US-12617000-B2 - System and method for estimating damage to a shaker table screen using computer vision

US12617000B2US 12617000 B2US12617000 B2US 12617000B2US-12617000-B2

Abstract

A system for cleaning, repairing, and/or replacing damaged shaker screens is disclosed. The system may comprise a shale shaker with a replaceable shaker screen, at least one camera, and a computer processor. The camera is positioned to capture images of the shale shaker screen and the processor is capable of receiving said images from the camera. The processor is configured to analyze the images and detect damaged regions of the shale shaker screen. The processor is also configured to determine when a screen is damaged above a predefined threshold. Certain embodiments allow for the automatic cleaning, repair, and/or replacement of the shaker screen.

Inventors

Peter A. Torrione

Assignees

HELMERICH & PAYNE TECHNOLOGIES, LLC

Dates

Publication Date: 20260505
Application Date: 20231110

Claims (20)

1 . A system for analyzing shaker screens comprising: a processor; and at least one camera operably connected to the processor, wherein the camera is positioned to capture at least one image of at least a portion of a shale shaker screen on a shaker table and wherein the processor is configured to: receive visual data from the at least one camera; analyze the visual data in order to detect damage to the shale shaker screen on the shaker table; determine whether a percentage of the shale shaker screen that is damaged exceeds a predefined first threshold; determine whether a single tear of the detected damage has an area greater than a predefined second threshold, wherein the predefined first threshold is different from the predefined second threshold; determine a location of the single tear on the shale shaker screen and whether the location of the single tear is at a predefined location; and provide an alert to an operator in response to at least one of (i) determining the location of the tear is at the predefined location, (ii) determining that the percentage of the shale shaker screen that is damaged exceeds the predefined first threshold, or (iii) determining that the area of the single tear exceeds the predefined second threshold.
2 . The system of claim 1 , wherein the predefined first threshold is from greater than 0% to 20%.
3 . The system of claim 1 , wherein the predefined second threshold is from 4 in 2 to 25 in 2 .
4 . The system of claim 1 , wherein the processor is configured to provide the alert by at least one of locking a user interface with a message on a screen of the user interface, sending a text message to a predefined phone number, sending an email message to a predefined email address, providing an audible alarm, providing a visual alarm, or activating an alert or alarm on a drilling rig.
5 . The system of claim 1 , wherein the processor is further configured to cause automation to clean or replace the screen in response to at least one of determining that the percentage of the shale shaker screen that is damaged exceeds the predefined first threshold or determining that the area of the single tear exceeds the predefined second threshold.
6 . The system of claim 1 , wherein the processor is further configured to determine a screen efficiency of the shaker screen based on the visual data and provide an efficiency alert responsive to the determined screen efficiency being outside of a predefined third threshold.
7 . The system of claim 1 , wherein the processor is further configured to obtain weight data of the shaker screen from at least one sensor under the shaker screen, monitor a rate of change of weight based on the weight data, and provide a weight alert responsive to the monitored rate of change of weight being outside of a predefined weight threshold.
8 . A method comprising: obtaining, by a processor, visual data from a camera positioned to capture at least one image of at least a portion of a shale shaker screen on a shaker table; analyzing, using the processor, the visual data and detecting, using the processor, damage to the shale shaker screen on the shaker table based on the analysis of the visual data; determining, using the processor, whether a percentage of the shale shaker screen that is damaged or clogged exceeds a predefined first threshold; determining, using the processor, whether a single tear of the damage to the shale shaker screen has an area greater than a predefined second threshold; determining, using the processor, a location of the single tear on the shale shaker screen and whether the location of the single tear is at a predefined location; and providing an alert to an operator in response to at least one of (i) determining that the location of the single tear is at the predefined location, (ii) determining that the percentage of the shale shaker screen that is damaged or clogged exceeds the predefined first threshold, or (iii) determining that the area of the single tear exceeds the predefined second threshold.
9 . The method of claim 8 , further comprising automatically cleaning the shaker screen in response to at least one of determining that the percentage of the shale shaker screen that is damaged or clogged exceeds the predefined first threshold or determining that the area of the single tear exceeds the predefined second threshold.
10 . The method of claim 8 , wherein the predefined first threshold is from greater than 0% to 20%.
11 . The method of claim 8 , wherein the predefined second threshold is from 4 in 2 to 25 in 2 .
12 . The method of claim 8 , wherein providing the alert comprises at least one of locking a user interface with a message on a screen of the user interface, sending a text message to a predefined phone number, sending an email message to a predefined email address, or activating an alert or alarm on a drilling rig.
13 . The method of claim 8 , further comprising determining a screen efficiency of the shaker screen based on the visual data and providing an efficiency alert responsive to the determined screen efficiency is outside of a predefined third threshold.
14 . The method of claim 8 , further comprising obtaining weight data of the shaker screen from at least one sensor under the shaker screen, monitoring a rate of change of weight based on the weight data, and providing a weight alert responsive to the monitored rate of change of weight being outside of a predefined weight threshold.
15 . A non-transitory computer readable storage medium comprising a plurality of instructions executable by one or more data processors, the instructions comprising instructions which, when executed on the one or more data processors, cause the one or more data processors to perform actions including: obtaining, by a processor, visual data from a camera positioned to capture at least one image of at least a portion of a shale shaker screen on a shaker table; analyzing, using the processor, the visual data and detecting, using the processor, damage to the shale shaker screen on the shaker table based on the analysis of the visual data; determining, using the processor, whether a percentage of the shale shaker screen that is damaged or clogged exceeds a predefined first threshold; determining, using the processor, whether a single tear of the damage to the shale shaker screen has an area greater than a predefined second threshold; determining, using the processor, a location of the single tear on the shale shaker screen and whether the location of the single tear is at a predefined location; and providing an alert to an operator in response to at least one of (i) determining that the location of the single tear is at the predefined location, (ii) determining that the percentage of the shale shaker screen that is damaged or clogged exceeds the predefined first threshold, or (iii) determining that the area of the single tear exceeds the predefined second threshold.
16 . The non-transitory computer readable storage medium of claim 15 , wherein the instructions further comprise instructions which, when executed on the one or more data processors, cause the one or more data processors to perform actions including providing the alert by at least one of locking a user interface with a message on a screen of the user interface, sending a text message to a predefined phone number, sending an email message to a predefined email address, or activating an alert or alarm on a drilling rig.
17 . The non-transitory computer readable storage medium of claim 15 , wherein the predefined first threshold is from greater than 0% to 20%.
18 . The non-transitory computer readable storage medium of claim 15 , wherein the predefined second threshold is from 4 in 2 to 25 in 2 .
19 . The non-transitory computer readable storage medium of claim 15 , wherein the instructions further comprise instructions which, when executed on the one or more data processors, cause the one or more data processors to perform actions including determining a screen efficiency of the shaker screen based on the visual data and providing an efficiency alert responsive to the determined screen efficiency is outside of a predefined third threshold.
20 . The non-transitory computer readable storage medium of claim 15 , wherein the instructions further comprise instructions which, when executed on the one or more data processors, cause the one or more data processors to perform actions including obtaining weight data of the shaker screen from at least one sensor under the shaker screen, monitoring a rate of change of weight based on the weight data, and providing a weight alert responsive to the monitored rate of change of weight being outside of a predefined weight threshold.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS This application is a continuation of U.S. patent application Ser. No. 15/251,994, filed Aug. 30, 2016, which claims the benefit of U.S. Provisional Patent Application No. 62/212,207 filed Aug. 31, 2015, each of which is incorporated by reference herein in its entirety. FIELD OF THE INVENTION The invention relates to systems and methods that use computer vision for estimating the damage done to a shaker table screen. BACKGROUND OF THE INVENTION Shale shakers are an integral part of drilling operations, often used to separate drilling fluids from particulate matter returning up the well-bore. A shale shaker typically consists of a “shaker table”, which may be a permanent fixture on the rig, and “shaker screens” which are typically replaceable and/or repairable parts that fit on the table. The shaker table is responsible for shaking the screens, and the screens are usually in direct contact with the drilling fluid and particle matter. Proper filtering of solids from drilling fluids may lessen the environmental impact of drilling, reduce costs, and result in efficient operations. Since they are in direct contact with the shaker fluids and particles, shaker screens are often clogged, damaged, and/or destroyed as they are used. Typically, this damage accumulates over time in the form of rips and tears in the shaker screen material. As drilling progresses, the screens are periodically cleaned, and generally rig personnel are responsible for venturing down near the shakers and visually inspecting the screens to determine when a screen needs to be replaced. This process is usually time-consuming, expensive, and/or subject to each individual's opinion about what constitutes a sufficiently damaged screen. To reduce the amount of time required for analysis, a video stream could be used to show an operator the clean shaker screen, but inter-operator variability would persist. Accordingly, there is a need for an automated computer vision based technique for observing and estimating the amount of damage on a shaker screen. This will, for example, enable automated determination of the optimal time to replace shaker screens. In turn, this may result in improved efficiency and/or reduced costs. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 a potential embodiment of the system using multiple cameras and distance sensing equipment. FIG. 2 a potential embodiment of the system showing stereo vision cameras and possible damage to a shaker screen. FIG. 3 depicts a typical well circulation system. FIG. 4 shows one embodiment of an automated screen cleaning system. FIG. 5 shows an alternate embodiment using a scale to determine screen damage. FIG. 6 shows a potential method of determining the damage level of a shale shaker screen. DETAILED DESCRIPTION OF THE INVENTION A preferred embodiment of the Shaker Damage Estimation System (SDES) may consist of a number of the following components. (1) A high-shutter-speed camera 110 placed in a position to see the shaker screen 125 during and/or immediately after shaker screen cleaning. (2) A light source 120 co-located with the camera 110 which provides adequate illumination of the shaker 105 when desired. (3) A processor 115 and computer vision program for detecting damage on a shaker screen 125 and/or, for example, estimating the percentage of the screen 125 that is damaged and/or other parameters. (4) A system for determining when a shaker screen 125 needs to be cleaned, replaced, and/or repaired based upon, for example, the percent of the screen 125 that is clogged and/or damaged and/or potentially other factors (e.g., one particularly large, damaged region or key portion impaired). (5) A system for providing an alert to the rig operator indicating that the screens 125 need to be cleaned, changed, and/or repaired. Disclosed embodiments will typically be used in combination with a well circulation system 200. A typical well circulation system 200 utilizes drilling mud or another liquid which may be pumped from a mud pit into a well bore. The mud is used to cool the drilling equipment as well as carry cuttings 101 up to the surface and deposit the cuttings 101 on a shaker table 105 and shaker table screen 125. The screen 125 separates the cuttings 101 and other particulate from the drilling fluid, which generally flows through the screen 125. The level of mud in the pit may be detected using a pit volume sensor 220. The flow of mud entering the well bore may be detected using a well flow-in sensor 210. The flow of mud exiting the well may be detected using a well flow-out sensor 215. The depth of the drill bit may be detected using a bit depth sensor 225. The information gathered by these sensors and various combinations of this information may be used in order to provide a, better understanding of the drill cutting characteristics and potential well conditions to an operator. As the screen 125 becomes clogged or damaged, the screen 125 and shaker table