate that the cuttings may be transferred to the first
cuttings storage vessel 302 by any means known in the art, for
example, by a pump or a pneumatic transfer device, as described
above.
[0067] During operation of slurrification system 300, fluid supply
line 378 may be configured to supply a fluid to first cuttings
storage vessel 302. One of ordinary skill in the art will
appreciate that the fluid supply line 378 may supply water, sea
water, a brine solution, chemical additives, or other fluids known
in the art for preparing a slurry of drill cuttings. As the fluid
is pumped into first cuttings storage vessel 302, cuttings from the
second cuttings storage vessel 390, or other components of the
rig's cuttings separation system, as described above, may be
transferred into first cuttings storage vessel 302.
[0068] As first cuttings storage vessel 302 fills with fluid and
cuttings, the mixture of fluid and cuttings is transferred to
module 352 through the inlet connection 370 of the module 352. In
one embodiment, the mixture may be transferred by a pneumatic
transfer device, a vacuum system, a pump, or any other means known
in the art. In one embodiment, the pneumatic transfer device may
include a forced flow pneumatic transfer system. The mixture of
fluid and cuttings is pumped through grinding device 354, wherein
the cuttings are reduced in size. The mixture, or slurry, is then
pumped back down to first cuttings storage vessel 302 via outlet
connection 374. The slurry may cycle back through module 352 one or
more times as needed to produce a slurry of a predetermined density
or concentration of cuttings as required for the particular
application or re-injection formation.
[0069] Referring now to FIG. 7, in one embodiment, module 652
further includes a valve 694 disposed downstream of grinding device
654, wherein valve 694 is configured to redirect the flow of the
slurry exiting the grinding device 654. In one embodiment, a PLC
661 may be operatively coupled to module 652 and configured to
close or open the valve 694, thereby redirecting the flow of the
slurry. In one embodiment, the PLC 695 may control the valve 694 to
move after a pre-determined amount of time of fluid transfer
through module 652. In another embodiment, a sensor (not shown) may
be operatively coupled to the valve 694 to open or close the valve
when a pre-determined condition of the slurry is met. For example,
in one embodiment, a density sensor (not shown) may be coupled to
valve 694, such that, when the density of the slurry exiting
grinding device 654 reaches a pre-determined value, valve 694
moves, i.e., opens or closes, and redirects the flow of the slurry
from the first cuttings storage vessel 302 to another cuttings
storage vessel, a slurry tank, a skip, or injection pump for
injection into a formation.
[0070] In another embodiment, a conductivity sensor (not shown) may
be coupled to valve 694, such that, when the density of the slurry
exiting grinding device 654 reaches a pre-determined value, valve
694 moves and redirects the flow of the slurry from the first
cuttings storage vessel 302 to another cuttings storage vessel, a
slurry tank, a skip, or injection pump for injection into a
formation. One of ordinary skill in the art will appreciate that
other apparatus and methods may be used to redirect the flow of the
slurry once a predetermined concentration of cuttings in
suspension, density, or conductivity has been met. Commonly, a
slurry with a concentration of up to 20% cuttings in suspension is
used for re-injection into a formation. However, those of ordinary
skill in the art will appreciate that direct injection of slurry,
using embodiments of the present disclosure, may provide for an
increased concentration of cuttings in the slurry.
[0071] A slurry formed by a slurrification system, as described
above, may be transferred to another cuttings storage vessel, a
slurry tank, a skip, or directly injected into a formation. Slurry
that is transferred to a tank, vessel, skip, or other storage
device, may be transferred off-site to another work site. In one
embodiment, the storage device may be lifted off of a rig by a
crane and transferred to a boat. Alternatively, slurry may be
transferred via a hose, tubing, or other conduit, from the storage
vessel dispose in the at least one leg of the drilling rig to a
slurry tank disposed on the boat.
[0072] In one embodiment, the slurry may be transported from one
work site to another work site for re-injection. For example, the
slurry may be transported from an offshore rig to another offshore
rig. Additionally, the slurry may be transported from an offshore
rig to an on-land work site. Further the slurry may be transported
from an on-land work site to an offshore work site.
[0073] Those of ordinary skill in the art will appreciate that the
components of systems 300, 500, and 600 may be interchanged,
interconnected, and otherwise assembled in a slurrification system.
As such, to address the specific requirements of a drilling
operation, in particular, for cuttings re-injection, the components
of the systems and modules disclosed herein may provide for an
interchangeable and adaptable system for slurrification at a
drilling location.
[0074] Advantageously, embodiments disclosed herein may provide a
materials storage and transport system that reduces the amount of
required space on a drilling rig. In another aspect, embodiments
disclosed herein may provide a method of transferring stored
materials to an offsite location. In yet another aspect,
embodiments disclosed herein may provide a storage and transport
system for cuttings that reduces the amount of required space on a
drilling rig.
[0075] Furthermore, embodiments disclosed herein may advantageously
provide a slurrification system that reduces the amount of required
space at a work site to operate the slurrification system. In
another aspect, embodiments disclosed herein may provide a
slurrification system that reduces the amount of equipment or
number of components required to prepare slurries for re-injection
into a formation. In yet another aspect, embodiments disclosed
herein may provide a safer slurrification system by reducing the
number of crane lifts required to install the system.
[0076] Advantageously, embodiments disclosed herein may also
provide for systems and methods that more efficiently store and
transport non-free flowing and free flowing materials on a drilling
rig. Because offshore platform space is often limited, and crane
operations to transfer large storage tanks or containers are often
expensive and dangerous, embodiments of the present disclosure may
decrease the cost of drilling operations by decreasing the number
of crane lifts.
[0077] While the invention has been described with respect to a
limited number of embodiments, those skilled in the art, having
benefit of this disclosure, will appreciate that other embodiments
can be devised which do not depart from the scope of the invention
as disclosed herein. Accordingly, the scope of the invention should
be limited only by the attached claims.
* * * * *