Note: Descriptions are shown in the official language in which they were submitted.
CA 02299951 2004-O1-08
PATENT APPLICATION
TITLE OF THE INVENTION
"METHOD AND APPARATUS FOR HANDLING AND DISPOSAL OF OIL AND GAS
WELL DRILL CUTTINGS"
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to oil and gas well
drilling and more particularly to the handling of cuttings
that are generated during oil and gas well drilling activity.
Even more particularly, the present invention relates to an
improved vacuum tank apparatus and method for handling cuttings
that are generated during oil and gas well drilling and in oil
and gas exploration. Tanks are provided on an oil
and gas well drilling platform and on a work
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boat positioned next to the platform. Both the platform and work
boat have vacuum units that help transfer cuttings from the
platform to the work boat.
2. General Background of the Invention
S In the drilling of oil and gas 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 and which can support joint after joint of drill pipe
connected end to end during the drilling operation. As the drill
bit is pushed farther and farther into the earth, additional pipe
joints are added to the ever lengthening "string" or "drill
string" . The drill pipe or drill string thus comprises a plurality
of joints of pipe, each of which has an internal, longitudinally
extending bore for carrying fluid drilling mud 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.
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 surface,
it is contaminated with small pieces of shale and rock which are
known in the industry as well cuttings or drill cuttings.
Well cuttings have in the past been separated from the
reusable drilling mud with commercially available separators that
are known as "shale shakers". Other solids separators-include mud
cleaners and centrifuge. Some shale shakers are designed to filter
coarse material from the drill ing mud while other shale shakers are
designed to remove finer particles from the well drilling mud.
After separating well cuttings therefrom, the drilling mud is
returned to a mud pit where it can be supplemented and/or treated
prior to transmission back into the well bore via the drill string
and to the drill bit to repeat the process.
The disposal of the separated shale and cuttings is a complex
environmental problem. Drill cuttings contain not only the mud
product which would contaminate the surrounding environment, but
also can contain oil that is particularly hazardous to the
environment, especially when drilling in a marine environment.
In the Gulf of Mexico for example, there are hundreds of
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drilling platforms that drill for oil and gas by drilling into the
subsea floor. These drilling platforms can be in many hundreds of
feet of water. In such a marine environment, the water is
typically crystal clear and filled with marine life that cannot
tolerate the disposal of drill cuttings waste such as that
containing a combination of shale, drilling mud, oil and the like.
Therefore, there is a need for a simple, yet workable solution to
the problem of disposing of oil and gas well cuttings in an
offshore marine environment and in other fragile environments
where oil and gas well drilling occurs.
Traditional methods of cuttings disposal have been dumping,
bucket transport, cumbersome conveyor belts, screw conveyors and
washing techniques that require large amounts of water. Adding
water creates additional problems of added volume and bulk,
messiness and transport problems. Installing conveyors requires
major modification to the rig area and involves many installation
hours and very high cost.
The following U.S. patents are illustrative of the prior art
and may be referred to for further details: 4,867,877; 4,255,269;
5,129,469 and 5,109,933.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a method for disposal of drill
cuttings from an oil and gas well drilling platform. The method
includes the steps of separating the drill cuttings from
substantially all of the well drilling fluid in which the drill
cuttings have been conveyed from an area being drilled.
The cuttings are then transferred to a materials collection
area such as a materials trough.
The drill cuttings are then transported to a holding tank
using a vacuum and a first suction line.
A vacuum is generated within the holding tank using a blower
so that drill cuttings are transported from the trough or
collections area to the tank via a suction line.
Cuttings are then transferred from the holding tank to a work
boat via a flow line. Further treatment such as recycling of
drilling mud can be performed on the boat.
The drill cuttings are typically transported directly to a
holding tank via a first suction line.
The vacuum is generated by a vacuum generating means or blower
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that is in fluid communication with the holding tank via a second
suction line.
The work boat preferably provides its own holding tank of very
large volume such as 100-1000 barrels. The holding tank on the
work boat is likewise provided with a blower that pulls a vacuum
on the tank to aid in transfer of cuttings from the holding tanks
on the platform to the holding tank on the work boat.
In one embodiment, the work boat simply collects cuttings
transferred to it from the drilling platform. In another
embodiment, the boat is equipped with treatment units that process
the cuttings. The cuttings can be slurried on one deck of the boat
and then pumped for storage to another deck area on the boat. In
yet another embodiment, the boat is equipped with treatment
apparatus that separates and recycles drilling fluids such as more
expensive synthetics.
BRIEF DESCRIPTION OF THE DRAWINGS
Figures 1-lA are elevational views of the preferred embodiment
of the apparatus of the present invention;
Figure 2 is a partial elevational view of the preferred
embodiment of the apparatus of the present invention;
Figure 3 is a sectional view taken along lines 3-3 of Figure
2;
Figure 3A is a sectional view illustrating an alternate
construction for the tank shown in Figures 2 and 3;
Figure 4 is a fragmentary elevational view of the preferred
embodiment of the apparatus of the present invention illustrating
the boat, vacuum unit and tank situated on the deck of the boat;
Figure 5 is an elevational view of the preferred embodiment
of the apparatus of the present invention showing an alternate
arrangement of storage tanks on the work boat portion thereof;
Figure 6 is a plan view of the preferred embodiment of the
apparatus of the present invention showing the work boat
configuration of Figure 5;
Figure 7 is an elevational view of the preferred embodiment
of the apparatus of the present invention showing an alternate
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arrangement of storage tanks on the work boat portion thereof;
' ~ Figure 8 is a top, plan view of the work boat of Figure 7;
Figure 9 is an elevational view of the preferred embodiment
of the apparatus of the present invention showing another alternate
arrangement of storage tanks on the work boat portion thereof;
Figure 10 is a top, plan view of the work boat of Figure 9;
Figure 11 is a schematic diagram showing the preferred
embodiment of the apparatus of he present invention and utilizing
the work boat of Figures 7 and 8;
Figure 12 is a schematic diagram of the preferred embodiment
of the apparatus of the present invention and utilizing the work
boat of Figures 9 and 10;
Figure 13 is a sectional view taken along lines 13-13 of
Figure 5;
Figures 14 and 15 are fragmentary perspective views of the
preferred embodiment of the apparatus of the present invention
showing the hose used to off load cuttings from rig to boat;
Figure 16 is an elevational view of an underwater storage tank
for use with the method of the present invention and showing an
alternate apparatus of the present invention;
Figure 17 is an end view of the underwater storage tank of
Figure 7;
Figure 18 is a perspective view of the storage tank of Figures
7 and 8 while in tow; and
Figure 19 is a schematic view of the alternate embodiment of
the apparatus of the present invention and showing the alternate
method of the present invention using an underwater storage tank.
For a further understanding of the nature, objects, and
advantages of the present invention, reference should be had to the
following detailed description, read in conjunction with the
following drawings, wherein like reference numerals denote like
elements and wherein:
DETAILED DESCRIPTION OF THE INVENTION
Figures 1-lA and 11-12 show generally the preferred embodiment
of the apparatus of the present invention and the method of the
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present invention, designated generally by the numeral 10 in
Figures 1, lA and by the numerals 10A, lOB in Figures 11, 12
respectively. In Figure l, a jack-up rig type drilling vessel is
shown for use with the method and apparatus of the present
invention. In Figure 1A, a fixed drilling platform is shown.
Cuttings disposal apparatus 10 is shown in Figures 1-lA in an
offshore marine environment that includes an offshore oil and gas
well drilling platform 11. The platform 11 (Figure lA) can include
a lower support structure or jacket 12 that extends to the ocean
floor and a short distance above the water surface 13. The
platform 11 can also be a jack-up rig (Fig. 1) or a semi-
submersible. A superstructure is mounted upon the jacket 12 or
upon jack-up rig legs 12A, the superstructure including a number
of spaced apart decks including lower deck 14, upper deck 15 and
in Figure lA an intermediate deck 16. Such a platform 11 typically
includes a lifting device such as crane 17 having boom 18 and
lifting line 19. In general, the concept of an offshore oil and
gas well drilling platform is well known in the art.
In Figures lA and 4-10, a work boat 20 is shown moored next
to platform 11 for use in practicing the method of the present
invention. Work boat 20 has deck 21 that supports vacuum unit 22,
vacuum lines 25, and one or more storage tanks 23. In Figures 5
10, multiple tanks are provided, designated respectively by the
numerals 23A-23E in Figures 5-6 and designated respectively of the
numerals 101, 103 in Figures 7-10.
The drilling platform or drilling rig 11 supports one or more
tanks for holding cuttings that have been removed from the well
bore during drilling, such as the plurality of rig tanks 26, 27,
28 in Figure lA and tanks 26, 27, 28, 29 in Figure 1.
The tanks 23 and 23A-23E on boat 20 are preferably very large
tanks, each having a volume of between for example between 100 and
1000 barrels. The tanks 26-29 on platform 11 can be, for example,
between about 50 and 1000 barrels in volume each. A suction line
24, 24A, 24B can be used to form a removable connection between the
plurality of rig vacuum tanks 26, 27, 28, 29 and the boat storage
tanks 23 or 23A-23E. The suction line 24 can be attached for
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example to a discharge manifold 31 (see Figures l, lA and 2). In
another embodiment, (see Figures 7-10), the suction line 29 can be
used to transmit cuttings from tanks 26, 27, 28, 29 to an
underwater storage tank, as will be described more fully
hereinafter. In Figures 14, 15, a connection arrangement is shown
for joining line 24 between platform 11 and boat 20.
During oil and gas well drilling operations, a receptacle on
rige 11 such as trough 77 receives drill cuttings that are removed
from the well bore and preferably after those drill cuttings have
been subjected to solids control, such as the removal of drilling
fluids (e. g. drilling mud) therefrom.
Cuttings in trough 77 are moved from the trough 77 to one or
more of the storage tanks 26, 27, 28, 29 using a vacuum unit 30.
Vacuum unit 30 is connected to suction manifold 39 as shown in
Figures lA and 2. Arrow 39 in Figure 2 shows the direction of air
flow in header 34. The suction manifold 34 communicates between
vacuum unit 30 and each of the rig vacuum tanks 26, 27, 28, 29 via
a spool piece or suction line 35. The suction line 35 includes
valve 36 for valuing the flow of air from each tank 26, 27, 28, 29
to vacuum unit 30 via suction manifold 34. An additional suction
manifold 37 communicates with each of the tanks 26, 27, 28, 29 and
with trough 77 via suction intake 38. In this fashion, valuing
enables cuttings to be transmitted to any selected tank 26, 27, 28,
29.
Valves 36 control flow of cuttings between each tank 26, 27,
28, 29 and manifold 37. Pressurized air from supply header 45 can
be injected into discharge line 32 downstream of valve 33 to assist
the flow of cuttings. Valves 48 can be used to valve such air
flow. Once vacuum unit 30 is activated, drill cuttings in trough
77 are suctioned from trough 29 using the intake 38 end of header
37. The intake end 28 of suction header 37 can be in the form of
a 3"-8" flexible hose, for example. Cuttings can then be
transmitted via header 37 to the desired tank 26, 27, 28 or 29.
Figures 2, 3, 3A and 13 show the construction of one of the
rig vacuum tanks 26, 27, 28, 29 more particularly. In Figure 3,
3A, the tank 28 is shown as a pressure vessel capable of holding
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,a vacuum (e. g. ) or pressure (e. g. ) and having
an interior 40 surrounded by cylindrically shaped side wall 41 and
two dished end portions 42, 43. At the lower end of tank 28
interior 40, an auger or augers 44 can be used to transfer cuttings
that settle in tank 28 to discharge line 32. The well drill
cuttings can then enter manifold 31. A valve 33 can be positioned
in between each tank 26, 27, 28 and discharge line 32 for valuing
the flow of cuttings from the tank interior 40 to discharge
manifold 31. Auger 44 can be operated by motor drive 46, having
a geared transmission as an interface between motor drive 46 and
auger 44.
The tank 28 in Figure 3A has some features that are optional
and additional to the tank 28 of Figure 3. Tank 28 in Figure 3A
has a cylindrically shaped side wall 41 and dished end portions 42,
43. Augers 44 can be used to transfer cuttings that settle in tank
28 to discharge 32. Drilling fluid to be recycled can be suctioned
from interior 40 of tank 28 using suction line 78 that is
adjustable up and down as shown by arrow 91 in Figure 3A. The
suction line 78 can be used to recycle drilling fluid after solids
within the interior 40 of tank 28 have settled, leaving the
drilling fluid as the upper portion of the material contained
within interior 40 of tank 28. Suction line 79 fits through sleeve
'80 that can be fitted with a set screw, pin, taper lock fitting or
similar fitting to grasp suction line 78 at the desired elevational
position.
In Figures 14 and 15, a connection is shown that can be used
to join the hose 24 that transmits cuttings from the rig 11 to the
boat 20. In Figures 14 and 15, the hose 24 can be in two sections,
24A, 24B that are joined together using fittings 99A-99B. Crane
lift line 19 attaches with its lower end portion to fitting 96
using a hook, for example, and an eyelet on the fitting 96 as shown
in Figure 14. The fitting 96 can include a pair of spaced apart
transversely extending pins 97, 98 that fit recesses 94, 95
respectively on respective saddle plates 92, 93 that are welded to
the rig 11 as shown in Figure 14. In this fashion, the rig
operator can raise the lower portion 24B of hose 24 upwardly until
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~ the~pins 97, 98 engage the recesses 94, 95 as shown in Figure 15.
With the hose lower end portion 94B so supported by the saddle
plates 92, 93, the pins 97, 98 rest in the recesses 94, 95. A rig
operator then connects the coupling member 99A to the coupling
member 99B as shown in Figures 14 and 15. The upper end portion
24A of hose 24 can be connected to header 31 as shown in Figure 1.
Figures 7-8 and 11 shown an alternate arrangement of the
apparatus of the present invention that incorporates optional
treatment features on the boat 20. In of Figures 7, 8 and 11, the
boat 20 is shown outfitted with storage tanks 103 in addition to
optional processing equipment that further processes the mixture
of cuttings and drilling fluids that are transmitted to the boat
via flow line 24.
In Figures 7 and 8, the vessel 20 has an upper deck 100 with
15 a plurality of tanks 101 stored under the deck 100 in hold 102, and
a second plurality of tanks 103 above deck 100 as shown in Figures
7 and 8. Vacuum system 22 on the boat 20 can pull a vacuum on any
selected one of the tanks 26-29. Each rig tank 26-29 in Figure 11
provides a discharge that communicates with discharge header 31.
20 The tanks 26-29 are constructed in accordance with the tank 28 of
Figure 3 or 3A.
In Figures 7-8 and 11, the boat 20 is provided with optional
equipment to further treat the cuttings that are collected in the
plurality of tanks 103 after the cuttings or a mixture of cuttings
and drilling fluid has been transferred via flow line 24 to the
boat 20.
The cuttings received in the plurality of tanks 103 on the
upper deck 100 of vessel 20 are further treated to slurrify the
combination of cuttings and drilling fluid in order to obtain a
desired particle size and a desired viscosity. This enables this
further treated mixture of cuttings and fluid to be pumped into
tanks 101 that are under deck 100. In this fashion, storage can
be maximized by slurrifying, and storing the cuttings/drilling
fluid mixture in the tanks 101 that are under deck 100 in hold 102.
In Figures 7, 8 and 11, the flow line 24 transmits cuttings
to header 104 that is valued with valves V so that incoming
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cuttings can be routed to any particular of the tanks 103 as
desired. Vacuum unit 22 on boat 20 can pull a vacuum through
header 105 on any selected tank 103. This is because each of the
tanks 103 is valued with valves V between the tank 103 and header
105. A walkway 106 accessible by ladder 107 enables an operator
to move between the various valves V and headers 104, 105 when it
is desired to open a valve V or close a valve V that communicates
fluid between a header 104 or 105 and a tank 103.
By closing all of the valves V that are positioned in between
a tank 103 and the vacuum header 105, the vacuum can be used to
pull a vacuum on cuttings grinder unit 108 via flow line 109 (see
Figure 11). A discharge header 110 is used to communicate
discharged fluid that leaves a tank 103 to cuttings grinder unit
108. Valves V are used to control the flow of fluid between each
tank 103 and header 110 as shown in Figure 11. Pump 111 enables
material to be transferred from cuttings grinder unit 108 via flow
line 112 to shaker 113 and holding tank 114. Material that is too
large to be properly slurried is removed by shaker 113 and
deposited in cuttings collection box 115 for later disposal.
Material that passes through shaker 113 into holding tank 119 is
slurried by recirculation from tank 114 to pump 116 and back to
tank 114. When a desired particle size and viscosity are obtained,
the slurry is pumped with pump 116 to one of the tanks 101. Each
of the tanks 101 is valued between discharge header 119 and tanks
101 as shown in Figure 11.
When the boat 20 reaches a desired disposal facility, pump 118
receives fluid from discharge header 119 for transmission via line
120 to a desired disposal site such as a barge, on land disposal
facility or the like.
In Figures 9-10 and 12, the apparatus of the present invention
is shown fitted with optional treatment features, designated
generally by the numeral lOB in Figure 12. In the embodiment of
Figures 9, 10 and 12, processing is used to remove desirable
drilling fluid from cuttings that are transferred to boat 20 via
line 24. In Figures 9, 10 and 12, the rig 11 has a plurality of
tanks 26-29, and inlet header 37, a vacuum system 30, a vacuum
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header 34, and pumps 90 to remove desirable drilling fluid at the
rig or platform 11 for recycling. However, in Figures 9-10 and 12,
recycling of drilling fluid also occurs on boat 20. Thus, the
equipment located on rig 11 is the same in the embodiment of
Figures 11 and 12. The equipment on boat 20 differs in the
embodiment of Figures 9-10 and 12. The boat 20 in Figures 9-10 and
12 includes a plurality of tanks 103 that discharge cuttings to a
first conveyor such as auger 121. Auger 121 directs cuttings that
are discharged by tanks 103 to a conveyor such as screw conveyor
122. Screw conveyor 122 deposits cuttings in separator 123. In
separator 123, some drilling fluids are removed and transmitted via
flow line 124 to recycled liquid holding tank 125. The separator
123 is preferably a hopper with a vibrating centrifuge, spinning
basket driven by a motor. Such separators 123 are commercially
available.
After drilling fluid has been separated at separator 123, dry
cuttings are transmitted to cuttings dryer unit 126 using screw
conveyor 127. The cuttings dryer unit 126 further dries the
cuttings so that they can be transferred to a vessel, barge, etc.
or dumped overboard via discharge pipe 130. Any fluid that is
removed from the cuttings at cuttings dryer unit 126 can be
recycled through pump 128 and flow line 129 to liquid holding tank
125 and then to the platform 11 via flow line 131.
Figures 16-19 show an underwater tank assembly 51 that can be
used to replace or supplement the tank 23 of Figure 1 or the
plurality of tanks 23A-23E in Figures 5 and 6. In Figures 16-19,
underwater tank assembly 51 can be stored on the sea bed 74 so that
it does not occupy rig space or space on the deck 21 of vessel 20.
Rather, the underwater tank assembly 51 can receive cuttings that
are discharged from tanks 26, 27, 28 on rig 11 by discharging the
cuttings from the selected tank 26, 27, 28 via header 31 and into
cuttings flowline 60. The cuttings flowline 60 can be attached to
header 31 in a similar fashion to the attachment of flowline 24
shown in Figure 1.
The flowline 21 transmits cuttings from header 31 to tank 23
on boat 20 or to a plurality of tanks 23A-23E on boat 20. The
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cuttings flow line 60 would be of sufficient length to extend from
the' discharge flowline 31 to the sea bed 74 and specifically to
inlet fitting 59 on main tank 52 of underwater tank assembly 51,
as shown in Figure 7. In this fashion, cuttings can be discharged
from the rig 11 tanks 26, 27, 28 to underwater tank assembly 51 in
the direction of arrow 61. As with the embodiment of Figures 1-6,
a vacuum unit such as vacuum unit 22 on vessel 20 or a vacuum unit
such as vacuum unit 30 on rig 11 can be used to pull a vacuum on
main tank 52.
In Figure 16, main tank 52 provides a vacuum fitting 56 to
which vacuum line 57 is attached. A vacuum unit 22 or 30 can pull
a vacuum on tank 52 with air flowing in the direction of arrow 58.
This flow enhances the flow of cuttings from the tanks 26, 27, 28
on rig 11 into main tank 52 in the direction arrow 61.
The main tank 51 has ballasting in the form of a plurality of
ballast tanks 53, 54. The combination of tanks 52, 53, 54 are
connected by a welded construction for example using a plurality
of connecting plates 74.
Ballast piping 62 communicates with fittings 63, 64 that are
positioned respectively on the ballast tanks 53, 54 as shown on
Figure 8. Control valve 65 can be used to transmit pressurized air
in the direction of arrow 66 into the ballast tanks 53, 54 such as
when the underwater tank assembly 51 is to be raised to the
surface, as shown in Figure 10, the upward movement indicated by
arrows 75.
Arrow 67 in Figure 16 indicates the discharge of air from
ballast tanks 53, 54 using control valve 55 when the underwater
tank assembly 51 is to be lowered to the sea bed 76. In Figure 19,
arrows 68 indicate the discharge of water from tanks 53, 54 when
the underwater tank assembly is to be elevated. Outlet fittings 69,
70 enable water to be discharged from ballast tanks 53, 54.
Support frame 55 can be in the form of a truss or a plurality
of feet for engaging the sea bed 76 when the underwater tank
assembly 51 is lowered to the sea bed prior to be being filled with
drill cuttings during use.
When main tank 52 has been filled with well drill cuttings and
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the tank assembly 51 has been raised to the water surface 13, the
tank assembly 51 can be towed to a disposal sight using tow line
72, tug boat 73 and tow eyelet 71 on tank 52.
It should be understood that the underwater tank assembly 51
can be used to supplement tanks 23, 23A-23E as described in the
preferred embodiment of Figure 1-6. Alternatively, the underwater
tank assembly 51 can be used for storage instead cf the boat
mounted tanks 23, 23A-23E.
The following table lists the parts numbers and parts
descriptions as used herein and in the drawings attached hereto.
PARTS LIST
Part Number Description
10 cuttings disposal
apparatus
11 platform
12 jacket
13 water surface
14 lower deck
15 upper deck
16 intermediate deck
17 crane
18 boom
19 lifting line
20 work boat
21 aft deck
22 vacuum unit
23 storage tank
23A storage tank
23B storage tank
23C storage tank
23D storage tank
23E storage tank
24 first suction line
25 second suction line
26 rig vacuum tank
27 rig vacuum tank
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28 rig vacuum tank
29 rig vacuum tank
30 vacuum unit
31 discharge manifold
32 discharge line
33 outlet valve
34 suction manifold
35 suction line
36 valve
37 manifold
38 suction intake
39 arrow
40 interior
41 wall
42 end
43 end
44 auger
45 supply header
46 motor drive
47 valve
48 valve
49 walkway
50 header
51 underwater tank assembly
52 main tank
53 ballast tank
54 ballast tank
55 support frame
56 vacuum fitting
57 vacuum line
58 arrow
59 inlet fitting
60 cuttings flow line
61 arrow
62 ballast piping
63 ballast fitting
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64 ballast fitting
- 65 control valve
66 arrow
67 arrow
68 arrow
69 outlet
70 outlet
71 towing eyelet
72 towline
73 tugboat
74 connecting plate
75 arrow
76 seabed
77 trough
78 suction line
79 screen
80 sleeve
90 pump
91 arrow
92 plate
93 plate
94 recess
95 recess
96 fitting
97 pin
98 pin
99A coupling member
99B coupling member
100 deck
101 tank
102 ~ hold
103 tank
104 header
105 header
106 walkway
107 ladder
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108 cuttings grinder unit
109 flowline
110 header
111 pump
112 flowline
113 shaker
114 holding tank
115 collection box
116 pump
117 header
118 pump
119 header
120 flow line
121 auger
122 screw conveyor
123 separator
124 flow line
125 tank
126 cuttings dryer unit
127 conveyor
128 pump
129 flow line
130 discharge pipe
131 flow line
V valve
The foregoing embodiments are presented by way of example
only; the scope of the present invention is to be limited only by
the following claims.
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