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SolidsControl PDF
SolidsControl PDF
Only in the last decade has the importance of minimizing drilled solids in drilling fluids
been fully realized. Both laboratory tests and practical field experience have revealed
that by closely monitoring and maintaining a minimum of drilled solids in the mud,
large savings in both money and time can be achieved. These savings can be categorized
as follows:
Increased drilling rate - less days per well
Increased bit life
Increased life of mud pump parts
The key to these three areas of savings is reducing and minimizing the concentration of
"undesirable" drilled solids. Formation pressures dictate the amounts of weighting
agents (i.e., barite, calcium carbonate, etc.) that must be present in the mud. These types
of solids are necessary and hence they are not considered in this discussion. Solids that
are considered "undesirable" are any solids that become incorporated in the mud during
the drilling process, i.e., salt, carbonates, clay. The accumulation of these types of solids
can present mud property problems (increases in viscosity and rheology, build-up of
mud weight, etc.) and decrease the drilling rate, bit life, and the life of mud pump parts.
Treatment of muds exhibiting solids related problems can involve any or all of the
following:
Chemical treatment
Dilution rates
Mechanical removal
Chemical treatment involves the use of flocculants to drop unwanted solids out of the
mud. However, this type of treatment is not recommended for use with many mud
systems because of the resulting adverse effects on mud properties.
Dilution is most often used as a means of correcting mud properties that have been
altered by the accumulation of drilled solids. By this method, the solids are not removed
- only their concentration has been lessened. Given further build up of solids in the mud
as drilling progresses, the problem in mud weight, rheology, etc. will once again
reappear. Dilution is often expensive due to:
Treatment of solids build up by mechanical means is often the most practical and cost
effective of the three available methods. Unwanted alterations in mud properties are
avoided and savings due to less dilution are realized. Generally speaking, the greater the
cost per barrel of a given mud, the greater the savings in using mechanical equipment to
rectify mud properties. The equipment used to mechanically remove solids from the mud
must be designed to fit the requirements of a given drilling operation, and not every
piece of equipment is relevant in every situation. Furthermore, the equipment
specifically selected to aid in mechanical removal of solids must be rigged up and
maintained to insure the units operate at peak performance.
Solids removal equipment systems can consist of any of the following:
Conventional shakers with screen sizes up to 30-40 mesh
High-speed shakers with screen sizes up to 100-200 mesh
A bank of 6, 8 or 12 inch cone desanders
A bank of 3 or 4 inch cone desilters
An 8 or 12 inch cone desilter over a fine screen shaker 100- 200 mesh - i.e., a
mud cleaner
Centrifuge
High Speed Shakers
Various high-speed shakers are available from different companies.
Double Deck Shaker
The double deck shale shaker introduced by BAROID has two screens mounted on a
flatbed construction. This unit differs from conventional shakers in three important
respects:
The shaking motion is circular rather than the up and down movement of
conventional shakers
The shaker screens themselves are virtually horizontal, and not like conventional
screens that can be at angles up too as high as 30 from the horizontal
The acceleration of the mud hitting the screens has been measured at 5 G's (i.e.,
ft/sec/sec)
These three factors result in the mud stream having a much harder and longer contact
time with the screens, which increases the efficiency of separation of solids from the
liquid phase. In addition, less mud is lost over the screens. The screens themselves can
range down to 100 mesh with the mesh cross section varying from square to an
exaggerated rectangle. A common combination of mesh sizes used is a 30 mesh screen
on the upper deck and an 80 mesh screen on the lower deck, as the working life of very
fine mesh screens is quite short. Drilled solids down to 177 microns in size are removed
by 80 mesh screens as opposed to 840-micron size particles on a 20-mesh screen. In
addition, if an inhibitive mud system is used, finer particles are often removed in
conjunction with particles greater than 177 microns in size. The shaker is powered by a
three-phase electric motor that plugs into rig supply systems.
Desilters and Desanders
Desilters and desanders should be chosen to handle the volumes of drilled solids
expected at the fastest anticipated drilling rate.
The required capacity of desilting/desanding may be calculated using the following
equation:
Hydrocyclone capacity, gpm = 8 x hole volume (gallons per foot) x maximum
penetration rate (feet per minute)
The desilters/desanders must be equipped with centrifugal pumps capable of providing
sufficient pressure to the hydrocyclones to allow them to operate in the desired pressure
range. In order to obtain the desired results from desanders and desifters, some of the
following points must be observed:
Correct installation of the desifter/desander banks
Provision of the correctly sized centrifugal pumps
Operation of the hydrocyclone in the design pressure ranges
Removal of large particle size solids upstream of the hydrocyclone bank to
minimize plugging of cones
Regular inspection and replacement of cones
When correctly installed and operating in the design range, desilters and desanders are
capable of removing up to 95% of solids particles greater than 15 microns in size.
Practical limitations:
When desanders and desilters are used with coarse screen shakers, plugging of
cones often occurs in the fast drilling top-hole sections, particularly when
drilling formations containing plastic shales.
Barite is ejected with the fine solids, therefore desilters cannot be used in
weighted mud systems, (i.e., in systems with densities of 11.0 ppg or greater).
Desilters and desanders should be used as early as possible when drilling with
unweighted fluids so that the maximum number of drilled solids may be mechanically
removed on the first circulation. While making a trip, the mud in the pits can be
circulated through the desilting equipment to remove the fine drilled solids.
Desilters and desanders are used for solids removal in unweighted mud systems having
mud weights up to 11.0 ppg. In general, the use of a centrifuge cannot be economically
justified for mud weights under 12.5 to 13.0 ppg.
Mud Cleaner
BAROID developed a piece of solids removal equipment designed specifically for the
intermediate mud weight ranges of 11.0 to 14.0 ppg. It consists of an eight-cone desilter
bank mounted over a small high-speed shaker, which works on the same principle as the
BAROID Double Deck Shaker. This piece of equipment is known as a Mud Cleaner.
The mud cleaner combines the advantages of:
Solids separation by means of the application of centrifugal force, i.e., the same
principle which desanders and desilters operate
Solids removal by screening
The first stage in the operation is the processing of the mud through the desilter bank.
The overflow is returned to the circulating system and the underflow is discharged on to
the vibrating shaker screen. This permits the recovery of the liquid phase and most of
the barite present in the underflow and the remainder of the solids are discarded.
The screen sizes vary, but the size most commonly used screen is a 200-mesh screen. It
has been found to be impractical to use screen sizes much below 200 mesh due to the
excessive loss of barite over the shaker screen. A 200-mesh screen removes fines down
to 75 microns in size.
Centrifuge
In weighted mud systems it is often desirable to reduce mud maintenance costs by
methods other than dilution. Since it is not practical to use desilting equipment in
weighted mud systems, a centrifuge is often used.
Mud centrifuges work on the decanting principle. The mudflow enters a chamber
rotating at a high speed and the action of the centrifugal force separates the mud stream
into two components.
Low specific gravity solids with most of the fluid phase
High specific gravity solids with a small amount of fluid phase
Most centrifuges consist of three units:
Centrifuge
Control panel
Power unit
Each unit is normally mounted on a separate skid, though in practice the centrifuge and
control panel may be mounted together on a large combination skid. The control panel is
equipped with flow-rators for mud and dilution water, and a tachometer to show the
revolutions per minute of the decanting centrifuge.
It is important that the mud and water through put and the number of revolutions per
minute of the centrifuge are kept in the correct operating ranges since the efficiency of
solids removal is directly dependent on both of these factors.
In unweighted mud systems, a high volume decanting centrifuge removes low specific
gravity drilled solids most efficiently and economically. The centrifuge can be operated
on unweighted muds at speeds up to 2200-2400 rpm, creating centrifugal forces in
excess of 200 G-force. The high volume centrifuge can remove fine solids down to two
microns (bentonite, clays, etc). The standard mud centrifuge used in processing
weighted muds can also be used in unweighted systems by simply using the machine in
the "desander mode".
Solids Removal - Principles and Techniques
The mechanisms of separation of solids from fluids can be classified according to the
nature of the forces that cause the removal of the particles from the fluid.
External forces
Internal forces
No forces
The principles most frequently used in solid-liquid separation are shown below:
Separation of solids from liquids
Sedimentation
(difference in density
necessary)
Gravity
(settling tanks,
thickeners)
Screening
(no difference in density
necessary)
Centrifugal
Hydrocyclone
(high shearing stresses,
low underflow concentration
Sedimenting Centrifuges
(low shearing stresses, high
concentration of thickened product)
Screening
Screening is a method of sorting particles according to their size. The solids are brought
into contact with a screening surface, which acts as a stop-go gauge. The undersize or
"fines" pass through the screen openings - the oversize or "coarse" do not.
Woven wire screens are often referred to by their mesh number; that is, the number of
wires per linear inch. The 75-micrometer screen is 200-mesh screen having a wire
thickness of about 50 micrometers and an open area of approximately 36%. The smallest
mesh used in industrial screens is about 160 mesh. With finer mesh sizes, other methods
of separation are usually more economical.
Screens, which vibrate rapidly with small amplitudes, are less likely to blind than
gyrating screens.
In an ideal situation, complete solids separation is achieved at the cut point. In actual
operation, the screen mesh size is usually chosen so that a balance is achieved between
the capacity and the effectiveness of the screen. Effectiveness may be defined as the
percentage of recovery of fines or coarse solids, or a combination of the two.
Capacity and effectiveness are opposing factors; increasing the former leads to a
decrease in the latter. Granular materials are the easiest to screen, however the
effectiveness falls off with acicular particles, which only pass through the screen in
certain orientations and they tend to blind the screen.
Cohesive materials also inhibit screening. Particle size distribution is also of importance
because narrowly classified particles are more difficult to screen than particles of a wide
size range.
Screens are usually the first piece of equipment used in the removal of drilled solids.
Screens may remove as much as 100% of the drilled solids or as little as 30% depending
upon the following conditions:
Bit type - i.e., conventional or diamond, short tooth, long tooth, etc.
Bit size - smaller bits make smaller cuttings
Types of drilling fluid
Oil muds tend to keep the cuttings intact
Water tends to finely disperse the cuttings
Resident time of cutting in the annulus
Mesh size of shaker screens
The reduction of screen size will greatly improve solids removal. The efficiency of these
devices are influenced by such factors as the fluids properties, the particle size of the
solids to be removed, and the work input of the screen on the fluid.
Fluid Properties
Because of the mechanics of the screen, the fluid properties can best be expressed in the
generalized Reynolds Number (Re) for Power Law fluids as shown below:
(d/12) N V 2- N P
R e = 1.86
8N K
where:
d
V
p
N
K
Re
=
=
=
=
=
=
inches
ft/sec
lb/gal
power law index
consistency index, lb/sec/ft2
Reynolds Number
As the Reynolds number increases, the inertial forces increase and the fluid should flow
through the screen faster.
Particle Size
As the particle size of the solid approaches the screen size, the effective flow area is
reduced and the screen will tend to blind. If the solids particles are larger than the screen
size, the fluid will flow around the particles and then through the screen.
Separation of Solids by Sedimentation
Due to the difference in density of the solids and the liquid, solids will settle due to
gravity. The rate of settling can be estimated from the general equations for particles
moving in fluids as shown below.
Strokes Law
Vm =
2 -p 2
r g for R e 1.0
9
Vm =
-p
8
g
r
p
3Q
Vm
p
r
g
Q
=
=
=
=
=
=
=
Where:
terminal velocity, (cm/sec)
SpG.Solid
SpG. Liquid
radius of sphere, (cm)
acceleration of gravity, (9.81)
coefficient of resistance = 0.4
coefficient of viscosity, (poise)
Stokes
Newton
General Equation
r1 (1- p)m1 = r2 (2 p)m2
Hindered-Settling Ratio
m = 1 Newton
m = 0.5
Stokes
ratio =
( 1 - p' ) m
2 - p' ) m
m=1
Newton
m = 0.5
Stokes
Sphericity =
The settling rate can be increased in drilling fluids by two methods. Increase the particle
size by the use of flocculants or increase the gravitational field by centrifugal forces.
In unweighted muds, certain polymers are effective flocculants, which will reduce the
amount of time and the pit area needed for settling. Tests should be run on the drilling
fluid to determine the optimum polymer treatment for maximum settling.
Centrifugal Sedimentaiton - Hydrocyclone
The basic separation principle employed in hydrocyclone is centrifugal sedimentation;
i.e., the suspended particles are subjected to centrifugal acceleration, which makes them
separate from the fluid. Unlike centrifuges, hydrocyclone have no moving parts and the
necessary vortex motion is performed by the fluid itself.
The flow pattern in a hydrocyclone has circular symmetry, with the exception of the
region in and just after the tangential inlet duct. The velocity of flow at any point within
the hydrocyclone can be resolved into three components: tangential velocity, radial
velocity, and vertical velocity, and these can be investigated separately.
A particle at any point within the flow in a hydrocyclone is basically subjected to two
forces: one force due to both external and internal fields of acceleration (gravity and
centrifugal forces) and the other force due to drag exerted on the particle by the flow.
The gravity effect is normally neglected in a hydrocyclone, therefore only centrifugal
and drag forces are taken into account. The movement of the particle in both tangential
and vertical (axial) directions is unopposed by any force, so that the velocity
components can be taken equal to the corresponding flow components. Since the
centrifugal force acts in the radial direction, it prevents the particles following the
inward radial flow. If the centrifugal force acting on a particle exceeds the drag, the
particle moves radically outwards and, if the drag is greater, the particle is carried
inwards.
The hydrocyclone parameters affecting the separation efficiency are too interrelated to
be presented in a simple form. However, the three parameters of special concern, which
can be characterized, are:
Diameter of hydrocyclone (maximum diameter of cone)
Diameter of inlet
Cone angle
Centrifuges
Decanting (scroll) centrifuges achieve centrifugal forces by a rotating horizontal conical
or cono-cylindrical bowl with an internal conveyor turning at a slightly different speed.
The conveyor removes the settled solids and therefore allows continuous processing of
the fluid.
For efficient separation, dilute suspensions are needed. As the solids concentration
increases, particle interference (hindered settling) occurs and reduces the settling rates.
The particle trajectory (T) in a centrifuge is a function of two forces, the direction of
flow (V) and Stokes settling velocity ().
SUMMARY
Proper control of drilled solids in drilling fluids should be the basic objective of a mud
engineer in order to maximize drilling performance with minimum costs. Thorough
analysis and evaluation of mud processing equipment in conjunction with proper
chemical control and excellent planning can and will reduce overall well costs
SOLIDS ANALYSIS
Determination of the solids content of a drilling fluid should be carried beyond
measurement of the volume percent solids as determined by the mud retort. The actual
solids content in terms of pounds per barrel and the distribution of the solids into the
categories of barite (specific gravity 4.2) and low gravity solids (drilled solids and added
clay viscosifiers with specific gravities near 2.6) is frequently desired, particularly for
high weight muds in temperature wells. The necessary data for making such a
calculation should be included in the mud check taken on the rig each day. Data needed
for the complete calculation are (1) mud density (Dm, lb/gal), (2) water, oil, and solids
content from retort (VW, VO, VS, percent by volume), (3) filtrate salinity (chloride,
mg/L) and (4) the methylene blue test (cc/cc).
Salinity Correction
Prior to calculating the average solids density and solids content, the volume percent
solids and water must be corrected for dissolved salts in muds having 10,000 mg/L
chlorides or higher. In most instances, the salt is sodium chloride and it will show up in
the retort analysis as solids.
The volume percent water from the retort analysis (VW) is corrected using a multiplier
(F) that is dependent on the chloride content of the mud filtrate. A plot of F versus
filtrate chloride is shown in Figure 1. The corrected water content is determined as
follows:
VW (corr)
= (F) (VW)
VW (corr)
F
VW
(1)
where:
= 100 - VW (corr) - VO
VO
(2)
where:
All equations below are written assuming the salinity correction has been made, using
the notations listed.
VW
VS
VO
F
Dm
Dw
=
=
=
=
=
=
SpG
Wbarite
Ws
Wlgs
=
=
=
=
The density low gravity solids = 21.66 lb/gal (8.33 x 2.6 = 21.66)
Barite weighs 1470 lb/bbl., 35.0 lb/gal, 4.2 SpG.
Low gravity solids weigh 910 lb/bbl., 21.7 lb/gal, 2.6 SpG.
Average Specific Gravity of Solids
The average specific specific gravity (SpG) of solids is calculated using the mud weight
(Dm), the corrected volume percent of water, oil and solids, and the densities of the
water and oil phases. Water density (Dw), including dissolved salts, is given in Figure 1
as a function of filtrate chloride. The specific gravity (SpG) of the solids is then:
SpG =
100 D m - VW D W - 7.1 VO
8.33 VS
(3)
The oil density is assumed here to be 7.1 lb/gal (0.85 grams per cc).
For muds containing no barite, it is best to assume a solids specific gravity of 2.6
rather than relying on the retort. The retort must still be used to determine the oil content
if oil is present. The procedure given above is reversed; assuming a solids specific
gravity of 2.6, and the volume percent solids (VS) is calculated by the following
equation:
VS =
100 (D m D W ) + VO (D W - 7.1)
21.66 - D W
(4)
(5)
The distribution of solids into barite (Wbarite) and low gravity solids (Wlgs) is as follows:
4.2 SpG - (4.2) (2.6)
Wbarite (lb/bbl) = WS
(4.2 - 2.6) SpG
(6)
(7)
For any given total solids specific gravity, the fraction of solids, which are barite and
low gravity solids, is illustrated in Figure 2. When the average specific gravity of solids
is 3.21, 50% of the solids by weight are barite and 50% are low gravity solids.
For unweighted fresh water muds with no oil, Wbarite = 0. In this case, the low gravity
solids content can be read directly from Figure 3, which is more accurate than using the
retort for measuring the volume percent solids.
Low Gravity Solids Composition
The term "low gravity solids" includes a wide variety of minerals, both formation solids
and commercial clays. Quartz, feldspar, limestone, dolomite, shale, etc. all have specific
gravities near 2.6. This value is chosen to represent the entire group of these minerals.
Some mud engineering manuals use a value of 2.5 to represent low gravity solids but we
feel 2.6 is a more representative value. Thus, added drilling clays and drilled solids are
grouped together under the low gravity solids designation. It is often important to
distinguish active clays, those which impart gel structure to the drilling fluid, from
inactive, low gravity solids which impart viscosity but little gel structure or filtration
control. The methylene blue test (MBT) is used to make the differentiation by
determining the cation exchange capacity of the mud. The cation exchange capacity, in
turn, can be related to an equivalent bentonite content, (E) by the following equation:
E (lb/bbl) = 5 x
(8)
This equation assumes a cation exchange capacity for commercial bentonite of 70meq/100 g using a methylene blue test solution of 0.01 meq/ml. If the bentonite
equivalent is assumed to represent active clays in the system, the inactive low gravity
solids are determined as follows:
Winactive (lb/bbl) = Wlgs E
(9)
Alternatively if the cation exchange of the drilled solids (C) is known, the low gravity
solids can be separated into the amount of commercial bentonite (B) and the amount of
actual drill solids (D). The procedure is as follows:
B=
A E - C Wlgs
A-C
D = Wlgs - B
where:
A
(10)
(11)
Discussion
The weak point in this scheme for calculating solids content is the retort analysis for
volume percent water, oil, and solids. As normally run, a 10-ml sample of mud is heated
in the retort and water and oil are evaporated leaving the mud solids in the sample
holder. The oil and water are condensed and collected in a 10 ml graduated cylinder.
The volume of each is read and multiplied by ten. The difference between 100 percent
and the sum of the oil and water volumes is considered the solids content. It should be
noted that the retort analysis was designed for determination of oil content and not for
solids. An error of one percentage point in the water volume, and thus in the solids,
volume can after the final calculated average specific gravity and solids composition
significantly. The retort tends to be particularly inaccurate at low solids contents. There
may also be a variation from sample to sample when a series of muds are being run
although generally, muds run by one operator or on one mud retort will yield consistent
results. The technique is accurate for observing trends in low gravity solids content over
a period of time, particularly when used in conjunction with the methylene blue analysis.
To make the retort analysis as accurate as possible, it it essential that the sample holder
be calibrated with water and thoroughly cleaned after each test and that the graduated
cylinder be calibrated to insure that it reads the proper total volume.
Example
Mud weight, Dm
Chloride,
Retort water, Vw
Retort oil, VO
Retort solids,VS
MBT (mud)
C.E.C (formation)
From Figure 1
F = 1.008
Dw = 8.47 lb/gal
From equation 1 and 2
VW (corr) = (1.008) (56) = 56.4
= 18 lb/gal
= 15,000 mg/L
= 56%
= 4%
= 40%
= 4 cc/cc mud
= 12 mg/100 g
SpG =
= 480 lb/bbl
Wlgs
The next and last step is to separate the low gravity solids (63 lb/bbl) into commercial
bentonite and drilled solids. The bentonite equivalent is:
E = (5) (4) = 20 lb/bbl
The amount of commercial bentonite (B) and drilled solids (D) are then:
B =
D = 63 11 = 52 lb/bbl
Of the 20-lb/bbl bentonite equivalent, 11 lb/bbl is derived from added commercial
bentonite and the rest is the drilled solids contribution.
The overall analysis of one barrel of the mud is then:
Water (15,000 mg/L chloride)
Oil
Barite
Bentonite
Drilled solids
0.564 bbl
0.040 bbl
480 lb
11 lb
52 lb
The calculation can be checked by adding up the volume of each component. The final
volume should be 1 bbl.
Water
Oil
Barite
Bentonite
Drilled solids
0.564
0.040
0.327
0.012
0.057
1.000
Total
Student problem No. 1
=
=
=
=
=
=
=
15.50 ppg
1000 mg/L
62 %
8%
30 %
17.5 lbs/bbl
12
(1470 lb/bbl)
(910 lb/bbl)
Figure 1
Figure 2
Figure 3
A mud system during drilling and circulation is undergoing continual change. Because
of the change, the mud must be treated to maintain its desired properties. In order to
make the most economical treatments, it is important to know the current component
concentrations, and based on assumed or calculated losses, be able to calculate the
amounts of materials required to maintain the system.
Utilizing material balance techniques it is possible to estimate the quantities of materials
needed to maintain a mud system. Assumptions and known information will be utilized
in developing the values for the material balance problems. Known information includes
hole size, penetration rate and nature of the solids drilled. Assumed data includes losses
to the formation through seepage and filtrate, hole wash-out, and losses through solids
control equipment. With this information, estimates of the daily chemical consumption
rates can be calculated.
For the purpose of this exercise, assume the following:
Hole sizes: 8.5"
Washout: 10%
Penetration rate: 35 ft/hr
Total circulating volume: 1,000 bbls
Losses due to solids control equipment: = 15 bbl/hr (1.5%/hr)
Losses due to filtration and seepage: 10 bbl/hr (1%/hr)
Losses due to adsorption on cuttings: 1 bbl/1 hr (0.1 %/hr)
The last analysis of the drilling fluid yielded the following data:
Mud weight: 12.0 ppg (1.44 SG)
Solids: 18.0% by volume
Water: 82.0% by volume
Determine the Average Specific Gravity of Solids
V1 D1 + V2 D2 = VF DF, where:
V1 = volume fraction of water (82%)
D1 = Density of water (8.33)
V2 = Volume of solids (unknown)
D2 = Density of solids (unknown)
VF = Volume of mud (100%)
DF = Density of mud (12.0 ppg)
Substituting:
28.72
= 3.45
8.33
Determine the concentrations of low gravity and high gravity solids in pounds/barrel.
Assume a specific gravity of 2.65 and 4.20 for low gravity solids and barite respectively.
V1 D1 = V2 D2 + V3 D3
Substituting:
(0.18) (3.45) = V2 (4.20) + (0.18 - V2) 2.65
0.18 (3.45 - 2.65) = (4.20 - 2.65) V2
V2 = 0.18
(3.45 - 2.65)
4.20 - 2.65
V2 = 0.0929
Therefore:
V3 = 18% - V2
V3 = 18% - 9.29% = 8.71
Pound/bbl barite: 4.2 (8.33) (42) (0.0929) = 136.51
Pound/bbl low gravity solids: 2.65 (8.33) (42) (0.0871) = 80.75
The composition of the mud is as follows:
Mud weight: 12.0 ppg
Solids: 18.0% by volume
Low gravity solids: 80.75 ppb
Barite: 136.51 ppb
Average specific gravity of solids: 3.45
The next step is to calculate the daily maintenance requirements. The requirements will
be related to the additions of water required to maintain the mud properties within
optimum limits. Water additions will be regulated by hole size, rate of penetration,
nature of solids drilled and removal of solids. As solids accumulate in the fluid, mud
weight, plastic viscosity and yield point may increase, and the rate of increase will be
governed by the degree of hydration, swelling and dispersion of the solids which is
controlled by the chemical environment of the mud.
It is necessary to know the amount of solids generated. Therefore, calculate the amount
of solids drilled per hour using the data supplied earlier.
Average hole size: Bit size + Washout
Average hole size: 8.5" + (8.5) (0.1) = 9.35 inches
Volume of hole/ft: (Average hole size) (0.000971)
Volume of hole/ft: (9.35)2 (0.000971) = 0.0848 or 0.085 bbl/ft
Volume of hole/hr: (0.085) (35) = 2.975 bbl/hr
The volume of drilled solids generated each hour is 2.975 barrels. Assuming a specific
gravity of 2.65 for the solids, pounds per hour of drilled solids will be:
Low gravity solids, bbl/hr: (350) (2.65) (2.975) = 2,759 lb
Note: The figure 350 used above denotes the weight of 1 bbl of fresh water (42 gal x
8.33 ppg = 349.86, or 350 lb).
We now need to calculate the rate at which water must be added to maintain a constant
mud weight. If the operating efficiency of the solids control equipment is known, those
efficiency values will be used. If the operating efficiency is not known, assumptions
must be made. This exercise assumes an operating efficiency of 50 percent.
The material balance equation used to calculate the amount of water required is as
follows:
VF DF = V1 D1 + V2 D2 where:
V2 =
VF
DF
V1
D1
V2
D2
V1 (D1 - D F )
(D F - D 2 )
Substituting:
V2 =
=
=
=
=
=
=
V1 ( D F - D1 )
, where :
(D 2 - D F )
Substituting:
V2 =
V2 = 1.58 bbl
Converting to pounds of barite per hour:
(1.58 bbl) (1,470 lb/bbl) = 2,323 lb/hr
Next, the amount of additional water must be calculated. We know that 2,323 pounds of
barite are being introduced into the system each hour.
Determine the amount of water required to maintain a 12.0 ppg mud weight using:
V1 D1 + V2 D2 = VF DF
V2 =
VF
DF
V1
D1
D2
V2
=
=
=
=
=
=
V1 (D1 - D F )
, where :
(D F - D1 )
Substituting:
V2 =
V2 = 9.91 bbl
Therefore, the required additions of barite and water which must be made to the system
to maintain a constant mud weight of 12.0 ppg and an ASG of 3.45 are:
Water
Barite
Low Gravity Solids
Total
bbl/hr
lb/hr
14.00
1.58
1.49
17.07
4,900
2.323
1,380
8,603
=
=
=
=
=
=
=
=
V1 D 2 + V2 D 2 + V3 D 3 + V4 D 4
, where :
VF
VF
DF
= V1 + V2 + V3 + V4
= Specific gravity of final mud (unknown)
Substituting:
DF =
=
=
=
=
=
=
VF ( D F - D1 )
, where :
(D 2 - D1 )
Volume of Barite:
V2 =
12 (1.44 - 1.00)
(4.20 - 1.00)
V2 = 1.65
Volume of barite required: 1.65 barrel/hour
Pounds of barite required: 2,426 pounds/hour
Volume of Water:
V1 = 12 - 1.65
V1 = 10.35
Volume of water required: 10.35 bbl/hr
The last step is the determination of the amounts of other materials required to maintain
the desired properties for the system. This exercise assumes a fresh water mud having
the following composition:
Chemical
lb/bbl
Lignosulfonate
Lignite
Bentonite
Caustic soda
8.0
4.0
20.0
2.5
lb/hr
4,749
232
116
580
72.5
lb/8 hr tour
37,992
1,856
928
4,460
580
lb/12 hr tour
56,988
2,784
1,392
6,960
870
sk/8 hr tour
sk/12 hr tour
sk/day
Barite
380
570
1,140
lb/day
113,976
5,568
2,784
13,920
1,740
Lignosulfonate
Lignite
Bentonite
Caustic soda
38
19
45
12
56
28
70
18
112
56
140
36
For the purpose of this exercise, the assumption was made that the solids contributed by
bentonite and barite which are not lost from a system due to filtration or seepage were
deposited as wall cake, and therefore removed from the system.
It must be emphasized that actual consumption rates will vary greatly depending on a
number of different factors such as:
Nature of formations being drilled
Efficiency of solids control equipment
Composition of the drilling fluid
Physical and chemical properties of the drilling fluid
Hole size and penetration rates
Barite Reclamation
A decanting centrifuge will normally process 12.0 ppg mud at the rate of 18 gpm and
recover approximately 70% of the barite in the mud processed. Using this assumption,
the amount of barite recoverable from the system can be estimated.
The amount of barite contained in this 12.0 ppg mud was calculated to be 136.51 ppb.
The centrifuge will process 25.7 bbls of mud per hour.
(18 gpm) (60 min/hr) (0.0238 bbl/gal) = 25.70 bbl/hr
At 70% efficiency, the amount of barite recovered = (136.51 ppb) (25.70 bbl/hr) (0.70)
= 2,456 lb/hr
Converting to barrels of barite/hr
2.456
= 1.67 bbl/hr of barite recovered
1.470
Determining the amount of water, low gravity solids and chemicals discarded:
25.70 - 1.67 = 24.0 bbl/hr discarded
The amount of additional water required to maintain a constant mud weight of 12.0 ppg
due to the barite being returned to the system via the centrifuge must also be calculated
using:
V2 =
VF
DF
V1
D1
V2
D2
=
=
=
=
=
=
V1 (D1 - D F )
, where :
(D F - D 2 )
V2 =
V2 = 10.48 bbl
Volume of water to add to maintain a mud density of 12.0 ppg is 10.48 bbl/hr.
Total volume returned to system while centrifuge is running is equal to the volume of
barite returned plus the water added to the system.
Volume returned = 10.48 + 1.67 = 12.15 bbl/hr
The centrifuge is processing 25.70 barrels of mud per hour and 12.15 barrels is being
returned to the system. New volume must be added to the system equal to the difference
between the processed volume and the returned volume.
New volume = 25.70 - 12.15 = 13.55 bbl/hr
Barite and water additions to build 13.55 bbl of new mud per hour.
V2 =
VF
DF
V1
D1
V2
D2
=
=
=
=
=
=
VF ( D F - D1 )
, where :
(D 2 - D1 )
V2 =
V2 = 1.86 bbl
V1 = 13.55 - 1.86
V1 = 11.69 bbl
The additions of barite and water that must be added to the system each hour.
Barrels
Barite
Water
1.86
11.69
Pounds
2,734
-0-
Sacks
28
-0-
Other materials must again be added to maintain the desired properties. The total
volume, 25.70 barrels per hour, processed by the centrifuge and replaced by discharged
barite and added water will need to be treated.
Chemical
sk/8 hr tour
Barite
Lignosulfonate
Lignite
Bentonite
Caustic soda
224
33
17
41
11
sk/12 hr tour
336
50
25
62
16
sk/day
672
99
50
124
31
Daily maintenance treatments for polymers consist of the polymer required to build new
volume and replace polymer lost through filtrate invasion and solids removal.
In addition to normal maintenance, the polymer concentration, ppb, is adjusted for
changes in volume and the type of mud solids.
If we assume a required concentration of 0.50-ppb polymer and a 10% loss of polymer
while drilling, we can calculate the required daily maintenance.
PL = PCVM %P, where:
PL
PC
VM
%P
=
=
=
=
Substituting:
PL = (0.5 ppb) (1,000 bbl) (0.10)
PL = 50 lb
To replace polymer lost from system, we must add 50lbs of polymer each day.
In our previous calculations, we found it necessary to create 54.88 barrels of new
volume per hour.
PA = VN PC, where:
PA = Polymer to be added to maintain required concentration in new volume,
lbs (unknown)
VN = New volume added to system, bbls (54.8)
PC = Required concentration of polymer, ppb (0.5)
Substituting:
PA
PA
=
=
27.4 pounds of polymer will need to be added each hour to maintain a concentration of
0.5 ppb in the new mud volume. The total polymer to be added each hour is that
required to replace lost polymer (2.1 lb/hr) and that required to build new volume (27.4
lb/hr). 29.5 lb/hr of polymer is required each hour as a maintenance treatment.
Converting the maintenance treatment to 50 lb sacks:
sk/8 hr tour
sk/12 hr tour
sk/day
15
SCREEN SELECTION
The equation for calculating the shaker capacity with solids-laden fluid (QS) based on
the shaker capacity with fluid only (QF), is given by
Qs =
[ ]
[1 + P]
QF
(Eq. 1)
[ROP x D ]
2
[Q]
(Eq. 2)
where
ROP
D
Q
To illustrate the use of Figs. 1 and 2 as well as Eqs. 1 and 2, compare the performance of
the shakers with downward-sloping (-15) deck (Fig. 1) to that of the flat-deck shaker.
The following conditions are assumed:
(15) (8.75) 2
P = 0.0067
325
= 0.24%
From the tables on Figs. 1 or 2 is equal to 0.64 for the market grade 80 x 80-mesh
screen. Substituting P and into Eq. 1 gives
Q =
[0.64]
[1 + 0.24]
QF
Q = 0.52 QF
Looking first the Figure 1 for the shaker with downward-sloping (-15) deck, we see that
for a PV/MW ratio of 9.0/9.0 or 1.0 and an 80 x 80 screen. QF = 330 gal/min. The
capacity for this shaker with solids-laden fluid Qs is
Qs = 0.52 (330)
Qs = 172 gal/min
QF for the flat deck shaker, with 80 x 80 mesh screens and PV/MW = 1.0 is found to be
about 750 gal/min (from Fig 2). The capacity for this shaker with solids-laden fluid, Qs
is
Qs = 0.52 (750)
Qs = 390 gal/min
For the stated conditions, the capacity of the flat deck shaker is more than twice that of
the shaker with downward-sloping (-15) deck and in fact, is adequate for the task at
hand. Two shakers of the downward sloping deck design would only marginally
accommodate the rig's circulation rate under these conditions.
The finest screens, which could be run on the shaker with downward-sloping deck under
these conditions, can be found from by trial an error. Assuming that the finest possible
screen is 50 x 50 mesh market-grade, is 0.77
Qs =
[0.77]
[1 + 0.24]
QF
or
Qs = 0.62 QF
From Fig. 1,QF is found to be about 870 gal/min. The capacity for this shaker with
solids-laden fluid, Qs is then
Qs
= 0.62 (870)
= 540 gal/min
This is in excess of the required capacity of 325 gal/min so one might wonder if 60 x 60
mesh screens would be possible.
For the 60 x 60 mesh screen, = 0.71 and
Qs =
[0.71]
[1 + 0.24]
or
Q = 0.57 QF
From Fig. 1, QF is seen to be about 600 gal/min, and
QS
= 0.57 (600)
= 342 gal/min
This capacity is only marginally adequate for the stated conditions. If it becomes
necessary to increase the rig circulation rate, or if the PV/MW ratio should increase only
slightly, mud loss over the end of the shaker will certainly result with the 60 x 60-mesh
Figure 1
Figure 2
Figure 3
ADG
ADS
AW
MW
VCS
VHGS
VLGS
LGS
HGS
VO
Volume of oil, %
VW
Volume of water, %
VDS
XDS
X DS =
10 -6 C
1 - 10 -6 C
VDS =
3.5 VW X DS
17.2 - 12.8 x C x 10 -6
ASG =
VLGS =
VCS (A W - A CS )
(A W - 2.6)
EXAMPLE
MW = 17.7 ppg
H2O = 10%
OIL = 50%
SOL = 40%
C = 350,000 ppm
X DS =
350,000 x 10 -6
= 0.5385
1 - 350,000 x 10 -6
VDS =
3.5 x 10 x 0.5385
17.2 - 12.8 x 350,000 x 10 -6
= 1.48%
= 38.52%
= 38.52%
ASG =
= 4.02
VLGS =
= 4.33%
= 34.19%
= 39.4 lb/bbl
= 502.6
=
=
=
=
=
14.0 ppg
52%
18%
30%
300,000 ppm
Absolute rating
Absorb
Absorbent
Absorption
Acid
Acidity (API)
Activated carbon
Activated clay
Adhesion
Admix
Adsorption
Agglomerate
Agglomerate (API)
Agglomeration
Agglomeration (API)
Aggregate
Aggregate (API)
Aggregation (API)
Formation of aggregates.
Alkali (API)
Alkalinity
Alum
Amorphous
Amphoteric Polymers
Anhydrous (API)
Without water.
Anion
Anionic
Anionic polymers
API
API gravity
ASTM
Attapulgite clay
ATM atmosphere
Attrition
Backwash
Baffle
Barite (API)
Barrel (API)
42 gallons.
Basal surface
Base
Base (API)
Basicity (API)
Bentonite (GEL)
Beta ratio
Beta ratio =
Ux
Dx
= Beta ratio at particle diameter x
= number of particles upstream size x and
2 Bx =
Bx
Ux
larger
Dx
= number of particles downstream size x
and larger
X
= particle diameter, microns
Bingham Model
Biopolymer
Bleed through
Blind spots
Blowdown
Body feed
Bottomhole pressure
Bridging
Brine (API)
Bypass valve
C-spacing
Cake
Cake filtration
Cake consistency
Cake thickness
Calcium
Calcium contaminants
Cation
Cationic polymers
Capacity
Cellulose
Centipoise (cP)
Centipoise (cP)(API)
Centrifuge
Centrifugal pump
Centrifugal separator
Chemical potential
Check valve
(Foot valve)
Clarity
Clay
Clay extender
Cloth
Coagulation
Coalesce, coalescence
Cohesion
Collapse pressure
Colloid
Colloid (API)
Colloidal
Colloidal suspension
Completion fluid
Compressibility
Concentration
Conductivity (electrical)
Consistency
Contaminant
Contamination
Contract Time
Controlled aggregation
Copolymer
Core
Corrosion (API)
Corrugations (Pleats)
Covalent bonds
Coulter counter
Critical flowrate
Crosslink
Crystal lattice
Crystalline swelling
Swelling resulting from the adsorption of nonmolecular layers of water on the basal crystal
surfaces on both the external and the inter-layer
surfaces.
Cumulative efficiency
Cuttings (drill)
Cycle
Filtration interval. Length of time a filter is onstream before cleaning is needed. Currently meant
to include cleaning time as well.
Darcy
Darcy's Law
DE
Deflocculant
Degradation
Degree of polymerization
Degree of substitution
Delta (F)
Dendritic deposition
Density
Desander
Desilter
Diatomite
Differential pressure
Differential efficiency
Differential efficiency
Diffusion (APT)
Direct indicating
viscosimeter
(Fann VG Meter)
Dispersed phase
Dispersion
Dispersion of aggregates
Dispersoid
Dissociation
Dissolved solids
Drilling fluid
Dry cake
Duplex
Eccentricity
Efficiency
Efiluent
Electro-chemical
Electrolyte
Electrostatic
Element
Encapsulation
Entrainment
Equivalent circulating
density (ECD)
Equivalent weight
(combining weight)
Feed
Feed head
Fiberglass
Filter (noun)
Filter (verb)
Filter aids
Filter cake
See element.
Filter leaf
Filter life
See "cycle".
Filter media
Plural of medium.
Filter medium
Filter performance
Filter press
Filter rating
Filter system
Filter vessel
See Housing.
Filterability index
Filtrate
Filtration
Filtration rate
Filtration ratio
Fines
Flat gel
Flocculate
Flocculants
Flocculant (API)
Flocculating agent
Flocs
See flocculate.
Flocculation
Flow density
Flow rate
Fluid loss
Flux
Flux rate
Formation damage
Formation pressure
Formation sensitivity
Frazier
Friable
Friction loss
Fullers earth
GPH
GPM
GSPM
Gel
Gel strength
Gelatinous
Gelation
Gelled up
Graft copolymer
Gravimetric
Gravimetric efficiency
Gravity, specific
Gyp or Gypsum
Hardness of water
Head
Heel
Heterogeneous
High pH mud
Homopolymer
Housing
Hydrate
Hydration
Hydrocyclone
Hydrodynamic
Hydrodynamic torque
Hydrodynamic volume
concentration
Hydrolysis
Hydrometer
Hydrophile
Hydrophilic
Hydrophobic
Hydrostatic head
Hydrostatic pressure
Hydroxide
Hyper-filtration
Impingement
Inertial deposition
Influent
Inhibited mud
Inhibitor
Initial efficiency
Interface
Interfacial tension
Interstices
Intrinsic viscosity
Ion
Ion exchange
Anion exchange
Cation exchange
Ions
Ionization
Kick
Laminar flow
Layer (sheet)
Leaf
Leaf filter
Life
Life efficiency
Lignosulfonates
Organic drilling fluid additives derived from byproducts of sulfite paper manufacturing process
from coniferous woods. Some of the common salts
such as ferrochrome, chrome calcium, and sodium,
are used as universal dispersants while others are
used selectively for calcium-treated systems. In
large quantities, ferrochrome and chrome salts are
used for fluid loss control and shale inhibition.
Lipophilic
Liquor
mg/L
Mf
Manifold
Marsh Funnel
Media
Plural of medium
Media migration
Medium
Membrane
Mesh
Mesh count
Micro-filtration
Micron
Microscopic counting
Migration
Milliliter
Molecular
Molecular substitution
Molecular weight
Monomer
Montmorillonite
Mud cleaner
Mud/gas separator
Multifilament
NACE
NFPA
Natural clays
Negative pressure
Vacuum or suction.
Neutralization (pH)
Newtonian fluid
Nominal rating
Nonionic
Non-Newtonian fluid
Nonwoven
On-stream
Osmotic swelling
P1
pH
1 Potential hydrogen.
2 A measurement of the acidity or alkalinity of a
substance. A pH
3 An abbreviation for potential hydrogen ion; the
negative logarithm of the hydrogen ion activity in
aqueous solutions. PH numbers range from 0-14,
with 7 being neutral.
Note
The pH may be expressed as the logarithm (base
10) of the reciprocal (or the negative logarithm) of
the hydrogen ion concentration.
The pH of a solution offers valuable information as
to the immediate acidity or alkalinity, as contrasted
to the total acidity or alkalinity (which may be
titrated).
Pm
PSD50
Particle
Particle motion
Particle/Pore ratio
Particle size
Particulates
Solid particles.
Particulate contamination
1 A unit of concentration.
Example
3 ppm would be 3 pounds of solids in 1,000,000
pounds of water.
2 Unit weight of solute per million unit weights of
solution (solute plus solvent), corresponding to
weight-percent except that the basis is a million
instead of a hundred. The results of standard API
titrations of chloride, hardness etc. are correctly
expressed in milligrams (mg) of unknown per liter
but not in ppm. At low concentrations, mg/l is
about numerically equal to ppm.
Peptization
Peptized day
Pill
Permeability
Permeability coefficient
Plastic fluid
1 A non-Newtonian fluid
Plate
Pleated cartridge
Pleated paper
Plugged
Polar molecules
Polyelectrolyte
Polymer
Polymers
Polypropylene
Polysaccharides
Pores
Pore diameter
Porosity
ppm
Precipitate
Precoat filter
Prefilt
Material to be filtered.
Premature blinding
Pressure drop
Pressure filter
Pretreatment
Pseudoplastic fluid
Pulsation
Quaternary amine
Quebracho
R.V.P.F.
Regeneration
Resin bonded
Retention
Reverse osmosis
See Hyperfiltration.
Salinity
Salt
Saturated solution
Scavenger
Screen
Screening
Sedimentation
Septum
Shale shaker
Shear force
Shear rate
Shear stress
Shear thickening
Shear thinning
Sheet (layer)
Sieving
See screening.
Slug
Slurry
Solids content
Solid particle
Solubility
Solution
Sp. G. -1
1 Specific gravity.
2 The weight of any substance relative to the
weight of water; SP G. Water = 1.0
Specific gravity
Spun bonded
Spun wound
Standpipe pressure
Starch
String wound
Supernatant
Supersaturation
Surface area
Surface filtration
Surface tension
Surfactant
Suspended solids
Suspension
Synergism,
Synergistic properties
Temperature
Thermal decomposition
Thinner
Thixotropy
Tubular filter
Turbidity
Turbidimetric efficiency
Ultrafiltration
Unloading
Valence
Viscometer,
Direct indicating
Viscosity
Volume percent
Wall cake
Workover fluid
Wound medium
Woven medium
Yield
Yield Point
Zeta potential