CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of US Provisional Application having Serial No. 62/862,683, filed June 18, 2019, which is incorporated by reference herein.

BACKGROUND

[0002] This section provides background information to facilitate a better understanding of the various aspects of the disclosure. It should be understood that the statements in this section of this document are to be read in this light, and not as admissions of prior art.

[0003] Oilfield drilling fluid, often called“mud,” serves multiple purposes in the industry. Among its many functions, the drilling mud acts as a lubricant to cool rotary drill bits and facilitate faster cutting rates. Typically, the mud is mixed at the surface and pumped downhole at high pressure to the drill bit through a bore of the drill string. Once the mud reaches the drill bit, it exits through various nozzles and ports where it lubricates and cools the drill bit. After exiting through the nozzles, the“spent” fluid or drilling material returns to the surface through an annulus formed between the drill string and the drilled wellbore.

[0004] A significant purpose of the drilling mud is to carry the cuttings away from the drill bit at the bottom of the borehole to the surface. As a drill bit pulverizes or scrapes the rock formation at the bottom of the borehole, small pieces of solid material are left behind. The drilling fluid or material exiting the nozzles at the bit acts to stir-up and carry the solid particles of rock and formation to the surface within the annulus between the drill string and the borehole. Therefore, the fluid exiting the borehole from the annulus is a slurry of formation cuttings or solids in drilling mud. Before the mud can be recycled and re-pumped down through nozzles of the drill bit, the cutting particulates or solids must be removed.

[0005] Apparatus to remove cuttings and other solid particulates from drilling mud are commonly referred to in the industry as“shale shakers.” A shale shaker, also known as a vibratory separator, is a vibrating sieve-like table upon which returning dirty drilling mud or material is deposited and through which clean drilling mud emerges. Typically, the shale shaker is an angled bed of mesh screens to filter the drilling mud or material. Returning drilling mud or material is deposited at the top of the shale shaker. As the drilling mud or material travels across the mesh screens, the fluid falls through apertures in the mesh screens to a reservoir below leaving the solid particulate material or solids behind. The combination of the angle of inclination with the vibrating action of the shale shaker table enables the solid particles or solids to be conveyed to the discharge end of the shaker table.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present disclosure is best understood from the following detailed description when read with the accompanying Figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

[0007] FIG. 1 is a side perspective view of a vibratory separator, according to one or more examples of the disclosure.

[0008] FIG. 2 is a side plan view of a vibratory basket, according to one or more examples of the disclosure.

[0009] FIG. 3 is a side plan view of a vibratory basket, according to one or more examples of the disclosure.

[0010] FIG. 4 is a side plan view of a vibratory basket, according to one or more examples of the disclosure.

[0011] FIG. 5 is a top plan view of a vibratory basket, according to one or more examples of the disclosure.

[0012] FIG. 6 is a flowchart depicting a method for separating fluid from drilling material in a vibratory basket, according to one or more embodiments of the disclosure.

DETAILED DESCRIPTION

[0013] Illustrative examples of the subject matter claimed below will now be disclosed. In the interest of clarity, not all features of an actual implementation are described in this specification. It will be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions may be made to achieve the developers’ specific goals, such as compliance with system -related and business- related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort, even if complex and time-consuming, would be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

[0014] Further, as used herein, the article“a” is intended to have its ordinary meaning in the patent arts, namely“one or more.” Herein, the term“about” when applied to a value generally means within the tolerance range of the equipment used to produce the value, or in some examples, means plus or minus 10%, or plus or minus 5%, or plus or minus 1 %, unless otherwise expressly specified. Further, herein the term“substantially” as used herein means a majority, or almost all, or all, or an amount with a range of about 51 % to about 100%, for example. Moreover, examples herein are intended to be illustrative only and are presented for discussion purposes and not by way of limitation.

[0015] Generally, a vibratory separator is being used continuously during drilling operations to separate fluid from spent drilling material. In view of the continuous operational demand for the vibratory separator, any repairs and associated downtimes with respect to the vibratory separator should be minimized as much as possible. Screen assemblies are disposed within a basket of the vibratory separator and configured to separate the fluid from the spent drilling material. Screen clothes or the meshes of the screen assemblies, through which the fluids and solids are separated from the spent drilling material, may wear out over time due to stress thereon and may need replacement. Therefore, the screen assemblies must be constructed to be removed and replaced from the basket after damage and/or wear to the screen clothes or the meshes are observable or detectable.

[0016] Accordingly, there is a recognized need for separator designs and/or basket and screen assembly configurations that may improve resiliency and durability of the screen assemblies and reduce amounts of stress applied to the screen assemblies and screening surfaces thereof. Embodiments of the present disclosure are directed to a vibratory separator having separator designs and/or basket and screen assembly configurations that efficiently separate the fluid and the solids of the spent drilling material at a desirable flow rate while minimizing wear and stress on the upper and lower feed end screen assemblies disposed in the basket of the vibratory separator.

[0017] Particularly, in one embodiment of the present disclosure, a vibratory separator may include a housing having a basket having a feed end and a discharge end with the discharge end positioned opposite the feed end and a drilling material inlet adjacent the feed end of the basket. A first upper screen assembly may be disposed in the basket at the feed end of the basket and in fluid communication with the drilling material inlet, and a first lower screen assembly may be disposed in the basket and in fluid communication with the drilling material inlet. Further, the vibratory separator may include an actuator connected to the basket and configured to provide vibratory motion to the basket, and a sump configured to receive drilling material that passes through the first upper screen assembly and the first lower screen assembly. Still further, a first fluid flow path, having a first total length, may fluidly connect the first upper screen assembly to the sump, and a second fluid flow path, having a second total length, may fluidly connect the first lower screen assembly to the sump. Moreover, wherein the first lower screen assembly may be disposed between the first upper screen assembly and the sump, and the first total length of the first fluid flow path may be greater than the second total length of the second fluid flow path.

[0018] In another embodiment of the present disclosure, a vibratory separator may include a housing having a basket having a feed end and a discharge end with the discharge end positioned opposite the feed end and a drilling material inlet adjacent the feed end of the basket. A first upper screen assembly may be disposed in the basket at the feed end of the basket and in fluid communication with the drilling material inlet, wherein the first upper screen assembly has a first end adjacent the feed end of the basket and a second end opposite the first end and extending outwardly towards the discharge end of the basket. A first lower screen assembly may be disposed in the basket and in fluid communication with the drilling material inlet, wherein the first lower screen assembly has a first end adjacent the feed end of the basket and an opposite second end extending outwardly towards the discharge end of the basket. Further, the vibratory separator may include an actuator connected to the basket and configured to provide vibratory motion to the basket, a sump configured to receive drilling material that passes through the first upper screen assembly and the first lower screen assembly, and a fluid discharge channel fluidly connecting the first upper screen assembly to the sump. A flow back channel or pan may fluidly connect the first lower screen assembly to the drilling material inlet, wherein the flow back channel or pan may be adjacent the second end of the first upper screen assembly and may be further disposed between the first upper screen assembly and the first lower screen assembly and angled downwardly towards the fluid discharge channel and the first end of the lower screen assembly that is adjacent the feed end of the basket. The flow back channel or pan may receive overflow fluid and/or solids from the first upper screen assembly and deliver or transfer the overflow fluid and/or solids to the first lower screen assembly.

[0019] Referring now to the drawings wherein like numerals refer to like parts, FIG. 1 shows a top perspective view of a shale shaker or vibratory separator 100 (hereinafter “the separator 100”), in accordance with one or more embodiments or examples of the present disclosure. In this embodiment, the separator 100 comprises a housing 101 defining a drilling material inlet 102, a drilling material discharge area or end 103 (hereinafter“the discharge end 103”), and an inner section 1 10. The separator 100 further comprises at least one actuator 104 (hereinafter“the actuator 104”), such as, for example, a motor, a motor system, and/or a motor or motion control device. In one or more embodiments, the actuator 104 is coupled to a rotary motor (not shown in the drawings), which upon engagement or activation, may impart or provide a vibratory motion to a vibratory basket 105 (hereinafter“the basket 105”) that is disposed within the housing 101 .

[0020] The basket 105 comprises a screen bed configuration to connect, attach, and/or secure a plurality of shaker screen panels or assemblies 106 (hereinafter“the screen assemblies 106”) to the separator 100. With the screen assemblies 106 securely connected or attached to the basket 105, the actuator 104 may be engaged, the basket 105 may begin to vibrate or oscillate, and the screen assemblies 106 do not loosen or separate from the basket 105. The screen assemblies 106 may be connected, attached, or secured to the separator 100 by any connection type known to one of ordinary skill in the art including, but not limited to, magnetic, pretension, and/or hookstrip assemblies.

[0021] The separator 100 further includes a sump 107 that is located below or beneath the screen assemblies 106 and the basket 105. The sump 107 is in fluid communication with the basket 105 and/or the screen assemblies 106 and configured to receive drilling fluids or material (hereinafter “the drilling material”) passing through the screen assemblies 106. As shown in FIG. 3, the drilling material provided to, or flowing into, the basket 105 includes a liquid state 302 (hereinafter“the liquid 302”) and solid state particulate matter 304 (hereinafter“the solids 304”).

[0022] As the drilling material flows through the screen assemblies 106, the drilling material and/or the liquid 302 may collect in the sump 107 below the basket 105. When the sump 107 becomes full, or at the discretion of a drilling operator, the sump 107 may be emptied through an outlet (not shown in the drawings). In alternate embodiments, the outlet to the sump 107 may include a valve for retaining drilling waste in the sump 107. Thus, the sump 107 may be a means for collecting drilling material, the liquid 302, and/or waste that has passed through screen assemblies 106. Additionally, the sump 104 may be a storage vessel for separated drilling material, the liquid 302, and/or the waste prior to downstream processing.

[0023] The screen assemblies 106 may be made from any material known to one of ordinary skill in the art including, but are not limited to, steel, composite, mesh, and fine screen cloth. In some embodiments, the screen assemblies 106 may have two or more overlaying layers of screen cloth or mesh. The layers of screen cloth or the mesh may be bonded together and placed over a support, supports, or a perforated or apertured plate of the screen assemblies 106. As the screen assemblies 106 are vibrated by the actuator 104, the solids 304 of the drilling material become trapped on top surfaces of the screen assemblies 106 and provide a flow of trapped solids that moves across the top surfaces of the screen assemblies 106 to the discharge end 103 for removal and disposal of the solids 304 from the separator 100.

[0024] The fineness, coarseness or mesh size of the screen cloth or the mesh of the screen assemblies 106 may vary depending upon mud or fluid flow rate of the drilling material provided to the separator 100 and/or a size or sizes of the solids 304 to be removed or separated from the liquid 302 of the drilling material. In some embodiments, the mesh size of the screen assemblies 106 may be the same, or substantially the same, mesh size for all of the screen assemblies 106 of the separator 100. In other embodiments, the mesh size may be different, or substantially different, mesh sizes for at least two screen assemblies 106 of the separator 100. [0025] As the drilling material collects in the bottom of the separator 100, some material may become stuck to sidewalls and/or a bottom of sump 107. To prevent the buildup of material in the sump 107, in some embodiments, sump 107 may be attached to the actuator 104 to providing vibratory motion to the sump 107. As vibratory motion is applied to the sump 107, material stuck to the sidewalls and/or the bottom of the sump 107 may be dislodged, thereby allowing the material to exit the through the outlet of the sump 1 07. In alternate embodiments, the vibratory motion to the sump 107 may be provided through at least one vibratory sump actuator (not shown in the drawings) disposed either internal or external to the separator 100. That is, separate actuators may provide vibratory motion to the basket 105 and the sump 107.

[0026] The separator 100 may also include a programmable logic controller 108 (hereinafter "the PLC 108"), which may include instructions for running the actuator 104 and/or one or more additional components associated with the separator 100, such as, but not limited to, nozzles, pressurization units, heating units, and/or the at least one vibratory sump actuator. The PLC 108 may control any process associated with the separator 100 that may require instructions for automation. However, in some embodiments, the actuator 104, the one or more additional components, and/or the processes may be controlled manually through the use of, for example, manually valves or control switches.

[0027] As shown in FIG. 2, the basket 105 includes the discharge end 103 and an opposite feed end 202 (hereinafter “the feed end 202”) that is adjacent to and/or in fluid communication with the drilling material inlet 102 of the separator 100. The basket 105 also includes an uppermost screen basket or bed 204 (hereinafter“the screen bed 204”) and a lowermost screen basket or bed 206 (hereinafter“the screen basket 206”) that is provided or positioned below or beneath the screen bed 204. The screen bed 204 and/or the screen basket 206 (collectively referred to hereinafter as“the bed 204 and basket 206”) may extend outwardly from the feed end 202 towards the discharge end 103. Moreover, the screen assemblies 106 may be connected, attached, and/or secured to the basket 105 via the bed 204 and basket 206.

[0028] In one or more embodiments, the bed 204 and basket 206 may extend across a total length of the basket 105 extending from the feed end 202 to the discharge end 103. In other embodiments, the screen basket 206 may extend across the total length of the basket 105 and/or the screen bed 204 may extend across a first portion of the total length of the basket 105. For example, the first portion of the total length of the basket 105 may be about 25%, about 33% about 50%, about 66%, about 75%, or about 90% of the total length of the basket 105. In some embodiments, the first portion of the total length of the basket 105 may be less than about 30%, less than about 50%, less than about 70%, or less than about 80% of the total length of the basket 105. In other embodiments, the first portion of the total length of the basket 105 may be greater than about 5%, greater than about 20%, greater than about 30%, greater than about 45%, greater than about 65%, or greater than about 75% of the total length of the basket 105. Moreover, the first portion of the total length of the basket 105 may range from any above-identified lower limit to any above-identified upper limit.

[0029] One or more intermediate screen baskets or beds (not shown in the drawings) may be provided or positioned between the bed 204 and basket 206. The one or more intermediate screen baskets or beds may be configured to receive, support, and/or secure the screen assemblies 106 of the separator 100. Further, the screen assemblies 106 may be connected, attached, and/or secured to the basket 105 via the screen bed 204, the screen basket 206, and/or the one or more intermediate screen baskets or beds. Moreover, the one or more intermediate screen baskets or beds may extend outwardly from the feed end 202 towards the discharge end 103.

[0030] In one or more embodiments, the one or more intermediate screen baskets or beds may extend across the total length of the basket 105 extending from the feed end 202 to the discharge end 103. In other embodiments, the one or more intermediate screen baskets or beds may extend across a second portion of the total length of the basket 105. In an embodiment, the first portion of the total length of the basket may be greater than, less than, or about equal to the second portion of the total length of the basket.

[0031] For example, the second portion of the total length of the basket 105 may be about 25%, about 33% about 50%, about 66%, about 75%, or about 90% of the total length of the basket 105. In some embodiments, the second portion of the total length of the basket 105 may be less than about 30%, less than about 50%, less than about 70%, or less than about 80% of the total length of the basket 105. In other embodiments, the second portion of the total length of the basket 105 may be greater than about 10%, greater than about 20%, greater than about 30%, greater than about 45%, greater than about 65%, or greater than about 75% of the total length of the basket 105. Moreover, the second portion of the total length of the basket 105 may range from any above-identified lower limit to any above-identified upper limit.

[0032] With the screen assemblies 106 connected, attached, and/or secured to the basket

105, the screen bed 204, the screen basket 206, and/or the one or more intermediate screen baskets or beds may transfer vibratory motion from the actuator 104 to the screen assemblies 106. To prevent, or reduce likelihood of, separation of the screen assemblies

106, screen tensioning apparatus, seals, float mounts, springs, wedges, pneumatic actuators, bladders, and/or housings (not shown in the drawings) may be provided or utilized to attach and/or secure the screen assemblies 106 to the screen bed 204, the screen basket 206, and/or the one more intermediate screen baskets or beds. In one or more embodiments, the housings, seals, and/or the float mounts may be utilized and made of a flexible or resilient material, such as, for example, rubber, plastic, or polymer.

[0033] The screen assemblies 106 of the separator 100 may be emplaced, provided, and/or positioned in a horizontal fashion, or a substantially horizontal fashion, on the screen bed 204, the screen basket 206, and/or the one or more intermediate screen baskets or beds. In some embodiments, the screen bed 204, the screen basket 206, and/or the one or more intermediate screen baskets or beds may be horizontally, or substantially horizontally, orientated within the basket 105 of the separator 100. In other embodiments, the screen bed 204, the screen basket 206, and/or the one or more intermediate screen baskets or beds may be upwardly angled towards the discharge end 105.

[0034] For example, the screen bed 204, the screen basket 206, and/or the one or more intermediate screen baskets or beds may be orientated at a first angle with respect to the longitudinal axis of the basket 105. In some embodiments, the first angle may be about 1 degree, about 5 degrees, about 10 degrees, about 20 degrees, or about 40 degrees. In other embodiments, the first angle may be no more than about 1 degree, no more than about 5 degrees, no more than about 10 degrees, no more than about 20 degrees, or no more than about 40 degrees. In further embodiments, the first angle may be no less than about 1 degree, no less than about 5 degrees, no less than about 10 degrees, no less than about 20 degrees, or no less than about 40 degrees. Moreover, the first angle may range from any above-identified lower limit to any above-identified upper limit. [0035] In one or more embodiments, the screen assemblies 106 may be flat or substantially flat, corrugated, depressed, and/or contain raised surfaces. In other embodiments, the screen assemblies 106 may have one or more surfaces that are concave or convex. Further, the basket 105, in which the screen assemblies 106 are mounted and/or secured, may be inclined at the first angle with respect to the longitudinal axis of the separator 100. As a result, the screen assemblies 106, mounted within and/or secured to the basket 105, are inclined at the first angle towards the discharge end 103. Moreover, the screen bed 204, the screen basket 206, and/or the one or more intermediate screen baskets or beds may also be inclined at the first angle towards the discharge end 103.

[0036] The screen assemblies 106, provided within the basket 105, may comprise at least one uppermost or first feed end screen assembly 208 (hereinafter“the first feed screen 208”) and/or at least one lowermost or second feed end screen assembly 210 (hereinafter “the second feed screen 210”). The screen bed 204 may connect, attach, and/or secure the first feed screen 208 to the basket 105, and the screen basket 206 may connect, attach, and/or secure the second feed screen 210 and the screen assemblies 106 to the basket 105. The first feed screen 208 may be provided above or on top of the second feed screen 210 and/or overlapping at least a portion of the second feed screen 210. In an alternative embodiment, the first feed screen 208 within the basket 105 may be offset with respect to the second feed screen 210. In one or more embodiments, a first tier of the separator 100 may comprise the second feed screen 210 along with the screen assemblies 106, and a second tier of the separator 100 may comprise the first feed screen 208. As a result, the separator 100 may provide the first feed screen 208 at or on the second tier of the separator 100 and/or the second feed screen 210 and the screen assemblies 106 at or on the first tier of the separator 100.

[0037] In one or more embodiments, the screen assemblies 106, provided within the basket 105, may comprise at least one intermediate feed end screen assembly (not shown in the drawings). The at least one intermediate feed end screen assembly may be connected, attached, and/or secured to the basket 105 via the one or more intermediate screen baskets or beds. The at least one intermediate feed end screen assembly may be provided or positioned between the first feed screen 208 and the second feed screen 210 and adjacent to the feed end 202. In one or more embodiments, the at least one intermediate feed end screen assembly may be below or underneath the first feed screen 208 and/or above or on top of the second feed screen 210. Moreover, the at least one intermediate feed end screen assembly may overlap, or be offset with respect to, the first feed screen 208 and/or the second feed screen 210 (collectively referred to hereinafter as“the feed screens 208, 210”).

[0038] A mesh size of the first feed screen 208 may be same as, or substantially the same as, a mesh size of the second feed screen 210 and/or the at least one intermediate feed end screen assembly. Alternatively, the mesh size of the first feed screen 208 may be different from, or substantially different from, the mesh size of the second feed screen 210 and/or the at least one intermediate feed end screen assembly. Further, the mesh sizes of the feed screens 208, 210 may be the same as, substantially the same as, different from, or substantially different from the mesh size of the screen assemblies 106. Still further, the mesh size of the at least one intermediate feed end screen assembly may be the same as, substantially the same as, different from, or substantially different from the mesh size of the feed screens 208, 210.

[0039] Moreover, fluid flow rates of the liquid 302 flowable through the feed screens 208, 210 and/or the at least one intermediate feed end screen assembly may be the same as, substantially the same as, different from, or substantially different from the fluid flow rates of the liquid 302 flowable through the screen assemblies 106. In one or more embodiments, the fluid flow rates of the liquid 302 flowable through the feed screens 208, 210 and/or the at least one intermediate feed end screen assembly may be less than, greater than, or about equal to the fluid flow rates of the liquid 302 flowable through the screen assemblies 106. In other embodiments, a fluid flow rate of the liquid 302 flowable through the first feed screen 208 may be less than, greater than, or about equal to a fluid flow rate of the liquid 302 flowable through the second feed screen 210 and/or the at least one intermediate feed end screen assembly.

[0040] At least one fluid discharge chute and/or channel 212 (hereinafter“the discharge channel 212”) may be provided below or beneath the first feed screen 208 and/or the at least one intermediate feed end screen assembly. The discharge channel 212 may be in fluid communication with the first feed screen 208 and/or the sump 107 as shown in FIG. 3. As a result, the liquid 302 of the drilling material entering the basket 105 via the feed end 202 from the drilling material inlet 102 may flow, pass, or move through the first feed screen 208 and into the discharge channel 212 and/or the sump 107. Thus, the liquid 302 of the drilling material may be separated from the solids 304 of the drilling material and may flow or move into the sump 107 via the first feed screen 208 and/or the discharge channel 212. The liquid 302 provided within the discharge channel 212 may be delivered to the sump 107 and/or additional processing equipment, such as, but not limited to, a skid, a storage or shipping container, a mixer, a mud pump, and an additional shale shaker or vibratory separator (not shown in the drawings).

[0041] In some embodiments, the discharge channel 212 may be provided, or integrally formed, within the screen bed 204 or below or behind the screen bed. Thus, the sump 107 may be in fluid communication with the first feed screen 208 via the screen bed 204 and/or the discharge channel 212. In other embodiments, the screen bed 204 may have at least one opening or channel formed within such that the first feed screen 208 is in fluid communication with the discharge channel 212 and/or the sump 107 via the at least one opening or channel formed within the screen bed 204. In a further alternative embodiment, the discharge channel 212 may have a top end or surface that is configured to receive the first feed screen 208 such that the first feed screen 208 is connected, attached, and/or secured to the basket 105 via the discharge channel 212. As a result, exclusion of the screen bed 204 from the basket 105 may be provided by the discharge channel 212 configured as such.

[0042] In one or more embodiments, the discharge channel 212 may comprise one or more troughs, drains, and/or conduit extending between the sump 107 and the screen bed 204 and/or the first feed screen 208. A total length of the discharge channel 212 may be defined between a top end or surface of the sump 107 and the screen bed 204 or the first feed screen 208. In an embodiment, the total length of the discharge channel 212 may be defined by a trough below the first feed screen 204 and a drain extending from the trough to the top end or surface of the sump 107.

[0043] A cross-sectional area of the discharge channel 212 may be the same as, or different from, a cross-sectional area of the first feed screen 208. A fluid flow rate of the liquid 302 flowable through the first feed screen 208 may be less than, greater than, or about equal to a fluid flow rate of the liquid 302 flowable through the discharge channel 212. In one or more embodiments, the fluid flow rate (gallons/minute) through or in the discharge channel 212 may be the same or substantially the same as the fluid flow rate (gallons/minute) through the first feed screen 208. The fluid flow velocity (feet/second) through the first feed screen 208 may be the same as, substantially the same as or different than the fluid flow velocity (feet/second) in or through the discharge channel 212 due to change in cross-section area of the discharge channel 212. In one or more embodiments, the fluid flow rate of the liquid 302 flowable through the discharge channel 212 may be less than, greater than, or about equal to a fluid flow rate of the liquid 302 flowable through the second feed screen 210 and/or the screen assemblies 106 of the separator 100.

[0044] A first fluid flow path from the drilling material inlet 102, the feed end 202 and/or the first feed screen 208 to the sump 107 is provided by the discharge channel 212. As a result, the liquid 302, or at least a portion of the liquid 302, of the drilling material entering the basket 105 may flow or move along the first fluid flow path to the sump 107. The solids 304 separated from the liquid 302 may remain on or at the first feed screen 208 and/or move towards the discharge end 103 via the vibratory motion applied to the basket 105 by the actuator 104. As a result, the solids 304 may move towards an end of the first feed screen 208 that is opposite with respect to the feed end 202.

[0045] A second fluid flow path from the drilling material inlet 102 and/or the feed end 202 to the sump 107 may be provided by the second feed screen 210 and/or at least one screen assembly of the screen assemblies 106. As a result, the liquid 302, or at least a portion of the liquid 302, of the drilling material entering the basket 105 may flow or move through the second feed screen 210 and/or the at least one screen assembly of the screen assemblies 106 along the second fluid flow path into the sump 107. The solids 304 separated from the liquid 302 may remain on or at the second feed screen 210 and/or the screen assemblies 106 and move towards the discharge end 103 via the vibratory motion applied to the basket 105 by the actuator 104. As a result, the solids 304 may move away from feed end 202 and exit the basket 105 at the discharge end 103.

[0046] The first fluid flow path to the sump 107 may have a total length defined between the top end or surface of the sump 107 and the first feed screen 208 or the screen bed 204. The second fluid flow path to the sump 107 may have a total length defined between the top end or surface of the sump 107 and the second feed screen 208, the screen assemblies 106, or the screen basket 206. In one or more embodiments, the total length of the first fluid flow path to the sump 107 may be less than, greater than or about equal to the total length of the second fluid flow path to the sump 107. In one or more embodiments, a total fluid flow rate through the first fluid flow path may be less than, greater than or about equal to a total fluid flow rate through the second fluid flow path. In an embodiment, the total length of the first fluid flow path is greater than the total length of the second fluid flow path, and the total fluid flow rate through the second fluid flow path is greater than the total fluid flow rate through the first fluid flow path.

[0047] At least one flow back trough, channel or pan 214 (hereinafter“the pan 214”) may be provided between the first feed screen 208 and the second feed screen 210 or the screen assemblies 106 as shown in FIG. 2. The discharge channel 212, or at least a portion of the discharge channel 212, may be provided between the pan 214 and the first feed screen 208 and/or the screen bed 204. Further, the pan 214 is provided near or adjacent to the end of the first feed screen 208 and may slope, or angle, downwardly towards the second feed screen 210, the discharge channel 212, and/or the feed end 202. In one or more embodiments, the pan 214 may be mounted, connected, attached, and/or secured to the basket 105 and/or made of a rigid material. In an embodiment, the rigid material of the pan 214 may be the same as, or substantially the same as, material of the basket 105, the screen bed 204, and/or the screen basket 206.

[0048] A first end of the pan 214, that is adjacent to first feed screen 208, may extend to a height that may be above a height of the first feed screen 208. The height of the first end of the pan 214 and the height of the first feed screen 208 may be based on a bottom end or surface of the basket 105. Moreover, the opposite second end of the pan 214 may terminate or end adjacent to the feed end 202, the discharge channel 212, and/or an end of the second feed screen 210 that is adjacent to the discharge channel 212 and/or the feed end 202.

[0049] Drilling material conveyed along the first feed screen 208 may flow, feed, or move to the pan 214 which may flow, feed, or move the drilling material to the second feed screen 210 as shown in FIG. 3. The drilling material provided to the second feed screen 210 from the pan 214 may comprise the liquid 302, the solids 304, or a mixture of the liquid 302 and the solids 304. The mixture of the liquid 302 and the solids 304 received by the second feed screen 210 may be separated on the second feed screen 210 and/or the screen assemblies 106 via the vibratory motion provided to the basket 105 by the actuator 104. As a result, the liquid 302 may be separated from the solids 304 and conveyed along the second fluid flow path to the sump 107. Moreover, the solids 304 separated from the liquid 302 may move or be conveyed along the second feed screen 210 and the screen assemblies 106 towards the discharge end 103 by the vibratory motion of the basket 105. As a result, the solids 304 may exit the basket 105 at or near the discharge end 103.

[0050] The drilling material received by, flowable across, or introduced to the feed screens 208, 210 may contain a percentage of the liquid 302 or the solids 304. In one or more embodiments, the percentage of the liquid 302 or the solids 304 may be greater than about 1 %, greater than about 5%, greater than about 10%, greater than about 20%, greater than about 30%, greater than about 40%, or about 50%. In other embodiments, the percentage of the liquid 302 or the solids 304 may be less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, less than about 5%, or less than about 1 %. In further embodiments, the percentage of the liquid 302 or the solids 304 may be about 1 %, about 5%, about 10%, about 20%, about 30%, about 40% or about 50%. Moreover, the percentage of the liquid 302 or the solids 304 may range from any above-identified lower limit to any above-identified upper limit.

[0051] A first amount of the drilling material, comprising the liquid 302 and/or the solids 304, may be provided or introduced to the first feed screen 208 from the feed end 202. Additionally, a second amount of the drilling material, comprising the liquid 302 and/or the solids 304, may be provided or introduced to the second feed screen 210 from the pan 214 as shown in FIG. 3 or directly from the feed end 202 by a parallel drilling material feeder 502 (hereinafter“the parallel feeder 502”) as shown in FIG. 5. The first amount of the drilling material may be greater than, less than, or about equal to the second amount of the drilling material. The liquid 302 separated from the drilling material at the first feed screen 208 may flow or move along the first fluid flow path to the sump 107 and the liquid 302 separated from the drilling material at the second feed screen 210 may flow or move along the second fluid flow path to the sump 107. As a result, the sump 107 may receive the liquid 302 from the first fluid flow path and/or the second fluid flow path as shown in FIG. 3. Moreover, an amount of the liquid 302 received in the sump 107 from the first fluid flow path may be greater than, less than or about equal to an amount of the liquid 302 received in the sump 107 from the second fluid flow path. [0052] As the drilling material introduced at the feed end 202 flows over, or conveys along, the feed screens 208, 210 and the screen assemblies 106 to the discharge end 103, the drilling material is classified as either beach material or pool/pond material (hereinafter “pond material”). The beach material refers to a drier drilling material wherein a majority of the liquid 302 has been removed from the solids 304, and the solids 304 may have formed in a pile or piles on the feed screens 208, 210 and/or the screen assemblies 106. The pond material refers to a non-dry drilling material comprising the liquid 302 with the solids 304 suspended within the liquid 302. A total screening surface area of the basket 105 may be provided by the feed screens 208, 210 and the screen assemblies 106, and a percentage of the total screening surface area of the basket 105 may contact or convey the beach material or the pond material. In one or more embodiments, a portion of the total screening surface area of the basket 105 adjacent to the discharge end 103 consists of the beach material and/or the solids 304 that may be dried or substantially dried solids.

[0053] In one or more embodiments, the percentage of the total screening surface area of the basket 105 that may be contacting and/or conveying the pond material may be at least about 50%, at least about 60%, at least about 70%, at least about 80%, or at least about 90%. In some embodiments, the percentage of the total screening surface area of the basket 105 that may be contacting and/or conveying the pond material may be less than about 90%, less than about 80%, less than about 70%, or less than about 60%. In other embodiments, the percentage of the total screening surface area of the basket 105 that may be contacting and/or conveying the pond material may be about 65%, about 70%, about 75%, about 80%, about 85%, or about 90%. Moreover, the percentage of the total screening surface area of the basket 105 that may be contacting and/or conveying the pond material may range from any above-identified lower limit to any above-identified upper limit.

[0054] Based on the percentage of the total screening surface area of the basket 105, at least the feed screens 208, 210 and a portion of the screen assemblies 106 may be contacting the pond material and/or conveying the pond material and/or the solids 304 towards or to the discharge end 103. As a result, the pond material may be provided at one or more fluid pond depths along the feed screens 208, 210 and/or the portion of the screen assemblies 106. As the fluid pond depth of the pond material increases at the feed screens 208, 210, a majority of the liquid 302 of the pond material may pass or flow through the feed screens 208, 210 and into the sump 107. Further, increased fluid pond depths on the feed screens 208, 210 may increase stress on the feed screens 208, 210 and/or may reduce screen life of the feed screens 208, 210. However, the basket 105 provides the first feed screen 208 in feed series with the second feed screen 210 and/or the screen assemblies 106. As a result, the feed screens 208, 210 and the screen assemblies 106 of the basket 105 may be fed in series, instead of being fed in parallel via the parallel feeder 502 shown in FIG. 5.

[0055] With at least the feed screens 208, 210 in feed series and having the same, or substantially the same, fluid pond depth of the pond material provided thereon, the fluid capacity of the basket 105 may increase without increasing the stress on the feed screens 208, 210, increasing a footprint of the separator 100, and/or reducing the screen life of the feed screens 208, 210. As a result, the feed screens 208, 210 may reduce a number of screen assemblies 106 necessary in the basket 105 compared to known two deck shale shakers or vibratory separators (not shown in the drawings). Moreover, the feed screens 208, 210 may reduce an overall cost of the separator 100 compared to the cost of known two deck shale shaker or vibratory separators.

[0056] In one or more embodiments, the fluid pond depth of the pond material at the first feed screen 208 may be greater than, less than, or about equal to the fluid pond depth of the pond material at the second feed screen 210. In an embodiment, the drilling material may be introduced to the first feed screen 208 at a flow rate such that the fluid pond depth of the pond material at the second feed screen 210 is about equal to the fluid pond depth of the pond material at the first feed screen 208. Alternatively, the drilling material may be introduced from the parallel feeder 502 directly to both feed end screens of the feed screens 208, 210 as shown in FIG. 5. As a result, the fluid pond depth of the pond material at the first feed screen 208 may be greater than, less than, or about equal to the fluid pond depth of the pond material at the second feed screen 210.

[0057] Additionally, the fluid pond depth of the pond material at the portion of the screen assemblies 106 may be greater than, less than, or about equal to the fluid pond depth of the pond material at the feed screens 208, 210. In some embodiments, the fluid pond depth of the pond material may extend across a percentage of the screening surfaces provided by the second feed screen 210 and the screen assemblies 106. For example, the percentage of the screening surface, where the fluid pond depth extends, may be greater than about 50%, greater than about 60%, greater than about 70%, greater than about 80%, or greater than about 90%. In some embodiments, the percent of the screening surface, where the fluid pond depth extends, may be less than about 90%, less than about 80%, less than about 70%, or less than about 60%. In other embodiments, the percentage of the screen surface, where the fluid pond depth extends, may be about 65%, about 70%, about 75%, about 80%, about 85%, or about 90%. Moreover, the percentage of the screen surface, where the fluid pond depth extends, may range from any above- identified lower limit to any above-identified upper limit.

[0058] The second feed screen 210 and the screen assemblies 106 may provide the basket 105 with an estimated or an actual first fluid capacity (hereinafter“the first fluid capacity”) with respect to separating the liquid 302 from the drilling material and flowing the separated liquid 302 along the second fluid flow path to the sump 107. Further, the feed screens 208, 210 and the screen assemblies 106 may provide the basket 105 with an estimated or an actual second fluid capacity (hereinafter“the second fluid capacity”) with respect to separating the liquid 302 from the drilling material and flowing the separated liquid 302 along the first fluid flow path and the second fluid flow path to the sump 107. Moreover, the second fluid capacity of the basket 105 may be greater than the first fluid capacity of the basket 105 by at least an increased percentage.

[0059] For example, the increased percentage achievable by the second fluid capacity over the first fluid capacity may be greater than about 20%, greater than about 25%, greater than about 30%, greater than about 35%, greater than about 40%, greater than about 45%, or greater than about 50%. In some embodiments, the increased percentage may be at least about 25% or 30% and no more than about 40% or 45%. Moreover, the increased percentage may range from any above-identified lower limit to any above- identified upper limit.

[0060] FIG. 4 shows the basket 105 wherein the screen bed 204 is sized and/or configured to receive and support the first feed screen 208 and at least one additional first feed screen 402 (hereinafter“first feed screens 208, 402”). The discharge channel 212 is fluidly connected to the first feed screens 208, 402 and the sump 107. As a result, the sump 107 is in fluid communication with the first feed screens 208, 402 via the discharge channel 212. Moreover, the liquid 302 may be separated from the drilling material at the first feed screens 208, 402, and the separated liquid 302 may flow or move along the first fluid flow path and/or through the discharge channel 212 to the sump 107. As a result, a fluid flow rate and/or a fluid flow capacity of the first feed screens 208, 402 may be greater than the fluid flow rate and/or the fluid flow capacity of the first feed screen 208 shown in FIGS. 2 and 3. Moreover, the second fluid capacity achievable by the basket 105 comprising the first feed screens 208, 402 as shown in FIG. 4 may be greater than the second fluid capacity achievable by the basket comprising the feed screens 208, 210 as shown in FIGS. 2 and 3.

[0061] The separator 100, comprising the basket 105 as shown in FIGS. 2-4, may impart or provide a rapidly reciprocating and/or vibratory motion to the basket 105, the screen assemblies 106, the feed screens 208, 210 (shown in FIGS. 2 and 3), or the first feed screens 208, 402 and the second feed screen 210 (shown in FIG. 4). The drilling material from which the solids 304 are to be separated may pour or flow from the feed end 202 onto the first feed screen 208, the feed screens 208, 210, the first feed screens 208, 402, and/or the second feed screen 210.

[0062] As the drilling material moves or flows toward the discharge end 103 of the basket 105, the liquid 302, or at least a portion of the liquid 302, may separate from the drilling material at the first feed screen 208 or the first feed screens 208, 402 and flow along the first fluid flow path through the discharge channel 212 to the sump 107. The solids 304 and/or a remaining portion of the liquid 302, that are unable to move or flow into the discharge channel 212, remain on top of the first feed screen 208 or the first feed screens 208, 402, and move toward the discharge end 103 and/or into the pan 214.

[0063] The solids 304 and/or the remaining portion of the liquid 302 may flow or move through the pan 214 to the second feed screen 210 and the screen assemblies 106. The remaining portion of the liquid 302 may separate from the solids 304 at the second feed screen 210 or the screen assemblies 106 and flow or move along the second fluid flow path to the sump 107. The solids 304, that are unable to move or flow into the second fluid flow path, may remain on the top of the second feed screen 210 and/or the screen assemblies 106 and/or move towards the discharge end 103 where the solids 304 may be collected. As a result, the liquid 302 of the drilling material may be collected in the sump 107 via the first fluid flow path provided by the discharge channel 212 and the second fluid flow path provided by the second feed screen 210 and/or the screen assemblies 106. [0064] FIG. 5 shows a top plan view of the basket 105 having the parallel feeder 502 provided or positioned at or near the feed end 202 and/or adjacent the discharge channel 212. The parallel feeder 502 is in fluid communication with drilling material inlet 102 and the feed screens 208, 210 such that drilling material from the drilling material inlet 102 may flow to the feed screens 208, 210. Drilling material, comprising the liquid 302 and the solids 304, may be provided from the parallel feeder 502 directly to the feed screens 208, 210. In one or more embodiments, a feed of the drilling material to the basket 105 may be split by the parallel feeder 502 and flowable over the feed screens 208, 210. The liquid 302 may be separated from the solids 304 and may flow along the first fluid flow path and/or the second fluid flow path into the sump 107 via the feed screens 208, 210, the discharge channel 212, and/or the screen assemblies 106 as shown in FIGS. 3 and 5. Moreover, the fluid flow rate of the drilling material being provided from the parallel feeder 502 to the first feed screen 208 may be less than, greater than, or about equal to the fluid flow rate of the drilling material being provided from the parallel feeder 502 to the second feed screen 210. As a result of the parallel feeder 502 flowing the drilling material to the feed screens 208, 210, the fluid pond depth of the drilling material at the first feed screen 208 may be greater than, less than, or about equal to the fluid pond depth of the drilling material at the second feed screen 210.

[0065] Referring now to FIG. 6 with continued reference to FIGS. 1 -6, FIG. 6 is a flowchart depicting a method 600 for separating fluid from drilling material comprising the fluid and solids suspended within the fluid. The method 600 may include introducing drilling material into a basket of a vibratory separator at a feed end of the basket, as at 602. Additionally, the method 600 may include separating a first portion of the fluid from the drilling material at a first upper screen assembly disposed in the basket, as at 604. The first portion of the fluid may be flowable from the first upper screen assembly along a first fluid flow path to a sump configured to receive the first portion of the fluid that passes through the first upper screen assembly.

[0066] The method 600 may further include separating a second portion of the fluid from the drilling material at a first lower screen assembly disposed in the basket, as at 606. The second portion of the fluid may be flowable from the first lower screen assembly along a second fluid flow path to the sump that is configured to receive the second portion of the fluid that passes through the first lower screen assembly. The first lower screen assembly may be disposed between the sump and the first upper screen assembly, and a first total length of the first fluid flow path may be greater than a second total length of the second fluid flow path. Moreover, the method 600 may include flowing the first portion of the fluid along the first fluid flow path to the sump and the second portion of the fluid along the second fluid flow path to the sump, as at 608.

[0067] The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the disclosure. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the systems and methods described herein. The foregoing descriptions of specific examples are presented for purposes of illustration and description. They are not intended to be exhaustive of or to limit this disclosure to the precise forms described. Obviously, many modifications and variations are possible in view of the above teachings. The examples are shown and described in order to best explain the principles of this disclosure and practical applications, to thereby enable others skilled in the art to best utilize this disclosure and various examples with various modifications as are suited to the particular use contemplated. It is intended that the scope of this disclosure be defined by the claims and their equivalents below.