Fluid Systems,

Incorporated
OWNERS MANUAL OM-DSR
Revised February 12, 1999
IMPORTANT: Read these instructions before
installing, operating, or servicing this equipment.

Specifications covered by this manual:

DSR
Model ___H-10
Serial Number
Purchase Order Number
Sold to
Date
Manual Serial Number

DO NOT DESTROY

Fluid Systems, Inc. • Belle Chasse, Louisiana 70037 USA

Manufacturers of Solids Control and Screening Equipment since 1979
February 1999
COPYRIGHT© Fluid Systems, Incorporated, 1999. All rights reserved. No part of this publication may be
reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any
form by any means without written permission of Fluid Systems, Inc.

If you are outside the US or Canada, please contact your local distributor or dealer.

If you purchased your equipment through a licensed agent, technical support may be provided as part of
your package. Contact Fluid Systems, Inc. in Belle Chasse, Louisiana USA 504-393-1804 or fax
comments to 504-393-7080 or e-mail to service@fsishakers.com.
 Table Of Contents

1.0 RECEIVING ..................................................................................................................... 4

2.0 PRINCIPLE OF OPERATION............................................................................................ 4
3.0 SEPARATION PARAMETERS.......................................................................................... 6
3.1 DESANDER CONE DIAMETER .................................................................................. 6
4.0 PLASTIC VISCOCITY ...................................................................................................... 6
5.0 FEET OF HEAD................................................................................................................ 6
6.0 APEX DIAMETER............................................................................................................ 7
7.0 MANIFOLD SIZING ......................................................................................................... 7
8.0 HYDROCYCLONE OPERATING GUIDELINES ............................................................... 7
9.0 MUD CLEANER OPTION................................................................................................. 9
10.0 INSTALLATION............................................................................................................... 9
11.0 DSR DESANDING UNIT ................................................................................................ 10
12.0 HYDROCYCLONE TROUBLE SHOOTING CHART....................................................... 11
13.0 HYDROCYCLONE MAINTENANCE SCHEDULE.......................................................... 11
13.1 BEFORE INITIAL STARTUP: ................................................................................. 11
13.2 24 HOURS AFTER INITIAL STARTUP:...................................................................... 11
13.3 72 HOURS AFTER INITIAL STARTUP:...................................................................... 12
13.4 DAILY: ....................................................................................................................... 12
13.5 WEEKLY .................................................................................................................... 12
13.6 SIX MONTHS ............................................................................................................. 12
1.0 RECEIVING

1.1 Upon receiving Fluid Systems, Inc. DSR hydrocyclone manifold check
the contents very carefully in case of damage or loss of parts during
shipment. If some damage or losses occur please report them to Fluid
Systems, Inc. at 504-393-1804 immediately.

1.2 If your unit is mounted over a shaker and is being used as a mud cleaner,
hold down brackets are provided to hold basket rigid, so that unit will not
be damaged during shipment. These brackets must be removed before
starting the shaker. (See appropriate shaker manual for shaker
instructions).

1.3 All spare and optional parts purchased with the machine will be packaged
and shipped with the machine unless other written instructions are given to
Fluid Systems, Inc.

2.0 PRINCIPLE OF OPERATION

2.1 In operation of a hydrocyclone the feed, a mixture of liquids and solids, is

fed from a pump module to the hydrocyclone under pressure tangentially
at a high velocity (about 35-psi water weight). Think of a tornado inside
of a bottle and you have a rudimentary idea of how a hydrocyclone
operates.

MANIFOLD PRESSURE VS FEED DENSITY

TU-10 DESANDING CONE

37

35
PRESSURE (PSI)

33

31

29

27

25
7.5 8 8.5 9 9.5 10 10.5 11 11.5
FEED DENSITY (LB/GAL)

Figure 800-115-1 TU-10 Chart

2.2 Pressure to the hydrocyclone manifold should be calculated per the
following chart. Exceeding the pressures indicated will damage the cone.
Low pressure will result in inefficient separation of solids.

2.3 Underflow (apex discharge): As feed enters the chamber, a rotation of the
fluid begins, causing centrifugal forces to act on particles that have
sufficient mass, moving them toward the outer wall of the hydrocyclone
and as more fluid enters the chamber, the particles migrate outward
towards the wall in a spiral pattern and at the same time being forced
toward the bottom of the cone by other feed slurry entering the cone under
pressure. Larger particles will settle preferentially and are discharged
from the bottom of the hydrocyclone by gradually working their way out
through the apex orifice. This product is termed the “underflow”, and
since it must be discharged as a fluid, contains an amount of feed fluid
often referred to as “void filling” material. (See Figure 800-115-2 below)
This excess fluid in the “underflow” is what we screen when
hydrocyclones are used as mud cleaners to reclaim the liquid phase of the
slurry (see item No. 9.0 below). The under flow is normally discharged at
atmospheric pressure.

2.4 Overflow (cone overs): As the “underflow” particles are migrating

downward in a spiral pattern the smaller particles with less mass begin to
migrate toward the center of the hydrocyclone along with the bulk of the
liquid phase and spiral upwards and out through the vortex finder. (See
Figure 800-115-2 below). This fluid is better known as “clean mud.” The
overflow is normally discharged at atmospheric pressure.
Vortex
(Air Core)

Overflow Discharge

Feed
Inlet Vortex Finder

Hydrocyclone

Apex Discharge

Air Entry

Figure 800-115-2 Hydrocyclone Operating Principles

 2.5 Customer should determine that the feed pump discharge head
accommodates the feed requirements of the hydrocyclone manifold as well
as the piping system used to interconnect.

2.6 Careful attention should be paid to piping selection as to diameter, elbow

selection, valve tees, and other fittings; all have a serious effect upon
proper discharge head available at the inlet of the hydrocyclone manifold.

3.0 SEPARATION PARAMETERS

A “Desander” is a unit made up of cones ranging from 6” to 12” in diameter.

Fluid Systems, Inc measures the size of the hydrocyclone on the inside diameter
of the cylindrical feed chamber.

3.1 DESANDER CONE DIAMETER

3.1.1 Cone diameter is the main factor in determining cut points and
processing capacity. Fluid Systems, Inc. desander cone capacities
are 500 GPM per cone.

FSI CONE CAPACITIES @ 75 ft head

3.1.2 High Volume Desanding Hydrocyclone: The (DSR234A) High

volume TU-10 hydrocyclone will process up to 500 GPM at 40 psi
manifold pressure.

Desanders will normally make a 78 micron medium cut.

3.13 The quantity of solids removed from an unweighted system by a

hydrocyclone can be calculated as follows:

lbs solids removed per cone = 98 (W - 8.3) Ur

where: W = density of underflow, lb gal

Ur = Underflow rate, gal min

4.0 PLASTIC VISCOCITY

Hydrocyclone performance is extremely sensitive to the plastic viscosity of the

feed slurry. The hydrocyclone performance declines with increasing plastic
viscosity.

5.0 FEET OF HEAD

HEAD PRESSURE should not be confused with PSI. Fluid Systems, Inc.
recommends a pressure head of 75 feet at the entrance of the hydrocyclone. The
 75 feet is enough to produce a good cut point but not high enough to cause rapid
wear of the cones.

6.0 APEX DIAMETER

As the apex hole size is reduced, less solids and liquids will be discharged. As the
apex hole is enlarged, more solids and liquids are discharged. Most DSR
desander cones will be shipped with a 3/4” apex. Other sizes are available.

6.1 A properly operating hydrocyclone should discharge liquids and solids,

have a hollow center and appear as a cone. A slight air vacuum drawing
upwards from the apex into the cone is a good indication of a properly
operating hydrocyclone.

6.2 A wide cone spray indicates that the apex orifice is too large, the
slurry to dilute, and a smaller apex should be installed.

6.3 Should the cone spray be void of the hollow center and resemble a “rope”,
the apex is too small or the solids concentration is too high. Under these
conditions, some oversize materials will no doubt report to the overflow
(clean mud). To correct this problem you may need to go to a larger apex
opening and allow the system time to clean up. Your system may require
additional hydrcoyclones because of solids overloading.

7.0 MANIFOLD SIZING

For many years hydrocyclones have been used quite successfully in the
classification of solid particles contained in liquid streams. Whenever an engineer
is faced with a cyclone application, the question always arises as to what size and
how many are needed. In order to properly “clean” your slurry, the number and
size of your hydrocyclones is important. Rule of thumb is to provide enough
hydrocyclones to process at least 110% of your circulation rate. Standard Fluid
Systems, Inc. Desanding header manifolds are provided in banks of 1,2,3 or 4
hydrocyclones.

The number of hydrocyclones can be estimated with the formula below:

No. of cones required = Maximum Circulation rate x1.1

Single cone flow rate

8.0 HYDROCYCLONE OPERATING GUIDELINES

8.1 Size manifold and equipment large enough to handle 10% over the total
amount of the circulation rate (see item 7.0).

8.2 Hydrocyclone units should be used in “steps”. First through the desander
cones then the Desilter 4” cones.
 8.3 The overflows should be discharged to the compartment down stream
from the feed compartment.

8.4 Do not feed cones slurry with materials that are larger than the apex
openings. Consider adding a finer mesh screen to the shakers so as to
remove as much material as possible before feeding the hydrocyclone
units.

8.5 Do not bypass the flow line shakers or operate it with torn screens.

8.6 Keep a working pressure gauge.

8.7 Avoid long feed/ discharge pipelines. Avoid installing elbows, valves etc.
in feed lines, which reduce Pressure to unit.

8.8 When discharging below bottom of hydrocyclone, add a “vent” pipe on the
return line in order to avoid “siphoning”
DSR233A DSR 233B
Victaulic Fittings Clamp

DSR 233B
Clamp

DSR236BP
DSR 233 Backing Plate
Cone Feed half ring
Section

DSR236RP
Retainer Plate

DSR 232
Center COne DSR235BP
Body Backing Plate
Half Ring

DSR235RP
Retainer Plate

DSR 231 Apex bottom

Figure 800-115-3 Hydrocyclone parts

Item No Part No Description

1 DSR234A Complete TU10 10” High volume hydrocyclone
2 DSR233A Victaulic fittings
3 DSR233B Clamp
4 DSR233 Cone feed section
5 DSR236BP Backing plate half ring
6 DSR236RP Retainer plate
 7 DSR232 Center cone body
8 DSR235BP Backing plate half ring
9 DSR235RP Retainer plate
10 DSR231 Apex bottom

9.0 MUD CLEANER OPTION

9.1 A mud cleaner is a bank of hydrocyclones mounted over a vibrating

screen. Material from the apex underflow dumps over the vibrating screen
making a certain cut point. It is designed to recover most of the liquid
phase as well as some of the weighted material depending on the mesh
size on the vibrating screen. The solids removed over the screen are
discarded.

9.2 Mud cleaners were designed to recover drilled solids to the size of barite
(74 microns) in weighted mud systems.

9.3 In an unweighted mud system, all mud processed by a mud cleaner should
then be processed by a centrifuge.

9.4 Always use finer screens on a mud cleaner than on your shakers. Do not
attempt to use a mud cleaner as both a flow line shaker and a mud cleaner.

9.5 Desanding mud cleaners are able to handle more volumes on smaller
screening machines because the concentration of solids is larger and
coarser than a desilting mud cleaner.

9.6 A desilting mud cleaner requires more screening area than the desanding
mud cleaner processing the same volume.

10.0 INSTALLATION

10.1 If your machine is outfitted as a mud cleaner check the appropriate shaker
manual for installation instructions for that particular shaker.

10.2 Lift points have been welded on the frame or manifold area of the
machine.

10.3 Make sure you have predetermined where your feed and discharge lines
are to travel. The shortest distance with the least amount of turns and
valves in the lines are preferred.

10.4 Level the skid/machine in both directions.

10.5 Cone unders discharge piping can be attached to the pipe nipple welded on
one end of the cone unders mud pan.
 10.6 Each Fluid System, Inc. Hydrocyclone unit has a pressure gauge. Check
appropriate machine for proper pressure listed below.

10.7 Shale/dump slides should be installed to collect all material being

discharged.

10.8 Water lines should be installed to move product being discharged in the
cone unders pan. A valve should be installed to control the flow of water.

10.9 The cone overs return line should be lower than the slurry level to allow

10.10 A “vent” should be installed on the cone overs discharge line if line is
discharging below apex of cone.

11.0 DSR DESANDING UNIT

11.2 Fluid Systems, Inc. DSR unit has been designed to remove all drill solids
larger than 45 microns from the drilling mud. Each hydrocyclone will
process mud at a rate of 500 gpm per cone regardless of mud weight.

11.3 The DSR Unit is able to process this high volume regardless of mud
weight, therefore, it is not necessary to reduce the volume handling
capacity of the unit as mud weight increases.

11.4 The TU-10 Cyclone is a low cost, lightweight, molded urethane cyclone
providing excellent wear life with maximum economy and ease of
handling.

11.5 The TU-10 Cyclone is molded in three sections consisting of:

11.5.1 The inlet head feature with involute feed entry design with ribbon
type feed nozzle (part No. DSR233), integral molded vortex finder,
and feed and overflow connections. The feed and overflow
connections are replaceable metal inserts, Victaulic grooved (part
No. DSR233A).

11.5.2 The conical section (part No. DSR232), incorporates flanges with
centering rims and steel backing rings. The molded urethane part
has a wall thickness of 1/2” at the top increasing to 3/4” at the
bottom.

11.5.3 The apex section is a molded standard urethane type (part No.
DSR231)

11.6 Depending on the slurry, if nothing seems to be coming out of the apexes,
replace them with larger ones. By the same token if too much liquid is
being discharged over the screens replace the apexes with smaller ones.
 11.7 The cones are designed to handle larger volumes of fluid by making a
finer cut than normal. It is the involute feature that starts the separation as
the fluid is entering the cone thus resulting in a lower cut point.

12.0 HYDROCYCLONE TROUBLE SHOOTING CHART

TROUBLE CAUSE WHAT TO DO

• No mud is discharged
from the Apex
• Too much mud being
Discharged from Apex
• Roping effect
• Cone discharge
unsteady
• Mud percent solids
increase
• High mud losses
• Plugged cone
• Not enough pressure
• cone is worn
• Small Apex
• Overloading cone
• Air or gas in feed line
• Insufficient cones
• Insufficient solids
control equipment
• Apex to large
• Cone worn out
• Un plug with welding
rod or disassemble cone
& clean
• check proper pressure
• Check to see that cone is
not worn
• Open apex/add more
cones
• Check shaker for torn
screens
• Pump grease in pump
packing or replace pump
packing
• Add cones
• Add solids control
equipment
• Tighten Apex
• Replace cone

13.0 HYDROCYCLONE MAINTENANCE SCHEDULE

13.1 BEFORE INITIAL STARTUP:

13.1.1 Check for damaged or missing cones.

13.1.3 Check that all victaulic clamps are tight

13.1.4 Make sure nothing is leaning on cones

13.1.5 Keep everyone clear at initial start up in case of cone blow out.

13.1.6 Check pressure on cones (see figure 800-115-1 above)

13.2 24 HOURS AFTER INITIAL STARTUP:

Check pressure on cones (see figure 800-115-1 above)

13.3 72 HOURS AFTER INITIAL STARTUP:

13.3.1 Check torque on each mounting bolt.

13.4 DAILY:

13.4.1 Check hydrocyclone for wear or damage. Replace if necessary.

13.4.2 Unclog cones if necessary

13.4.3 Check pressure. (see figure 800-115-1 above)

13.5 WEEKLY

13.5.1 Check cones for wear or damage

13.6 SIX MONTHS

13.6.1 Replace apex rubbers

13.6.2 Spot paint any worn areas on equipment.