Drilling Fluids Circulation Systems PDF

Drilling Engineering 1 Course
3rd Ed. , 3rd Experience

1. Drilling Fluid Circulation System
A. Introduction
B. Mud Pumps
a. Duplex PDP & Triplex PDP
C. Solids removal
D. Solid Control Equipment
a. Shale shakers
b. Degasser
c. Mud Cleaners
E. Treatment and Mixing Equipment
drilling fluid roles
The drilling fluid plays several functions in the
drilling process.
The most important are:
clean the rock fragments from beneath the bit and
carry them to surface,
exert sufficient hydrostatic pressure
against the formation
to prevent formation fluids from flowing into the well,
maintain stability of the borehole walls,
cool and lubricate the drillstring and bit.
Fall 14 H. AlamiNia Drilling Engineering 1 Course (3rd Ed.) 4

Drilling fluid circulation
Drilling fluid is forced to circulate in the hole
at various pressures and
flow rates.
Drilling fluid is stored
in steel tanks located beside the rig.
Powerful pumps force the drilling fluid
through surface high pressure connections
to a set of valves called pump manifold,
located at the derrick floor.

Drilling fluid circulation (Cont.)
From the manifold,
the fluid goes up the rig
within a pipe called standpipe
to approximately 1/3 of the height of the mast.
From there the drilling fluid flows through a flexible
high pressure hose to the top of the drillstring.
The flexible hose allows the fluid
to flow continuously
as the drillstring moves up and down
during normal drilling operations.

swivel
The fluid enters in the
drillstring through a special
piece of equipment called
swivel located at the top of the
kelly.
The swivel permits rotating the
drillstring while the fluid is
pumped through the drillstring.
A swivel
drilling fluid in wellbore
In wellbore
The drilling fluid then flows down
the rotating drillstring and
jets out through nozzles in the drill bit
at the bottom of the hole.
The drilling fluid picks the rock cuttings
generated by the drill bit action on the formation.
The drilling fluid then
flows up the borehole through
the annular space
between the rotating drillstring and borehole wall.

drilling fluid at surface
At surface
At the top of the well (and above the tank level),
the drilling fluid flows through the flow line
to a series of screens called the shale shaker.
The shale shaker is designed to
separate the cuttings from the drilling mud.
Other devices are also used to clean the drilling fluid
before it flows back into the drilling fluid pits.

Process of mud circulation
The principal
components of the mud
circulation system are:
pits or tanks,
pumps,
flow line,
solids and contaminants
removal equipment,
treatment and mixing
equipment,
surface piping and valves,
the drillstring.
Rig circulation system
The tanks
The tanks
(3 or 4 – settling tank, mixing tank(s), suction tank)
are made of steel sheet.
They contain a safe excess (neither to big nor to small)
of the total volume of the borehole.
In the case of loss of circulation,
this excess will provide the well with drilling fluid
while the corrective measures are taken.
The number of active tanks depends on
the current depth of the hole
(bypasses allow to isolate one or more tanks.)
The tanks will allow enough retaining time so that
much of the solids brought from the hole
can be removed from the fluid.

Mixing and suction tanks

MUD HANDLING EQUIPMENT
Rig sizing must incorporate
mud handling equipment as
these equipment determine the
speed of drilling and the quality
of hole drilled.
The equipment includes:
Shale Shakers
The type of mud (i.e. oil-based or
water-based) determines the type
of the shaker required and the
motion of the shaker. Deep holes
require more than the customary
three shakers.

MUD HANDLING EQUIPMENT (Cont.)
Mud Pits
The number and size of pits is
determined by the size and depth
of hole.
Other factors include: size of rig
and space available, especially on
offshore rigs. The size of a mud pit
is usually 8-12 ft wide, 20-40 ft long
and 6-12 ft high.
Mud degasser
Centrifuges and mud cleaners
Desanders and desilters

reciprocating positive displacement
pumps vs. centrifugal pumps
The great majority of the pumps
used in drilling operations are
reciprocating positive displacement pumps (PDP).
Advantages of the reciprocating PDP when
compared to centrifugal pumps are:
ability to pump fluids with high abrasive solids contents
and with large solid particles,
easy to operate and maintain,
sturdy and reliable,
ability to operate
in a wide range of pressure and flow rate.

positive displacement pumps
compartments
PDP are composed of two major parts, namely:
Power end:
receives power from engines and transform the rotating
movement into reciprocating movement.
The efficiency Em of the power end,
that is the efficiency with which rotating mechanical power is
transformed in reciprocating mechanical power
is of the order of 90%.
Fluid end:
converts the reciprocating power into pressure and flow rate.
The efficiency Ev of the fluid end
(also called volumetric efficiency),
that is, the efficiency that the reciprocating mechanical power is
transformed into hydraulic power, can be as high as 100%.

Pump configurations
Rigs normally have two or three PDPs.
During drilling of shallow portions of the hole,
when the diameter is large,
the two PDPs are connected in parallel
to provide the highest flow rate necessary
to clean the borehole.
As the borehole deepens,
less flow rate and higher pressure are required.
In this case, normally only one PDP is used
while the other is in standby or in preventive
maintenance.

Affecting parameters on flow rate
The great flexibility in the pressure and flow rate
is obtained with the possibility of
changing the diameters of the pair piston–liner.
The flow rate depends on the following
parameters:
stroke length LS (normally fixed),
liner diameter dL,
rod diameter dR (for duplex PDP only),
pump speed N (normally given in strokes/minute),
volumetric efficiency EV of the pump.
In addition, the pump factor Fp is defined as
the total volume displaced by the pump in one stroke.
Types of
the positive displacement pumps
The heart of the circulating system is
the mud pumps.
There are two types of PDP:
double-action duplex pump, and
single-action triplex pump.
Triplex PDPs, due to several advantages,
(less bulky, less pressure fluctuation,
cheaper to buy and to maintain, etc,)
has taking place of the duplex PDPs
in both onshore and offshore rigs.

CENTRIFUGAL PUMPS
This type uses an impeller
for the movement of fluid
rather than a piston reciprocating
inside a cylinder.
Centrifugal pumps are used
to supercharge mud pumps and
providing fluid to
solids control equipment and
mud mixing equipment.

Duplex vs. Triplex pumps
A basic pump consists of a piston (the liner)
reciprocating inside a cylinder.
A pump is described as single acting
if it pumps fluid on the forward stroke (Triplex pumps)
and double acting
if it pumps fluid
on both the forward and backward stokes (Duplex).

Duplex pumps
Piston scheme (double action) A duplex unit

Triplex pumps
Piston scheme (single action). A Triplex unit

Pump liners
Pump liners fit inside the pump
cavity.
These affect the pressure rating and
flow rate from the pump.
For a given pump, a liner has the
same OD but with different internal;
diameters.
The smaller liner (small ID) is used in
the deeper part of the well where
low flow rate is required but at
much higher operating pressure.
The size of the pump
is determined by the length of
its stroke and the size of the liner.

the pump factor
The duplex mud pump consists of
two double–action cylinders.
This means that drilling mud is pumped
with the forward and backward movement of the barrel.
For a duplex pump (2 double–action cylinders) the pump
factor is given by:
The triplex mud pump consists of
three single–action cylinders.
This means that drilling mud is pumped only in the
forward movement of the barrel.
For a triplex pump the pump factor is:

VOLUMETRIC EFFICIENCY
Drilling mud usually contain little air and
is slightly compressible.
Hence the piston moves through a shorter stroke than
theoretically possible before reaching discharge
pressure.
As a result the volumetric efficiency is always less than
one; typically 95% for triplex and 90% for duplex.
In addition due to power losses in drives,
the mechanical efficiency of most pumps is about 85%.

Pump Flow Rate
For both types of PDP, the flow rate is calculated
from:
For N in strokes per minute (spm), dL, dR, and LS in
inches, Fp in in3, and q in gallons per minute (gpm)
we have:
Note that in this particular formulation,

the volumetric efficiency of the pump
is included in the pump factor.

Pump operating pressure
The horse power requirements of the pump
depends on the flow rate and the pressure.
The operating pressure depends on
flow rate, depth and size of hole, size of drillpipe and
drillcollars, mud properties and size of nozzles used.
A full hydraulics program needs to be calculated to
determine the pressure requirement of the pump.

Pump Power
Pumps convert mechanical power into hydraulic
power. From the definition of power P=Fv
In its motion,
the piston exerts a force [F] on the fluid that is equal to
the pressure differential in the piston Δp times
the area A of the piston, and
the velocity v is equal to
the flow rate q divided by the area A, that is
For PH in hp, p in psi, and q in gal/min (gpm) we have:

pump factor & hydraulic
power
Compute the pump factor in gallons per stroke and
in barrels per stroke for a triplex pump having
5.5 in liners and
16 in stroke length,
with a volumetric efficiency of 90%.
At N = 76spm, the pressure differential between
the input and the output of the pump is 2400 psi.
Calculate
the hydraulic power transferred to the fluid, and
the required mechanical power of the pump if Em is 78%.

pump factor & hydraulic
power
The pump factor (triplex pump) in in3 per stroke is:
Converting to gallons per stroke and to barrels per

stroke gives:
The flow rate at N = 76spm is:
The hydraulic power transferred to the fluid is:
To calculate the mechanical power required by the

pump we must consider the efficiencies:

Surge Dampeners
Due to the reciprocating action of the PDPs,
the output flow rate of the pump presents a
“pulsation” (caused by the changing speed of the
pistons as they move along the liners).
This pulsation is detrimental
to the surface and downhole equipment
(particularly with MWD pulse telemetry system).
To decrease the pulsation,
surge dampeners are used at the output of each pump.

schematic of a typical surge dampener
A flexible diaphragm
creates a chamber filled
with nitrogen at high
pressure.
The fluctuation of
pressure is compensated
by a change in the
volume of the chamber.
A relief valve located in
the pump discharge line
prevents line rupture in
case the pump is started
against a closed valve.
Surge dampener
aim of the solids removal system
Fine particles of inactive solids
are continuously added to the fluid during drilling.
These solids increase the density of the fluid and
also the friction pressure drop, but
do not contribute to the carrying capacity of the fluid.
The amount of inert solids must be kept as low as possible.
Recall mud is made up of
fluid (water, oil or gas) and solids (bentonite, barite etc).
The aim of any efficient solids removal system is
to retain the desirable components of the mud system
by separating out and discharging
the unwanted drilled solids and contaminants.

Solids in drilling fluids classification:
based on specific gravity, (or density)
Solids in drilling, classified by specific gravity, may
be divided into two groups:
High Gravity Solids (H.G.S.) sg = 4.2
Low Gravity Solids (L.G.S.) sg = 1.6 to 2.9
The solids content of a drilling fluid will be made up
of a mixture of high and low gravity solids.
High gravity solids (H.G.S) are added to fluids
to increase the density,e.g. barytes,
whilst low gravity solids (L.G.S)
enter the mud through drilled cuttings and
should be removed by the solids control equipment.

Solids in drilling fluids classification:
based on particle size
Mud solids are also classified according
to their size in units called microns (µ).
A micron is 0.0000394 in or 0.001 mm.
Particle size is important in drilling muds
for the following reasons:
The smaller the particle size,
the more pronounced the affect on fluid properties.
The smaller the particle size,
the more difficult it is to remove it or
control its effects on the fluid.

particle size classification
The API classification of particle sizes is:
Particle Size (µ) Classification Sieve Size (mesh)
> 2000 Coarse 10
2000 - 250 Intermediate 60
250 - 74 Medium 200
74 – 44 Fine 325
 44 - 2 Ultra Fine -
 2-0 Colloidal -

solids control equipment
Solids contaminants and gas entrapped in mud can
be removed from mud in four stages:
Screen separation:
shale shakers, scalper screens and mud cleaner screens.
Settling separation in non-stirred compartments:
sand traps and settling pits.
Removal of gaseous contaminants
by vacuum degassers or similar equipment
Forced settling by the action of centrifugal devices
including hydrocyclones (desanders, desilters and micro-cones)
Mud cleaners and centrifuges.

Complete mud removal system
with mud cleaner and centrifuge

sketch of
a typical solids control system
Figure shows
a sketch of a
typical solids
control system
(for
unweighted
fluid).

a typical two–screen shale shaker
The screens
are vibrated by
eccentric heavy
cylinders
connected to
electric motors.
The vibration
promotes an
efficient
separation
without loss of
fluid.
A two–screen shale shaker
Linear shale shaker
The figure
shows
a layout for
solids control
equipment
for
a weighted
mud system.

shale shaker mechanism
 The shale shaker
removes
the coarse solids
(cuttings) generated
during drilling.
 It is located at the
end of the flow line.
 It constitutes of
one or more
vibrating screens in
the range of
10 to 150 mesh
over which the mud
passes before it is
fed to the mud pits.
Shale shaker configurations

The procedure
Shale shakers and scalper screens (Gumbo shakers)
can effectively remove up to 80% of all solids from a
drilling fluid,
if the correct type of shaker is used and
run in an efficient manner.
Removal procedure:
Mud laden with solids passes over the vibrating shaker
where the liquid part of mud and small solids
pass through the shaker screens and
drill cuttings collect at the bottom of the shaker
to be discharged.

types of shaker operation
There are two types of these shakers are fitted
shaker operation: with retrofit kits
to allow quick and simply
elliptical shakers and
replacements.
Field experience indicate
they work better with The shakers should also
water based muds
be in a covered,
linear motion shakers. enclosed housing
more suited with a means of
to oil based muds.
ventilation and
An absolute minimum of each shaker
three shale shakers is fitted with a smoke hood.
recommended and that
Sample of shale shakers

SETTLING SEPARATION
IN NON-STIRRED COMPARTMENTS
The solids control pits work on
an overflow principle.
The sand traps are the first of the solids control pits and
are fed by the screened mud from the shale shakers.
There should be no agitation from suction discharge
lines or paddles.
Any large heavy solids will settle out here and
will not be carried on into the other pits.

Degassers
Gases that might enter the fluid
must also be removed.
Even when the fluid is overbalanced,
the gas contained in the rock cut by the bit
will enter the fluid and must be removed.
The degasser removes gas from the gas cut fluid
by creating a vacuum in a vacuum chamber.
The fluid flows down an inclined flat surface
as a thin layer.
The vacuum enlarges and coalesce the bubbles.
Degassed fluid is draw from chamber
by a fluid jet located at the discharge line.

Removal Of Gaseous Contaminants
Gas entrapped in mud must be removed
in order to maintain the mud weight to a level needed to
control down hole formation pressures.
Gas is removed from mud using a vacuum degasser.
It is a simple equipment containing a vacuum pump and
a float assembly.
The vacuum pump creates a low internal pressure which allows
gas-cut mud to be drawn into the degasser vessel and it then
flows in a thin layer over an internal baffle plate.

Vacuum degasser
The combination of
low internal pressure and
thin liquid film
causes gas bubbles to
expand in size,
rise to the surface of
the mud inside the vessel
and break from the mud.
As the gas moves toward
the top of the degasser
it is removed
by the vacuum pump.
The removed gas is
routed away from the rig
and is then either vented
to atmosphere or flared.

A typical degasser diagram
(A vacuum chamber degasser)

FORCED SETTLING BY CENTRIFUGAL
DEVICES
Desanders and desilters are hydrocyclones and
work on the principle of separating solids from a liquid
by creating centrifugal forces inside the hydrocyclone.
Hydrocyclones
are simple devices with no internal moving parts.
are classified according to the removed particle size as
desanders (cut point in the 40–45μm size range) or
desilters (cut point in the 10–20μm size range).
At the cut point of a hydrocyclone
50% of the particles of that size is discarded.

The process of the Hydrocyclones
(Desanders and Desilters)
Mud is injected tangentially
into the hydrocyclone
 the resulting centrifugal
forces
drive the solids to the walls
of the hydrocyclone and
 finally discharges them from
the apex
with a small volume of mud.
 The fluid portion of mud
 leaves the top of the
hydrocyclone as an overflow
and
 is then sent to the active pit
to be pumped downhole
again.

Desanders
The primary use of desanders is
in the top hole sections
when drilling with water based mud
to help maintain low mud weights.
Desanders
should be used if the sand content of the mud rises
above 0.5% to prevent abrasion of pump liners.
should never be used with oil based muds,
because of its very wet solids discharge.

The desander
It is a set of two or
three 8in or 10in
hydrocyclones,
and are positioned
after the shale shaker
and the degasser (if
used).

Desilters
The desilter
is a set of eight to twelve 4in or 5in hydrocyclones.
It removes particles that can not be removed by the desander.
Desilters, in conjunction with desanders, should be
used to process low mud weights used to drill top hole
sections.
If it is required to raise the mud weight this must be
done with the additions of barytes, and not by allowing
the build up of low gravity solids.
Desilters should never be used with oil based muds.

Solid control equipment
Typical throughput
capacities are:
Desanders
12"cone
500 gpm per cone.
6" cone
125 gpm per cone.
Desilters
4"cone
50 gpm per cone.
2" cone
15 gpm per cone.
(b) Desilter
Particle size classification
A typical
drilling solid
particle
distribution
and particle
size range
classification
are shown in
the diagram.
The diagram
includes the
particle size
distribution of
typical
industrial
barite used in
drilling fluids.
Decanting centrifuge
The centrifuge is a solids control equipment
which separates particles even smaller,
which can not be removed by the hydrocyclones.
It consists of a rotating cone–shape drum,
with a screw conveyor.
Drilling fluid is fed through the hollow conveyor.
The drum rotates at a high speed and creates a
centrifugal force that causes the heavier solids to decant.
The screw rotates in the same direction of the drum
but at a slight slower speed,
pushing the solids toward the discharge line.
The colloidal suspension exits the drum
through the overflow ports.

Internal view of a centrifuge
The drums
are enclosed
in an external,
non–rotating
casing
not shown in
the figure.

Mud Cleaners
A mud cleaner
is a desilter unit in which
the underflow is further processed
by a fine vibrating screen,
mounted directly under the cones.
The use of mud cleaners with oil based muds
should be minimized since
experience has shown that mud losses of 3 to 5 bbls/hr
being discharged are not uncommon,
coupled with the necessity to adhere to strict
environmental pollution regulations.

mud cleaner
Inert solids in weighted fluid
(drilling fluid with weight
material like
barite, iron oxide, etc)
can not be treated with
hydrocyclones alone
because the particle sizes of the
weighting material are within the
operational range of desanders
and desilters.
Weighting material are relatively
expensive additives, which must
be saved.

mud cleaner schematic
The mud
cleaner
separates
the low
density inert
solids
(undesirable)
from the
high density
weighting
particles.
Unit of a mud cleaner

Hydrocyclones
Hydrocyclones discriminate light particles from
heavy particles.
Bentonite are lighter than formation solids
because they are of colloidal size
(although of the same density).
Barite particles are smaller than formation solids
because they are denser.
The desilter
removes the barite and
the formation solids particles in the underflow,
leaving only a clean mud
with bentonite particles
in a colloidal suspension in the overflow.

Hydrocyclones (Cont.)
The thick slurry in the underflow
goes to the fine screen,
which separate the large (low density) particles
(formation solids)
from the small (high density) barite particles,
thus conserving weighting agent and the liquid phase
but at the same time returning many fine solids to the
active system.
The thick barite rich slurry is treated with dilution
and mixed with the clean mud (colloidal bentonite).
The resulting mud is treated
to the right density and viscosity and
re–circulates in the hole.
Principle of the mud cleaner
Mud cleaners
 are used mainly
with oil– and
synthetic–base
fluids
where the liquid
discharge from
the cone cannot
be discharged,
either for
environmental
or economic
reasons.
 may also be
used with
weighted
water–base
fluids
 to conserve
barite and the
liquid phase.
A diagram of a mud cleaner
Drilling fluid components
Drilling fluid is usually a suspension of clay
(sodium bentonite) in water.
Higher density fluids can be obtained
by adding finely granulated (fine sand to silt size)
barite (BaSO4).
Various chemicals or additives are also used
in different situations.
The drilling fluid continuous phase is usually water
(freshwater or brine) called water–base fluids.
When the continuous phase is oil
(emulsion of water in oil) it is called oil–base fluid.

Mixing Equipment
Water base fluids are normally made at the rig site
(oil base mud and synthetic fluids
are normally manufactured in a drilling fluid plant).
Special treatment and
mixing equipment exists for this purpose.
Tank agitators, mud guns, mixing hoppers, and
other equipment are used for these purposes.

drilling fluids physical properties
blenders
The basic drilling fluids physical properties are density,
viscosity, and filtrate.
Fresh water density is 8.37 pounds per gallon (ppg).
Bentonite adds viscosity to the fluids and also increases the
density to about 9 to 10 ppg.
Higher density (15 to 20 ppg) is obtained with barite, iron
oxide, or any other dense fine ground material.
Tank agitators or blenders
are located in the mud tanks
to homogenize the fluid in the tank.
help to keep the various suspended material
homogeneously distributed in the tank
by forcing toroidal and whirl motions of the fluid in the tank.

Mud agitator
Tank agitators or blenders toroidal and whirl motions

Sample of Mud agitator

Mud guns
Mud guns
are mounted in gimbals
at the side of the tanks,
allow aiming a mud jet
to any point in the tank
help to homogenize the
properties of two tanks,
and spread liquid
additives in a large area
of the tank
(from a pre-mixed tank).
Centrifugal pumps
power the mud guns.
Mud gun
mixing hopper
The mixing hopper
allows adding powder substances and
additives in the mud system.
The hopper is connected to a Venturi pipe.
Mud is circulated by centrifugal pumps and
passes in the Venturi at high speed,
sucking the substance into the system.

Mud hopper

1. (CDF) Jorge H.B. Sampaio Jr. “Drilling
Engineering Fundamentals.” Master of
Petroleum Engineering. Curtin University of
Technology, 2007. Chapter 2
2. (WEC) Rabia, Hussain. Well Engineering &
Construction. Entrac Consulting Limited, 2002.
Chapter 16 and 7

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Drilling Engineering 1 Course

3rd Ed. , 3rd Experience

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Fall 14 H. AlamiNia Drilling Engineering 1 Course (3rd Ed.) 12

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Piston scheme (double action) A duplex unit

Piston scheme (single action). A Triplex unit

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Note that in this particular formulation,

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For PH in hp, p in psi, and q in gal/min (gpm) we have:

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Converting to gallons per stroke and to barrels per

The flow rate at N = 76spm is:

The hydraulic power transferred to the fluid is:

To calculate the mechanical power required by the

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Shale shaker configurations

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Unit of a mud cleaner

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