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Drilling
Drilling out hole with bit and generate cuttings The mud brings the cutting up to surface At surface, cutting will be separated out from mud. Cutting will be discarded
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Drilling
SOLID CONTROL
MUD
At surface, cutting will be separated out from mud. Cutting will be discarded
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What is mud
LIQUID
WATER OIL
SOLIDS
BENTONITE/GEL BARITE CHEMICALS SALT DRILL SOLIDS
MUD
WATER-BASE MUD OIL-BASE MUD
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ON TOP OF THE MUD TANKS Just before the mud coming out from down hole returns to the mud tanks
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DESILTER CENTRIFUGE
DESANDER
SHALE SHAKER
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Size Range (microns) > 2000 250 - 2000 74 - 250 44 - 74 2 - 44 0-2 Range (microns) 80 - 2000 30 - 200 1 - 200 3 - 100 10 - 100 7.2 - 7.8 1.0 - 5
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Solids Control
TYPE OF SCE
1. Gravity or Settling In the past, large earthen pits are used as settling traps and the pit becomes the solids control equipment. These methods are becoming obsolete for the oil & gas drilling industry and are definitely not cost effective. Today, sand trap pits are common used offshore. The appropriate size for a sand trap pit is 75 barrels. Too small a sand trap pit may not allow proper settling and too large a pit will not be cost effective.
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TYPE OF SCE
2. Dilution A common method of trying to offset the build-up of drilled solids is the addition of more liquid to the system. This is dilution and does not remove cuttings but instead reduces (or dilutes) their concentration in a drilling mud, thereby reducing the presence of total solids in the mud. It is important to note that dilution is expensive. Dilution, for every 1bbl of solids introduced to the mud, 20 bbls of fresh fluid is required to return the drilling fluid to the correct concentration (At 5% Solids)
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TYPE OF SCE
3. Solids Removal Equipment Solids removal by mechanical separation can achieve the benefits of low solids content and at the same time significantly reduce the many costs associated with dilution. The primary types of solids removal equipment include: Shale Shaker De-sanders, De-silters (Hydro-cyclones) Mud Cleaners Centrifuges.
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SHALE SHAKERS
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SHALE SHAKERS
If shakers are not used effectively - other SCE downstream will not perform properly
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SHALE SHAKERS
The first and most effective (in volume terms) of removing solids. Usually 60 -80% efficient at removing the solids that have been drilled. All shale shakers rely on screening of the drilling fluid through a vibratory surface. The number and motion of the vibratory surface varies from one manufacturer to another.
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SHALE SHAKERS
To handle 100% of the circulation rate. The shale shaker development may be defined by the types of motion produced by the machines: Elliptical, unbalanced design Circular, balanced design Linear, straight-line design.
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Vibratory Motion
Conveys solids to the solids discharge end. Allows liquid to pass through the screen. Create a limited amount of G-forces.
Linear There are three types of motions being used:
Elliptical
Circular
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SHALE SHAKERS
Design performance of shakers are defined by: Type of Motion Stroke length Rpm of vibrator
Vibration motion along the deck depends on: Position of the vibrator/motor Direction of rotation
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Amplitude of motion is the distance from the mean position of the motion to the point of maximum displacement. For a circular motion, the amplitude is the radius of a point on the screen deck side. The stroke is the total movement or twice the amplitude
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Linear
The rate of travel of cuttings depends on the slope of the motion axis, the slope of the screens, the length of stroke, and the vibration frequency. Linear motion machines can be run uphill, which allows greater deck coverage by the fluid and provides a higher solids load capacity.
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Linear
The stroke length for a given design depends on the eccentric weights employed and rpm of the vibrator. The greater the eccentricity of the weights and higher the rpm, the greater the thrust. There are practical limits in any design as to the horsepower a shaker can utilize.
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G force
Sample Shaker G Factor measurement Aid Periodic check of the shaker g force will give immediate indications of mechanical problems with the shakers.
Stroke (inches) x RPM2 g factor = 70490
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Gumbo Problem
Gumbo solids are young, unconsolidated clays that tend to be sticky and easily dispersed. They hydrate and disperse on the way up the hole. What is not removed at surface is entrained in the mud system as colloidal sized particles (>2 microns). Problems include: The more energy put into gumbo solid, the more plastic the solid becomes. Blinding of shaker screens. Increased mud dilution and chemical additions.
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Gumbo Traps/Screens
Three main methods exist for removal: Bars/Trap: the earliest gumbo removal systems where made up of a series of inclined bars used to deflect the gumbo overboard. Chains : Gumbo chains drive the gumbo along an inclined bed and discharges it. Conveying Method : as used in the Derrick Flo-Primer. This conveyor belt carries the gumbo away efficiently and allows the fluid to pass through the urethane mesh (Mesh sizes 5, 10, 20 & 30 are available)
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SHALE SHAKERS
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FLC 513/514
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x x
BEST
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SCREENS DESIGN
Difference between two dimensions and three
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Screen Conductance
Screen conductance is the permeability of the screen cloth divided by the thickness of the cloth and is given in kiloDarcy's per millimeter (KD/MM). Screen conductance is a measure of the amount of fluid that will pass through a screen. Screen permeability is determined by the porosity of the screen and wire surface area, which causes drag on the fluid and restricts movement of the fluid through the screen. Conductance can be calculated from knowledge of the weave of the cloth, the mesh count, and the wile diameter.
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API RP 13-E
Manufacturers Designation D-50 Cut point in Microns D-16 Cut Point in Microns D-84 Cut Point in Microns Conductance in Kilodarcies per Millimeter Actual Screen Area Available for Screening in Sq. Ft. Tag with all information Perma nently Attached to the screen in a Visible Place.
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API RP 13-E
DERRICK BUFFALO, NY U.S.A. D-5O/69 D-16/49 D-84/84 CONDUCTANCE 1.39 AREA 8.3 PATENTED - PMD 48-30 DX 250
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HYDRO-CYCLONES
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HYDRO CYCLONES
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HYDRO CYCLONES
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HYDRO-CYCLONE
DE-SANDERS DE-SILTERS till 40 microns till 20 microns
MUD CLEANERS vibrating screen underneath to recover expensive fluid solid removal will depend upon the screen size with 200 mesh possible to remove 76 microns
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HYDRO-CYCLONE
Hydro-cyclones (centrifugal force separation process) Downstream from the Shale Shaker, Hydro-cyclones (besides shakers) are the only other mud treatment tool to effectively treat 110% of the maximum circulating volume.
De-sander capacity Per 10 cone = 500 GPM Cut point = 40-60 microns
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Solid Discharge end is conical called underflow Vortex Finder - Extending inwards at the top & in the center Overflow opening much larger than inlet & underflow
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If there are not too many solids (by volume) in the downward spiraling stream, the spray underflow appears. Solids discharged are covered by a liquid film, vary from 90% (in case of very fine solids) to 50% (in case of very coarse sand) being removed The inside stream moving upwards at high velocity carries air with it by friction, and this air moving upward is replaced by air entering the underflow opening.
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Fill pits with Water start the centrifugal pump - feed Hydrocyclone Wide Open the underflow With under flow fully open water will spin out in a thin shell Too Wet Discharge Adjust the underflow slowly to smaller size till water spray becomes a drip
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Hydro-Cyclone Benefits
Benefits of having hydro-cyclones: Allows for coarser mesh or lower deck angle to be run on fine screen shakers while balancing the load between the two. Providing longer screen life (mud cleaner mode) Provides redundancy between shakers and centrifuges in closed or semi-closed loop systems Operate as a solids scalper for centrifuge operation
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Mud Cleaner
Mud Cleaner: Use to salvage expensive fluids back to active system
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Desander
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Desilter
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CENTRIFUGES
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Use Centrifuges are typically used to: Remove drilled solids from the active mud system Process recovered drilling fluid from the Extractor Dryer & Hi-G Dryer.
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Decanting Centrifuge
Downstream treatment of the hydrocyclones is the centrifuge. Centrifuges are effective tool to removed solids particle size down to 2 micron. A single centrifuge can handle approximately 10% to 20% of the circulation rate.
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Bowl
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Derrick DE7200
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Brandt/Varco HS-2172
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Derrick VFD-1000
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= higher feed volume = better cut point = lower feed volume = lower cut point = increase cut point = increase cut point
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G Force
G-Force = .0000142 x rpm2 x bowl diameter (in) + + + Increased G- Force = Increased G- Force = Increased G- Force = Increased G- Force = Increased G- Force = Finer cut point (remove more and smaller particles) Cleaner effluent (lower density effluent) Drier solids discharge Greater stress on moving parts Increased torque (drier discharge)
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Calculating G Force
Example 1: 24 Bowl Rotating at 2000 rpm (Based on A large bowl Centrifuge) gs = (2000) x (0.0000142) x (24) gs = 1363
Example 2:
(Based on a DE-1000 FHD Centrifuge) gs = (2600) x (0.0000142) x (14) gs = 1343 The large bowl centrifuge has to spin 600 rpm less to obtain the same G Force.
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Sol. Disc.
Sol. Disc.
Barite return to active Suction from desilter overflow 12 ppg OBM 9.5 - 10 ppg OBM
Fine LGS solids overboard Clean mud return to active > 8 ppg OBM
Pump # 1
Pump # 2
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Micron 74 50 40 HGS 30 Centrifuge Removal 20 LGS 10 2 0 % 10 20 30 40 50 60 70 80 90 100 800 1000 rpm 2000 rpm 3000 rpm
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Cutting Dryer
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Cutting Dryer
Cuttings Dryer The industry has recently adapted specialized system technology to comply with the strict limitations (EPA compliant) being placed on the discharge of synthetic base fluids and their associated drilled cuttings.
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Feed System
The dryer receives wet cuttings from the rig solids control equipment via an application specific combination of: Screw conveyor(s) Positive displacement cuttings pump Vacuum collection system. Gravity
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BEFORE
AFTER
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SYSTEM LAYOUT
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OVERFLOW
UNDERFLOW
IN TO WELLBORE
MUD PUMP
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System Layouts
Shale Shakers
Sandtrap
Degasse r Desande r
Desilter/ Mudcleaner
Waste Agitator
Tank
Equaliser Overflow
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