Drilling rig with a modular wellbore strengthening material recovery system

Abstract

A drilling rig with a modular wellbore strengthening material recovery system having an active drilling fluid tank system and on an on-rig shaker. The drilling rig with the modular wellbore strengthening material recovery system can have a processor connected to data storage, a pump, a motor, a power supply, a high solids capacity accelerated settling device, and a recovery shaker. The recovery shaker can have a top vibrating screen deck, a bottom vibrating screen deck, and a vibrating hack flow pan, which can be fluidly connected between the top vibrating screen deck and the bottom vibrating screen deck.

1 . A drilling rig with a modular wellbore strengthening material recovery system, comprising:
 a. an active drilling fluid tank system, a power supply, and an on-rig shaker connected to the power supply, for separating and containing a shaker underflow and on-rig shaker waste, and a waste containment system;   b. a pump mounted to the drilling rig fluidly receiving an on-rig shaker effluent forming a pressurized on-rig shaker effluent, the pressurized on-rig shaker effluent having an adjustable hydraulic head;   c. a motor for driving the pump connected to the power supply;   d. at least one high solids capacity accelerated settling device configured to receive the pressurized on-rig shaker effluent at a constant head ranging from 20 feet to 125 feet of head, forming effluent and an accelerated settling device underflow has a capacity of from 700 gallons per minute to 2100 gallons per minute removing wellbore strengthening material; and   e. a recovery shaker connected to the power supply, the recovery shaker receiving the accelerated settling device underflow, the recovery shaker comprising:
 (i) a top vibrating screen deck; 
 (ii) a bottom vibrating screen deck; and 
 (iii) a vibrating back flow pan fluidly connected between the top vibrating screen deck and the bottom vibrating screen deck, the recovery shaker separating: 
 (iv) a recovered wellbore strengthening material from the top vibrating screen deck flowed into the active drilling fluid tank system, wherein the recovered wellbore strengthening material comprises particles with a diameter from 0.01 inches to 0.75 inches;
 1. a top screen filtrate from the top vibrating screen deck flowed through the vibrating back flow pan to the bottom vibrating screen deck; 
 2. a bottom screen effluent from the bottom vibrating screen deck recycled to the active drilling fluid tank system; and 
 3. a waste transferred to the waste containment system. 
 
   
     
     
         2 . The drilling rig of  claim 1 , further comprising a processor in communication with a data storage, the data storage containing computer instructions to instruct the processor to provide a variable frequency control to the motor of the pump to control the on-rig shaker effluent pumped from the active drilling fluid tank system. 
     
     
         3 . The drilling rig of  claim 2 , wherein the processor is electrically connected to the power supply. 
     
     
         4 . The drilling rig of  claim 1 , wherein the motor is configured to variably drive the pump. 
     
     
         5 . The drilling rig of  claim 1 , further comprising a mechanical conveyor for transporting the recovered wellbore strengthening material to the active drilling fluid tank system, and wherein the mechanical conveyor electrically engages the power supply. 
     
     
         6 . The drilling rig of  claim 1 , using the effluent for transporting the recovered wellbore strengthening material to the active drilling fluid tank system. 
     
     
         7 . The drilling rig of  claim 1 , further comprising a recovery pump for receiving a clean drilling mud from a drilling mud containment tank, the recovery pump mixing the clean drilling mud with the recovered wellbore strengthening material and transporting mixed clean drilling mud with the recovered wellbore strengthening material to the active drilling fluid tank system without using the effluent, wherein the recovery pump and a recovery motor are electrically connected to the power supply. 
     
     
         8 . The drilling rig of  claim 1 , further comprising at least one of: a jack up, a tension leg platform, a drill ship, a Spar, a semisubmersible, or a land based drilling rig. 
     
     
         9 . The drilling rig of  claim 1 , wherein the recovered wellbore strengthening material comprises: ground walnut shells, calcium carbonate, ground cotton hulls, ground cane stalks, ground pecan shells, bark, mineral fiber, hair, flaky pieces of plastic, flakes of cellophane sheeting, granular limestone, granular marble, chips of wood, granular particles of Formica and combinations thereof. 
     
     
         10 . The drilling rig of  claim 1 , wherein the recovered wellbore strengthening material comprises particles with a diameter from 0.01 inches to 0.75 inches. 
     
     
         11 . The drilling rig of  claim 1 , wherein the on-rig shaker comprises a plurality of on-rig shakers connected in parallel, and each on-rig shaker fluidly connected to the active drilling fluid tank system and the waste containment system and electrically connected to the power supply. 
     
     
         12 . The drilling rig of  claim 1 , wherein the active drilling fluid tank system comprises at least one of: multiple tanks fluidly connected, a sand trap, fluid process pits connected in series, and a suction tank. 
     
     
         13 . The drilling rig of  claim 2 , wherein the processor communicates with a network and the network communicates with at least one client device. 
     
     
         14 . The drilling rig of  claim 1 , wherein the adjustable hydraulic head ranges from 20 feet to 125 feet of head. 
     
     
         15 . The drilling rig of  claim 1 , further comprising a plurality of high solids capacity accelerated settling devices connected in parallel, the plurality of high solids capacity accelerated settling devices each configured to treat each pressurized on-rig shaker effluent to match a drilling fluid circulating volume for the drilling rig. 
     
     
         16 . The drilling rig of  claim 2 , further comprising a pressure transducer connected to a feed manifold, the feed manifold in fluid communication between the pump and the at least one high solids capacity accelerated settling device, wherein the pressure transducer is in communication with the processor and the data storage further comprises computer instructions to control pump speed based on detected inlet pressure from the pressure transducer by computing a comparison between the detected inlet pressure and preset pressure limits stored in the data storage. 
     
     
         17 . The drilling rig of  claim 1 , further comprising a portable power supply for powering the processor, the motor, the recovery motor, the recovery pump, the mechanical conveyor, the recovery shaker and a second recovery shaker. 
     
     
         18 . The drilling rig of  claim 1 , wherein the recovery shaker comprises from 3 vibrating screen decks to 7 vibrating screen decks. 
     
     
         19 . The drilling rig of  claim 1 , further comprising a plurality of recovery shakers connected in parallel, wherein each recovery shaker is connected to the power supply. 
     
     
         20 . The drilling rig of  claim 1 , further comprising a plurality of single deck recovery shakers connected in series.