Drill Solids Removal

• Do Nothing and Let Solids Build up - Add

New Mud When Mud Properties Can Not
Be Controlled.
• Dilute Mud and Rebuild System to Meet
Specs and Dump Excess Mud
• Use Solids Control Equipment to Minimize
Amount of Dilution Required
Solids Control Equipment
 Solids Control Equipment
• Improved Penetration Rates
• Reduced Mud Costs
• Reduced Torque and Drag
• Lower Dilution Requirements
• Reduced System Pressure Losses
• Better Cement Jobs
• Reduced Lost Circulation
• Reduced Formation Damage
• Less Differential Sticking
• Reduced Environmental Impact
• Lower Disposal Costs
 Shale Shakers
• First Line of Defense
• Removes Large Quantity Without
Degradation
• In Weighted Muds, Primary Solids Removal
Device
• Process Entire Circulation Rate
 Shale Shaker Performance
• Vibration Pattern
• Vibration Dynamics
• Shaker Screen Characteristics
• Rheological Properties (PV)
• Solids Loading Rate
 Vibration Patterns - Circular

• Basket Moves in Circular Motion

• All Regions Move in Identical Pattern
• Vibrator on Each Side @ Center of Gravity
• Axis of Rotation Perpendicular to Side of Basket
• Designed for Horizontal Configuration
• Does Not Drive Soft, Stick Clays Into Screens
• Best Suited for Soft Clays
• Scalping Shakers for Coarse Solids Removal
 Vibration Patterns - Elliptical
Motion
• Vibrators Located Above Shaker Basket
• Torque Is Applied to Basket
• Rocking Motion With Different Vibration Patterns
• At Feed End, Elliptical Pattern and Conveyance Is Good
• At Discharge End, Elliptical Pattern Back Toward Feed
End
• Deck Is Pitched Downhill to Overcome Uphill Movement
• Downhill Deck Restricts Ability to Process Fluid
• Soft , Stick Clays and Scalping Shaker
 Vibration Patterns - Linear
Motion
• Two Counter-Rotating Vibrators Which Operate in Phase
• From Center of Gravity, Bisects at 90 ° Between Two
Rotation Axis
• Counterweights Rotate in Opposite Direction, Net Force
on Basket Is Zero
• Force Through Shakers Center of Gravity
• Angle of This Force Is 45°-50° for Maximum Conveyance
• Solids Can Be Conveyed Uphill by Linear Motion
• Pool Formed to Provide Additional Head and Fluid
Throughput
• Poor Performance in Soft Sticky Clays
 Vibration - Acceleration
• Basket Undergoes Acceleration Which Changes in
Magnitude and Direction
• Placement of Vibrator Determines Vibration Pattern and
Acceleration Direction
• Vertical Component Has Most Effect on Liquid
Throughput
• Most Shakers Operate at Acceleration Within Range of 2.5
- 5.0
• Flow Capacity/Dryness Improve With Increased
Acceleration but Shorter Screen Life
• Reducing G Where Extra Flow Capacity Is Available,
Screen Life Improves
 Deck Angle
• Uphill Deck Angle Provides Protection Against Overflow
• As Deck Angle Increases, Throughput Increases but
Conveyance Decreases
• Solids Conveyance in Pool Is Slower Due to Viscous Drag
Forces
• High Deck Angle Causes Stationary Solids Mound in Pool
Area
• There Will Still Be Conveyance of Solids at Discharge End
• Extended Resident Time Will Grind Soft Cuttings Before
Conveyed Out of Pool
 Shaker Screen Characteristics
• Hookstrip Screens Are Not Rigid and Deck Must Be
Crowned
• Full Contact With Supports Is Critical
• Screen Tension Should Be Checked Periodically
• Crowned Deck Causes Uneven Fluid Coverage
• Fluid May Extend Along the Sides Reducing Available
Screen Area
• Reduce by Increasing Deck Angle and Use High
Efficiency Screens
 Corrugated Screens
• Wave Design Increases Area by 40 % Over
Flat Screens
• Reported Increase in Shaker Capacity and
Allow for Finer Screening
 Optimizing Screen Life
• Perforated Plate Screens Exhibit Longer
Life Than Hookstrip Screens
• Panels With Smaller Perforated Plate Sizes
at the Feed End
• Reduce Deck Angle to Improve Solids
Conveyance
• Check That All Support Rubbers Are in
Good Condition
 Screen Selection
• Run Same Screen Mesh Over Entire Deck
• When Running Different Mesh, Coarser
Mesh Should Be on Discharge End
• Select Finest Screen Giving 70 - 80 % Fluid
Coverage
• Run Coarser Screen on Top Deck on
Tandem or Upstream Shaker
• Fine Screen on Top Deck Can Impede
Cuttings Conveyance on Lower Deck
 Cuttings Dryness
• Cuttings Dryness Depends Upon Cutting Size Distribution and Mud
Viscosity
• Fine Solids Have Higher Associated Liquid Due to High Surface Area
• High Solids Loading Will Have Negative Impact on Dryness
• Increase Deck Angle Increases Contact Time on Screen
• Coarser Screens Cause Fluid Endpoint to Recede and Cutting Size
Increase
• Unweighted Muds Provided Downstream Equipment Available and
Cuttings Are Firm
• Weighted Muds Require Finer Screens Since Downstream Equipment
Is Limited
• Increased Acceleration Removes Excess Liquid but Screen Life
Decreases
 Sticky Solids
• Use Scalping Shakers Ahead of Fine Mesh
Screens
• Use Downhill or Flat Deck Angles
• Sticky Solids Will Not Stick to Wet Screens
 Polymer Muds
• Prehydrate the Polymers Before Adding to
the System
• Expect a Reduction in Flow Capacity of
Shakers
 Blinding/Plugging
• Unbounded Triple Layer Screens Provide
Best Resistance
• Single Layer, Square Mesh Screens Is Most
Susceptible
• If Excess Shaker Capacity Is Available, Run
Finer Screens
 Shaker Manifolding
• Design to Provide an Even Distribution of
Cuttings to Shakers
• Flow line Drop of 1’ Per 12’ Run and Diameter of
12”
• Solids Will Travel a Straight Path Resulting in
Uneven Loading
• Avoid Branch Tees and Dead End Tees Will
Evenly Distribute Solids
• Shakers Should Be Level
 Degasser
• Removes Entrained Gas From the Mud
• Gas Cut Mud Will Impair Performance of
Centrifugal Pumps
• Entrained Gas Will Reduce Mud Density
 Degasser Principles
• Gas Bubbles Reach Liquid-Gas Interface
Before Bursting
• Increase Bubble Size by Drawing a Vacuum
• Create a Thin Film
• Create Turbulent Action
• Impart Centrifugal Force to Drive Gas to
Surface
 Types of Degassers
• Atmospheric - Unweighted Muds and Low
Yield Points
• Vacuum - Higher Mud Weights and Higher
Yield Points
 Installation
• Provide Enough Capacity to Treat Entire
Circulating Rate
• Located Downstream From Shale Shaker
• Upstream of Equipment Requiring a
Centrifugal Pump
• Suction Should Be 1’ From Floor of Well
Agitated Pit
 Operation
• Vacuum Degasser Should Discharge Below
Mud Surface
• Atmospheric Degasser Should Discharge
Across Surface of Tank
• Vacuum Degasser Must Take Power Suction
From the Discharge Pit
• Power Mud Centrifugal Pump Must Supply
Necessary Feed Head
 Hydro cyclone
• Remove Fine Solids Missed by Shaker in
Unweighted Muds
• Shakers Remove Large Sized Solids So Not
to Plug Hydro cyclones
 Operation
• Mud Enters Tangentially at High Velocity
• Md Spirals Downward and Centrifugal Force
Moves Solids Toward Wall
• Solids Settle According to Their Mass - Largest
First
• As Cone Narrows, Fluid Turns Toward Overflow
• Creates Low Pressure Area Pulling Air From
Underflow Outlet
• Air and Cleaned Fluid Move to Overflow Through
Vortex Finder
 Operation
• Solids With Sufficient Mass Continue Out the
Underflow
• Maximum Cone Wear Occurs at or Near the
Underflow
• If Solids Are Too Fine, No Liquid Should Be
Discharged
• Fine Solids With More Specific Area, Liquid
Removed Is Higher
• Difference Between Feed and Underflow Density
Is Not Reliable Indicator
 Performance
• Hydro cyclones Diameters Range From 1”
to 12”
• Cones of Diameters 6” or Larger Are Called
Desanders
• Cones of Diameter Less Than 6” Are Called
Desilters
 Variables on Hydrocyclone
Performance
• Cone Diameter Is Main Factor Determining
Processing Capacity
• Large Cones Have Higher Throughput but
Reduced Separation
 Variables on Hydrocyclone
Performance
• Plastic Viscosity Affects Performance of
Hydrocyclones
• Performance Decreases With Increasing
Plastic Viscosity
 Variables on Hydrocyclone
Performance
• Feed Head- Feed Pressure Affects Performance
• Insufficient Head Reduces Fluid Velocity in Cone and
Separation Efficiency
• Excessive Head Will Cause Premature Wear
• Head Is Related to Pressure and Fluid Density by P =
0.052 X H X R
• Most Hydrocyclones Require 75’ of Head
• Required Pressure of a Given Mud Density Approximated
by P = 4 X R
• Correct Pump Sizing to Provide Sufficient Heat at Desired
Flow Rate
 Underflow Diameter
• Reduce Underflow Diameter, Fewer Solids Will Have
Sufficient Mass for Discharge
• Spray Discharge - Umbrella Shaped Discharge - Preferred
• Inside Stream Moving Upward Will Pull Air With It
• Rope Discharge - High Solids Concentration and No Room
for All Solids
• Solids Back up and Only Largest Solids Will Exit
• Many Solids Will Not Exit and Returns in the Overflow
• Make Sure Opening Is Clear or Add More Hydrocyclones
 Desander
• Primary Role Is to Reduce Solids Loading to the
Desilter
• Use When Shakers Are Unable to Screen Down to 140
Mesh (100 M)
• 75 M Is Best Performance Expected From Desanders
• In Weighted Muds, Barite Due to High SG, Will Be
Removed
• Higher Plastic Viscosity in Weighted Mud Will
Reduce Efficiency
• 10” Cones Recommended As Provides Best
Combination of Operation and Capacity
 Desilter
• Should Be Used on All Unweighted Water
Muds
• Process Underflow With Centrifuge When
Using Expensive Muds
Sizing Hydrocyclone Manifolds
• Required Cones Is 110 % of Maximum
Circulating Rate / Single Cone Flow Rate
• Cone Size, in Cone Capacity, GPM @ 75’
Head
• 2 20
• 4 50
• 6 100
• 8 125
• 10 500
• 12 500
 Operating Guidelines
• Operate Enough Cones to Process Over 100 % of Circulation Rate
• Overflow Discharged to a Pit Downstream From Feed Pit and Use
Bottom Equalization
• Agitate All Hydrocyclone Removal and Discharge Pits to Ensure
Uniform Feed
• Do Not Allow Cones to Operate With Plugged Apexes or Inlets
• Spray Discharge Is Preferred - Rope Discharge Indicates Inefficiency
• Do Not Bypass Shaker or Operate With Torn Screens
• Manifolds Should Be Located Above Mud Level to Prevent Siphoning
• Replace Flange-Type Cones With Quick-Connect Type
• Replace Worn Cones Immediately or Blank off Feed and Outlet Line
• Have Working Pressure Gauge on Manifold Feed Inlet
• Size Suction and Discharge Piping to Provide Velocity of 5 - 10 Ft/Sec
• Use One Centrifugal Pump Per Hydrocyclone Manifold
 Mud Cleaners
• A Bank of Hydrocyclones Mounted Over a Vibrating
Screen
• Free Liquid and Solids Smaller Than Screen Returned to
Circulating System
• Used in Weighted Muds to Remove Solids and Recover
Barite
• Fine Screen Shakers Process Full Circulation Whereas
Mud Cleaners Treat a Portion
• Barite Losses Over Mud Cleaner Higher Than Same Size
Shaker Screens
• If Additional Shakers Cannot Be Installed, Mud Cleaner
Can Be Advantageous
 Operating Guidelines
• Plugged Cones or Large Solids off Screen Imply Problem With Shale
Shakers
• Mud Cleaner Cones Should Be 6” or Smaller
• In Unweighted Muds, Use As a Desilter by Blanking off Screen
• Run in Parallel With Other Desilters - Suction From Desander
Discharge Pit
• Dry Desander Discharge by Directing Over Mud Cleaner Screen
• Hydrocyclones Should Be Run Wet As Possible to Improve Solids
Removal
• In Weighted Muds, Use When 150 Mesh Screens Cannot Be Run on
Shaker
• Remove Enough Cones to Keep Screen From Discharging Too Much
Liquid
• In Oil-Based Muds, Monitor Composition/Rate Over Screens
• Dilution Water Added at Screen Will Reduce Underflow Viscosity
 Decanting Centrifuges
• Capable of Removing Very Fine Solids
Compared to Other Equipment
• In Unweighted Muds, Reduce Solids and
Liquid Discharge
• In Weighted Muds, Reclaim Barite While
Removing Collodial Solids
• Primary Separation Device Used in
Dewatering Systems to Reduce Liquid
Discharge
 Performance Parameters
• Viscosity - Settling Velocity Is Inversely
Proportional to Fluid Viscosity
• Diluting the Centrifuge Feed Improves
Performance
• Polymer Muds Have High Fluid Viscosity
and Affects Performance
 Unweighted Muds
• Removes Fine Drill Solids Missed and
Provides a Relatively Dry Discharge
• At Least 25 % of Circulating Rate Should
Be Centrifuged
• High G, High Capacity Centrifuges Are
Recommended to Maximize Separation
• Maximum Efficient Processing Rate Will
Seldom Exceed 250 GPM
 Hydrocyclone Underflow
• Centrifuge Can Process Underflow of Desilter Cones
• System Performance Improved by Opening Cone Apex to
Discharge More Fluid
• Additional Volume From Active System Downstream of
Hydrocyclone
• A Separate Centrifuge Pit Is Required and Usually Small
(< 50 Bbls)
• Both High and Low Equalization Required
• Low Equalizer Supplies Makeup Volume for Unweighted
Muds
• In Weighted Muds to Process the Overflow of Barite
Recovery
 Operating Guidelines -
Unweighted Mud
• Suction Taken From the Desilter Discharge and
Overflow Returned to Downstream Pit
• Provide Enough Centrifuge Capacity to Process 25 % of
Circulation Rate
• Run at Maximum RPM to Achieve Highest G-Force
• Always Wash Out the Centrifuge Upon Shutdown
• If Centrifuge Is to Be Used on Both Weighted and
Unweighted, Rig up for Both
• Solids Discharge Shute Angled Greater Than 45 ° or Use
a Wash Line
 Weighted Muds
• Recover Weighting Material and Discharge
Mud With Collodial Solids
• Recover Barite From Reserve Mud Before
Discarding Mud
• Barite Losses Can Be Reduced Making the
Maximum Solids/Liquid Separation
Operating Guidelines - Weighted
Mud
• Use Hydrocyclone to Reduce Solids Loading in Feed
Mud - Use Overflow Mud
• Provide Enough Centrifuge Capacity to Process 5 - 15
% of Circulation Rate
• Add As Much Dilution Water to Feed to Improve
Separation
• Return Solids to Well-Agitated Pit Before
Suction/Mixing Tanks
• Always Wash Out the Centrifuge Upon Shutdown
 Two-Stage Centrifuging
• Used Unweighted Muds When Liquid Phase
Cannot Be Discarded
• Most Frequently Used in Weighted Oil-Based
Muds
• First Centrifuge Recovers Weight Material
• Liquid Overflow Fed to Higher G-Force
Centrifuge to Discard Solids
• First Centrifuge Must Make Good Separation
With Little Barite Carryover
 Two-Stage Centrifuging
• Second Centrifuge Must Operate at Highest
Possible G-Force
• Economics of Two Stage Centrifuging Are Site
Dependent
• OBM With Barite Concentration Greater Than
4 Lb/Gal Are Candidates
• Deweighting Oil Muds Discarding Barite More
Economical Than Dilution
 Centrifugal Pump
• Designed for Low Pressure, High Flow Rate
Requirements
• Pump and Piping Must Be Sized Correctly
to Deliver Flow and Head
 Principle of Operation
• Rotating Impeller Mounted Inside a Pump
Housing
• Fluid Is Accelerated to the Circumference by the
Impeller
• Accelerated Fluid Exits Impeller Entering
Housing and Is Converted to Pressure Energy
• Head Generated by Centrifugal Pump Decreases
Little As Flow Rate Increases
• Flow Rate Through Cone Is Not Affected Much
by Head
 Centrifugal Pump Sizing
• Determine the Total Flow Rate Needed
• Q(Gpm) = (Number of Cones)(Flow Capacity/Cone)
• Determine the Total Head Required - Most Hydrocyclones
Require Inlet of 75 ‘
• Ht = 75’ + Lift Height (Ft) + Friction Losses (Ft)
• Lift Height Is Height Between Hydrocyclone Manifold and
Mud Surface
• Friction Losses Is Equivalent Loss of Head Through Lines,
Elbows, Tees
• Using Pump Performance Curve, Choose Impeller for
Flow Rate and Total Head
• Determine Required Horsepower:
• BHP Mud = (R)(BHP Curve)/8.34
 Estimating Impeller Size
• Measure the Fluid Density, Pump Rpm
• A Valve on the Discharge and Accurate
Pressure Gauge Between Pump and Valve
• With Pump Running, Close the Discharge
Valve and Read Pressure Gauge
• Convert Pressure to Head (Ft)
• Plot Head on Pump Curve for 0 Gpm and
Estimate Effective Impeller Size
 Pipe Sizing
• Suction and Discharge Line Should Be As
Short As Possible
• Flow Velocities Should Range From 5 to 10
Ft/Sec
• High Velocities Erode Elbows and Cause
Distribution Problems
• Inadequate Suction Line Can Cause
Cavitation
• Velocity (Ft.Sec) = Q/(2.48)(Di2)
 Agitators
• Suspends weight material, provides
homogenous mixture
• All removal pits except sand trap should be
well agitated
• Mud guns impart shear which may degrade
drill solids
• Mechanical agitators ensures solids control
equipment cannot be bypassed
 Compartment Equalization
• Adjustable equalizer needed between solids
removal and addition-suction
• Mud from bottom of last solids pit and
discharge to addition-suction top
• High equalization between removal and
suction improves ability to detect gains
• Equalizer Minimum equivalent diameter =
(GPM/15)1/2
 Recommended Equalization
• Location Equalization
• Sand Trap Exit High
• Degasser High
• Desander Low
• Desilter Low
• Centrifuge Low
• Solids Removal-Addition High-adjustable
• Addition-Blend Low
• Blend-Suction Low
 Sand Trap
• A settling compartment downstream of
shakers
• With fine screen shakers, serves as a backup
• Not stirred and mud exits over a high weir
• Floor should have 45° slope and 20-30 bbls
sufficient
• A quick opening valve that can be closed
against mud flow
 Equipment Arrangement
• Solids removal equipment arranged
sequentially to remove finer solids
• Each device takes suction upstream and
discharges to next pit
• Each device should be fed by a single
purpose pump with no routing option
• Overflow discharges to mud ditches and
mud gun use are other routing errors