The MudCube is the first compact, lightweight solids control system for all type of drilling fluids, eliminating the traditional process of shaking fluid and solids.The MudCube primary solids control technology separates solids and liquid differently from the traditional type of high G forces vibrating shale shakers, using a combination of high air flow and vacuum to separate all types of drilling fluids from drilled solids.
The MudCube is a technology developed to replace traditional shakers.
The MudCube uses a combination of high air flow and vacuum pulled through a rotating screen (filter belt) rather than the high g forces and vibration used by the standard shakers to separate mud and solids. This technology is proven to have higher levels of solids removal efficiency, which in turn reduces the volume of drilling fluid lost, minimizes the tonnage of waste generated, and raises drilling fluid performance, which all contribute to an overall reduction in cost.
The MudCube Fluid Management System was first permanently installed on an offshore rig in 2012, offshore Norway. The system not only provides highly efficient and effective two-phase separation of liquids and solids but also raises health and safety standards while minimizing the overall environmental impact by reducing mud losses and corresponding drilling waste tonnages. It is fully field proven and to date, it has been used to drill more than 100 wells in 9 countries by 15 operators.
More Efficient and Cost-Effective than Existing Technology
The MudCube has proven Opex benefits, including:
? Reduced waste
? Increased re-use of drilling mud
The MudCube system has been extensively tested by:
? Statoil
? Chevron
? ConocoPhillips
? Petrobas
? Saudi Aramco
? Dong
? Talisman
? Det Norske
? Shell
? HESS
? Occidental Petroleum
? Murphy Oil
Its enclosed system was consistently found to have compelling HSE advantages.
? The Mudcube has an excellent track record from offshore drilling operations in the North Sea.
? It’s extremely quiet, allowing conversations easily conducted in the MudCube container.
? It can be controlled remotely with its equipped interior cameras, sensors and control system.
How It Works
The MudCube primary solids control technology separates solids and liquids differently from the traditional type of vibrating shaker, using a combination of high air flow and vacuum to separate drilling fluid and drilled solids. A rotating filter belt carries mud and drilled solids forward while air, at 20,000 liters per minute, is pulled through this belt taking with it the liquid phase, the drilling fluid.
The “cleaned” drilling fluid is then returned to the active mud system. This leaves the solids phase to be carried forward on the filter belt to be discharged either directly overboard or to a cuttings handling system where the waste is either treated on location or shipped to shore for processing.
The drilling fluid from the main header box enters the MudCube at the top. The MudCube then filters the drilling fluid by vacuuming the fluid through the filter belt. The cuttings are offloaded from the MudCube by gravity, either for discharge or to a cuttings handling system. The MudCube has one air-knife installed on the inside of the vertical part of the filter-belt to remove any cuttings that may have “stuck” to the belt. In addition to this air-knife the MudCubes are equipped with water-knives, designed to clean the filter belt and improve filtration when drilling with water based mud through very sticky clay type formations. The MudCube has pneumatic micro-vibrators installed underneath the filter-belt. The vibrators create a resonance in the filter belt to improve conductance and avoid near size particles blocking the holes of the filter belt.
Remote Operation and Automation
MudCube allows for real-time monitoring and remote operation.
? The MudCube can be controlled and operated remotely due to camera, sensors, and control system
? Cameras are installed inside the MudCube, allowing for visual monitoring process without moving away from control room
? An operator panel is connected via Ethernet to PLC for visualizing and controlling/ monitoring of the process
The Filter Belt
The filter belts are designed specifically for the MudCube and are available in all standard API mesh sizes. These filter belts have a longer life than those used on standard shakers since they are not pre-tensioned or exposed to any high G-Forces, as they would be with the traditional tensioned screens. The filter belt is driven by a frequency-controlled electric motor to enable screen belt speed to be adjusted as required. This ensures good cleaning results for drilling fluids of differing properties and both the type and volume of cuttings.
A high speed will move the cuttings faster from the inlet end of the belt to the cuttings handling system thus allowing a higher flow into the MudCube. Too high a speed will however increase the residual fluid on the cuttings leaving the MudCube and increase the total volume of drilling waste produced. For operations where high viscosity fluids are being used, a slow speed will improve the cleaning process.
? Rotating non-tensioned filter belt
? Stainless steel
? Full API RP 13C Mesh Ranges are available
? Variable rotating speed
? Micro-vibrators used as needed to improve conductance
? Air knife used to clean the screens
? Any screens failure monitored
? Use Velcro to connect the filter belt
? Replacement time : 2 minutes – no additional working area needed
? Less inventory weight than conventional shaker screens
? No need for external screen washer “self-cleaning”
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