Solids Control & Waste

Management
An Introduction

Customer School January 2004

 Solids Control & Waste Management

Solids Control- What is it?

Equipment for removal of solids The only

contaminant we ALWAYS get in drilling
Fluid.

Waste Management- What is it?

A strategy for the use of ‘Best Practises’
in the Containment, Transportation,
Treatment and Disposal of drilling
wastes.

Customer School January 2004

 Solids Control & Waste Management

Solids Control- What is it?

The most important equipment

on the rig!!!
WHY?

Waste Management- What is it?

A strategy that protects the

company, the environment
and the ability to drill at all!

Customer School January 2004

 The Fluid Process
ADDITIVES

SOLIDS
SOLIDS
WELL
WELL BORE
BORE MIXING
MIXING
CONTROL
CONTROL

SOLIDS + FLUID

WASTE
WASTE
MANAGEMENT
MANAGEMENT

Customer School January 2004

 Drilling Fluid Functions
Drilling Fluid Fluid pumped
down
•Carries drilled solids to the Fluid to
surface surface treatment
•Transmits down hole Casing

information
Drill pipe
•Controls formation pressure
•Lubricates and cools the bit Drilled solids

•Coats the hole with cake

Bore hole
Solids Control Flushing action
Maintains desired fluid
properties Drill bit

by removal of drilled solids

Customer School January 2004

 Drilling Fluid Components

OIL
OIL
LIQUID WATER
WATER

SYNTH-
SYNTH- LOW
LOW FRESH
FRESH
DIESEL
DIESEL CRUDE
CRUDE WATER
BRINE
BRINE
ETIC
ETIC TOXIC
TOXIC WATER

EMULSIFIERS
EMULSIFIERS AND
AND SOLUBLE
SOLUBLE
SOLUBLE
SOLUBLE CHEMICALS
CHEMICALS CHEMICALS
CHEMICALS

REACTIVE SOLIDS INERT

REACTIVE INERT

COM.
COM. CLAYS
CLAYS HYDRATABLE
HYDRATABLE WEIGHTING
WEIGHTING INERT
INERT DRILL
DRILL
AND
AND POLYMERS
POLYMERS DRILL
DRILL SOLIDS
SOLIDS SOLIDS
SOLIDS SOLIDS
SOLIDS

Customer School January 2004

 Mud Solids
PV, YP and gels are all affected by mud solids. These may
be divided into two types, high and low gravity.

High Gravity Solids (HGS)

This term refers to the weighting material added to a weighted

mud to increase mud density.

The ideal weighting agent should have the following properties:

a. High specific gravity to minimize volume required for a

given density.

b. Must be chemically inert.

c. Low abrasiveness.

Customer School January 2004

 Mud Solids Cont’d
The most commonly used weighting agent is barite or barium sulfate
(BaSO4), commonly referred to as barite. This was first used as a mud
additive in 1923 to control gas influx to a well in California.

The API specification for barite is:

Specific gravity - 4.2 minimum
Particle size - maximum 3% > 74 microns
minimum 5% > 44 microns

Other weighting agents commonly used include hematite (Fe203),

specific gravity 4.9 - 5.3 and dolomite (calcium / magnesium carbonate)
specific gravity 2.8 - 2.9. Haematite is used where mud weights in
excess of 18 - 19 ppg are required, i.e., severely over pressured areas.
Dolomite is used for a low -weight weighted system where the reservoir
must be stimulated by acidizing.

Customer School January 2004

 Mud Solids Cont’d

Low Gravity Solids (LGS)

Low gravity solids comprises all other solids in the mud. The
average specific gravity of LGS is usually
taken to be 2.6 or 2.65 in solids analysis
calculations. LGS can be further
subdivided as follows:

Desirable - commercial solids added to provide

specific mud properties, e.g., bentonite,
and polymers

Undesirable - drilled solids

Customer School January 2004

 Mud Solids Cont’d
Desirable Solids

These include the following:

Bentonite or Gel

Bentonite is a high grade of fine grained, natural occurring

sodium montmorillonite clay used in drilling mud. It is primarily
used to increase viscosity and control fluid loss. Bentonite is
made up of a large number of flat, thin sheets. Because of its
plate-like structure and chemical make-up, it has the ability to
absorb water and swell (or hydrate) 10-15 times its original
volume when placed in fresh water.

Customer School January 2004

 Mud Solids Cont’d
Desirable Solids Bentonite or Gel (cont.)

Some of the specific properties bentonite provides are:

1. Adequate viscosity to suspend weight material.

2. A thin, impervious filter cake and proper colloidal particle size
distribution for improved fluid loss control.
3. Viscosity to remove cuttings from the well bore.
4. Adequate gel strengths to suspend cuttings when mud
circulation is stopped.
5. Lubricity which reduces friction and equipment wear.

API specifications on bentonite for use in drilling muds are:

1. A yield of at least 90 bbls per ton in fresh water.

2. No more than 4% should be retained on a 200 mesh
screen (74 microns) in the ‘wet screen analysis’.

Customer School January 2004

 Mud Solids Cont’d

Desirable Solids Polymers

Various polymers may be added to water based mud for

viscosity control or to aid in prevention in the hydration,
swelling and dispersion of clay minerals.

Customer School January 2004

 Density of Mud Additives

Material Specific Gravity ppg ppbbl

Oil 0.84 7 294
Water 1.0 8.33 350
Low Gravity Solids 2.6 21.7 910
Bentonite 2.6 21.7 910
Calcium Carbonate 2.8 23.3 980
Barite 4.2 min. 35 1469
Haematite 5.0 41.7 1749
Drilled Solids 2.0 - 3.0 - -

Customer School January 2004

 Adverse Effect of Drilled Solids
• Reduced ROP
• Increased Mud Costs
• Increased Risk of Differential Sticking
• Increased Drag and Torque
• Increased Erosion of Surface Equipment
• Increased Risk of Lost Circulation and Formation
Damage
• Poor Cement Jobs
• Increased Environmental Impact

– Prove it?

Customer School January 2004

 Adverse Effect of Drilled Solids
9000 EP-3 Drilling Data. Pre equipment
upgrade
10000 EP-4 Post Equipment upgrade

Can Solids 11000

Control really 12000

EP -4 On Bottom Torque

save money? 13000

EP-4 Off Bottom Torque

EP-3 On Bottom Torque

14000
EP-3 Off Bottom Torque
5 10 15 20
x100 Kg

9000
EP-4 Slack off Weight
The Proof, by 10000
EP-4 Pick up Weight
the upgrade of 11000
EP-4 Rotating Weight
the shale 12000
EP-3 Slack off Weight
shakers alone! 13000
EP-3 Pick up Weight

14000
EP-3 Rotating Weight

100 150 200 250 300

1000 ft/lb

Customer School January 2004

 API Solids Size Classification

Category Size Range (µm) Examples

Coarse >2000 Human hair 30 - 200

Intermediate 250 - 2000 Talcum powder 5 - 50
Medium 74 - 250 Cement dust 3 - 100
Fine 44 - 74 Cosmetic powder 35
Ultra-fine 2 - 44 Red blood corpuscles 7
Colloidal <2

Customer School January 2004

 Drilled Solids Degradation

A 20 micron drilled The same solid cut Another 1/4 cut on

solid surface area = in half on each face each face.
2400 sq. microns
An idealistic
The original 20
representation of
micron solid reduced
the gradual
and sized 2 micron
reduction in size
particles. Surface
of a re-cycled
area 24,000 sq.
drilled solid by
microns.
mechanical
forces.
Customer School January 2004
 Differential Sticking
Fs = PAF
Where:
Fs = Sticking force (lbs.
P = Differential Pressure (PST)
A = Area of Contact (Sq. In.)
F = Sticking Coefficient
CASE A: CASE B:
Low Solids, High Solids,
Thin Wall Cake Thick Wall Cake
P = 520 (PSI) P = 520 (PSI)
F = 0.2 F = 0.2
A = 240 Sq. In. (1” width of drill pipe A = 960 Sq. In. (4” width of
against 20’ length of filter cake drill pipe against 20’ length of
filter cake
Fs = 520 x 0.2 x 1 x 20 x 12 = 24,960 lbs. Fs = 520 x 0.2 x 4 x 20 x 12 = 99,840 lbs.

Customer School January 2004

 P.S.D. of A.P.I. Barite

30

25

20

15

10

0
0.01 0.1 1.0 10 100
1000
PARTICLE DIAMETER - MICROMETERS
Customer School January 2004
 Barite Particle Size on Rheology

160
140 PV - Adding 3 Micron and under Barite
YP = Yield Point lb./100 sq. ft

YP - Adding 3 Micron and under Barite

120 PV - Adding API Barite
PV = Plastic Viscosity, cp

YP - Adding API Barite

100
80
60
40
20
0
0 20 40 60 80 100 120 140 160 180 200

Barite Concentration (pp/bbl)

Customer School January 2004
 Reactive Solids on Rheology

Extra
Extra clays
clays give
give
large
large increase
increase
in
in viscosity
viscosity
Extra
Extra clays
clays give
give
Viscosity

small
small increase
increase
in
in viscosity
viscosity

5% 10%

% Clay in Mud
Customer School January 2004
 Solids Control - The Key to Economy

Drilling rate

 Control of density and flow properties

 Life of bits and surface equipment
 Accuracy of downhole information

Fluid costs

 Disposal volumes and costs

 Cementing problems
 Risk of differential sticking

Customer School January 2004

 Methods for Solids Control

Three ways to obtain desired fluid properties:

DILUTION
Addition of new fluid

DISPLACEMENT
Partial Replacement of Fluid

MECHANICAL SEPARATION
Removal of Drill Solids
(by particle size and density difference)

Customer School January 2004

 Solids Removal with Dilution

Drilled Drilling Fluid

Solids (0% Drilled Solids)

Solids
Control
Equipment Fluid to
replace
volume
Mud of solids
from Mud
discharged
Hole to
and mud
Solids plus mud Hole
lost
discharge
Customer School January 2004
 Dilution Equation
VR = VS (LS - LD)
LD - LA

Where: VR = Dilution volume required LS = Volume % LGS in system

VS = Volume of mud in LD = Volume % LGS desired
circulating system
LA = Volume % LGS in dilution fluid

Example a) System volume = 1000 bbl

LGS in system = 8%
LGS desired = 6%
Dilution with water i.e. zero % LGS
VR = 1000 (8-6) = 2000 = 333 bbl
6 6
b) If the dilution fluid contained 2% bentonite, this
would be:
VR = 1000 (8-6) = 2000 = 500 bbl
6-2 4

Customer School January 2004

 Solids Removal with Displacement

Drilled Drilling Fluid Dilution

Solids (0% Drilled Solids) Fluid

Solids
Control
Equipment Fluid to
replace
volume of
Mud solids Mud
from discharged To Hole
Hole and mud lost
Solids plus mud Mud / Solids
with solids
discharge Discarded
(Dumped)

Customer School January 2004

 Displacement Equation
VR = VS (LS - LD)
LS - LA

Example (Using same figures as dilution examples)

a) VR = 1000 (8-6) = 2000 = 250 bbl

8 8

b) VR = 1000 (8-6) = 2000 = 333 bbl

8-2 6

Customer School January 2004

 Summary
Water Vol. 2% Bentonite
Required (bbl) Slurry Required (bbl)
Dilution 333 500
Displacement 250 333
The major disadvantages of dilution are:
a) Cannot continue indefinitely since limits imposed by split capacity would be
exceeded.
b) High cost due to large volumes needed.

c) Increased maintenance costs for larger system.

Displacement maintains a constant system volume, but has three disadvantages

compared to mechanical methods:

a) Environmental impact of displaced mud, High cost due to large volumes
needed and the high disposal costs.

Customer School January 2004

 Solids Control System Design Criteria

1. Removal of drilled solids at the first available

opportunity with the minimum of mechanical handling.

Solids Removal Efficiency:

Mass flow rate of solids removed x 100

Mass flow rate of solids in feed

2. Removal of drilled solids in as

concentrated a form as possible.

Decanting Efficiency:

(% Solids Discharge - % Solids Feed) x 100

100 - % Solids Feed

Customer School January 2004

 Solids Control System Design Criteria

Dilution reduces the concentration of contamination not the

volume!

The effect of the solids appears to go away but then returns as

the solids degrade and increase in surface volume.

So Dilution is a means to maintain volume in the hole and

additionally reduce the effects of solids.

IT SHOULD NOT BE SEEN AS A METHOD OF REDUCING

SOLIDS CONTAMINATION ALONE!!!

Dilution for solids concentration reasons is costly. 20 x the

volume of the contamination. There is no economic substitute
for good solids control !!!
Customer School January 2004
 The Equipment!

Customer School January 2004

 Solids Control System

Customer School January 2004

 Mechanical Separation Equip
Operating Ranges and Efficiency
% Solids
Removed

Shale Shale Shakers 30 - 70

5 - 10
Mud Cleaners
5 - 10
Desanders
10 - 15
Desilters
30 - 40

Decanting Centrifuges

150 125 100 75 50 25 0 Microns

Customer School January 2004

 Shale Shakers
Equipment Overview

The First and most important piece of solids Control

equipment

hHandles 100% of circulating volume

hRemoves solids larger than 74 µm
hSeparation by straining through screen

Optimisation:

hLinear / elliptical motions

hMesh size and type
hDeck angle

Customer School January 2004

 Hydrocyclones

h Separation by density difference

Desanders
h Diameter: 6 - 12”
h Handles 125% of circulating volume
h D50 cut point 40-45 µm

Desilters
h Diameter: 4”
h Handles 150% of circulating volume
h D50 cut point 20-25 µm

Customer School January 2004

 Mud Cleaners

h Desilter/desander mounted over fine mesh shale shaker

h For use in weighted and / or expensive fluid systems

h Discards drilled solids while retaining expensive barite,

chemicals and liquids in the fluid system

Customer School January 2004

 In Detail

Customer School January 2004

 Shaker Functions

• Primary defence against drilled solids

contamination
• Handle the entire circulating flow rate
• Remove drilled solids on the basis of size at
the first pass
• Allow barite and other additives to remain
in the circulating system

Customer School January 2004

 Shaker Development

• Shaker technology first introduced to the oil

industry in 1930s (Baroid)
• Elliptical motion utilising coarse screen sizes
• Circular motion introduced in the 1960s along
with dual deck machines (Baroid)
• Linear motion became standard in the late 1980s
(Derrick, Rigtech etc)
• Balanced elliptical motion introduced in the 1990s
(Swaco, Rigtech)

Customer School January 2004

 Major Manufacturers

• Swaco
• Derrick
• Brandt (Varco)
• Fluid Systems
• Others:
– Harrisburg (National Oilwell)
– Gann
– Kemtron

Customer School January 2004

 Examples
Linear :
• Swaco ALS
• Varco VSM100 & 300
• Derrick Flo-Line
• Brandt LCM2D
• Fluid Systems Inc, Kemtron

Balanced Elliptical
• Swaco BEM3
• Swaco BEM600
Customer School January 2004
 Dual-Deck Shakers

Examples
• BEM600
• VSM 100 & 300
• Brandt Cobra

Customer School January 2004

 Circular Motion
Direction of Rotation
Vibrator

Circular Motion
As the name implies, the shaker basket moves in a uniform circular motion when
viewed from the side . This is a “balanced” vibration pattern because all regions of
the shaker basket move in phase with the identical pattern. In order to achieve
“balanced” circular motion, a vibrator must be located on each side of the shaker
basket at its center of gravity (CG) with the axis of rotation perpendicular to the side
of the basket. The Brandt Tandem is a common example of a circular motion shale
shaker.

Customer School January 2004

 Linear Motion
Counter Rotating
Eccentric

n
t io
o
t M
n
l ta
esu
R
of
n
t io
c
ire
D
Solids Direction

Because the counterweights rotate in opposite directions, the net force on the shaker
basket is zero except along a line passing through the shaker’s center of gravity. The
resultant shaker motion is therefore “linear.” The angle of this line of motion is usually at
45-50 ° relative to the shaker deck to achieve maximum solids conveyance. Because
acceleration is applied through the shaker CG, the basket is dynamically balanced; the
same pattern of motion will exist at all points along the shaker.
Customer School January 2004
 Elliptical Motion (Unbalanced)

Vibrator

Elliptical & Circular

The difference between circular motion and unbalanced elliptical motion is a matter
of vibrator placement. To achieve unbalanced elliptical motion, the vibrators are
typically located above the shaker basket. Because the vibrator counterweights no
longer rotate about the shaker’s center of gravity, torque is applied on the shaker
basket.

Customer School January 2004

 Elliptical Motion (Balanced)

Customer School January 2004

Customer School January 2004
 Features & Benefits

Features
• Balanced Elliptical Motion (BEM)
• Two side-mounted Martin motors CDX18-5950
• Power consumption – 2 hp (1.5 kW) per motor
• G Force - 5.0 g
• Aspect ratio - 2.37

Benefit
• Improved efficiency and dryer cuttings

Customer School January 2004

 Shaker Screens

Customer School January 2004

 Weave Types

Plain Twill Hollander

Reverse Dutch Twill 5 Shed Twill

Hollander
Customer School January 2004
 Screen Definitions
w d p warp

weft

1”
n

Warp Wires running lengthwise in the cloth as

woven.

Weft Wires running crosswise in the cloth as

woven.
Customer School January 2004
 Screen Definitions
w d p warp

weft

1”
n

Aperture (w) Space between adjacent parallel wires, in

mm.
(25.4 / n) - d

Wire Diameter (d) Diameter of wire before weaving, in mm.

Customer School January 2004

 Screen Definitions
w d p warp

weft

1”
n

Mesh Count (n) Number of apertures per lineal inch

measured from the centre of one wire to
a point 1 inch (25.4 mm) distant.
25.4 / (w + d)
Pitch (p) Distance between the centres of two
adjacent wires in mm, i.e. w + d.
25.4 / n
Customer School January 2004
 Screen Definitions
w d p warp

weft

1”
n

Open Area The fractional open surface area of the

wirecloth in flow direction (applicable for
square meshes only).
(w²) / (w + d)² * 100

Customer School January 2004

 Screen Cloth Open Area

The term ‘Open Area’ is only attributed to the wirecloth itself and
NOT the finished screen where steelwork, plastic bonding,
clamping bars, etc. can all affect the effective screening area.

It should also be noted that screen support rails (which are not part
of the screen itself) will also affect the passage of fluid through the
screen.

It is also important that ‘Open Area’ is not confused with ‘Screen

Area’ as they are in no way related.

Customer School January 2004

 Types of Wire cloth

Market Grade TBC Superfine

All these cloth types have the same mesh count

and all have different aperture sizes

Customer School January 2004

 API Specification

API RP-13E is standard designation for

shale shaker screens

– Manufacturers designation (nominal mesh size)

– d16, d50 and d84 cutt points
– Conductance
– Non-blanked area

Customer School January 2004

 Separation Efficiency

Layered MESH sizes are based upon an average

aperture size derived from the use of two fine cloths -
one over the other.
These cloths will be dissimilar and will in fact be
coarser than indicated by the mesh size shown.
The use of API designations, which show D16, D50
& D84 figures is crucial in determining which meshes
are the most effective.
It should be clear that a more accurate cut will be
achieved from the use of square mesh screens than
through the use of layered meshes.
Customer School January 2004
 Cutt Point
• Cutt pronounced “koot”
• Cutt points represent separation potentials of
various particle sizes
• The separation potential curve describes the range
of aperture sizes present on a screen
• Cutt points of d16, d50, and d84 are used
• Example:
– d84 for a 210 mesh screen = 94 microns
– 84% of the open area of the screen is composed of
apertures less than 94 microns

Customer School January 2004

 Separation Potential Curve Market Grade 150 x 150

100
90 Separation Potential Curve (‘Cutt’ Points)

80

70

60

50

40

30

20

10

0
70 80 92 100 102 107 110 112 114 120 130
Equivalent Spherical Diameter Micrometer

Customer School January 2004

 Screen Performance

Customer School January 2004

 Defining Screen Performance

• €, $, £ - Cost

• Screen Life

• Screen Capacity

• Separation Efficiency
Customer School January 2004
 Reasons for Premature Failure

• Overloading
• No load
• Blinding & plugging
• Wrong screen choice
• Corrosion
• Mechanical damage
• Poor solids transport/Abrasive solids

Customer School January 2004

 Screen Life - Modes of Failure

Fatigue Failures Abrasion Failures

Customer School January 2004

 Shaker Loading

Increased chance
Heavily Loaded
– Deep Pond Ph of fatigue failures

Lower Loading Ph
– Shallow Pond

Customer School January 2004

 Choosing the Right Mesh Type

• TBC cloth – Light loading applications with low risk

of blinding

• XR – Abrasive conditions, heavy loading

• TRSF/DX – High risk of blinding eg fine sands

• Magnum – High flow capacity, less blanked area

Customer School January 2004

 Mechanical Damage

Caused by:
• Careless storage and handling
• Hooking mesh cloth when removing cartridge
screens
• Over tensioning hookstrip screens
• Scraping screen surface to remove solids
• Scoring pressure washer nozzles across the mesh
surface
Etc…..

Customer School January 2004

 Poor Solids Transport

Caused by:
• Screen design
Keep screens as clean
• Screen repairs
as possible to minimise
• Blinding the effect
• Fluid properties

Customer School January 2004

 A scraper was used
on this screen
leaving it blinded.
This does not help
solids transport!

Customer School January 2004

 Shaker Flow Distribution

Customer School January 2004

 Maximising Screen Life

• Run the correct screens for the conditions

• Don’t overload the screens
• Stop no load conditions where possible
• Don’t run adjustable shakers on high ‘G’ levels for
extended periods
• Clean screens regularly
• Repair burst panels
• Diverter Plate Design

Customer School January 2004

 Separation Performance

• Separation performance is defined by the

screen aperture

• The smaller the aperture the finer the cut

Note: Nominal mesh size does not

necessarily describe the cut

Customer School January 2004

 Separation Performance Cont’d.

• The only way to compare screens based on

separation performance is to use the separation
efficiency curves

• Separation efficiency curves can be described by

the d50, d16 and d84 values

Note: d50 alone does not describe the range of

aperture sizes present on a screen

Customer School January 2004

 TBC, DX and XR Mesh

Customer School January 2004

 Screen Capacity

Related to:

• Screen design
• Fluid properties
• Shaker configuration

API conductance can be used as a guide

Customer School January 2004

 Factors Affecting Capacity

Screen Design

– Weave type and mesh size

– Frame non-blanked area
– Number of layers
– Frame structural properties (rigidity, profile)

Customer School January 2004

 Shaker Operation

Screen Tension and Condition

Screens should be correctly stored and handled, and

should always be tensioned in accordance with
manufacturers recommendations.

Incorrectly tensioned screens have impaired separation

efficiency and vastly reduced working life.

Customer School January 2004

 Shaker Operation

Selection of Screen Size

The finest available mesh should be fitted which can be run

without loss of whole mud from the front of the screens.

As a general rule, the back two thirds to three quarters of the

screen should be covered with mud. This allows for surges
and rig heave when offshore.

Angled single deck units of the Derrick Flo-Line type are

designed to operate with a horseshoe shaped pond of mud,
concave towards the front edge.

Customer School January 2004

 Preventing Plugging

• Reduce the tunnel length

– Use Ultra Fine mesh Mesh Particle

• Prevent particle from lodging

– 3-layer screen Particle
Top Mesh
– Rectangular mesh

Middle Mesh
• Pressure wash screens

Customer School January 2004

 Shaker Operation

Blinding
Screen blinding is caused by a reduction in the fluid
transmission capability of the screens which leads to
whole mud over screen losses. There are two main
reasons for this:
a) Coating
The coating of screen wires by dried or sticky solids. This
reduces aperture size and can drastically reduce the
screen’s conductance.

Screens should always be thoroughly washed down with a

pressure wash gun if the shakers are to be turned off for a
period of time. If coating is occurring due to sticky solids
during drilling then a pressure gun should be constantly
available at the shakers.

Customer School January 2004

 Shaker Operation

Blinding (cont.)

a) Coating (cont.)

This should have a base oil feed for oil based mud and
water for water based mud. The best way to deal with this
problem is to have a set of clean screens standing by
ready to change at connection time. The screens removed
should be thoroughly cleaned ready for changing at the
next connection.

If it is necessary to use the pressure gun while the screens

are fitted, it should not be blasted down perpendicular to
the screen since this breaks down the solids and forces
them through the screen.
Customer School January 2004
 Shaker Operation

Blinding

a) Coating (cont.)

If this problem is very severe, it may be necessary to

change to coarser screens until the problem
formation has been drilled.

Rectangular mesh screens may also alleviate this

problem.

Customer School January 2004

 Shaker Operation

Blinding

b) Plugging

As the name suggests, this problem occurs due to

plugging of the screen apertures by particles of about the
same size, often referred to as near sized particles.

The problem is most likely to occur with plain square

weave screen cloths in unconsolidated sand formations.
Rectangular or layered screens will not suffer so severely
from this problem for reasons already outlined.

Customer School January 2004

 Shaker Operation

Blinding

b) Plugging (Cont.)
When screens blind, many people have a tendency to fit a
coarser mesh. This does alleviate the problem, but is very
poor solids control practice since the sand is then allowed
through the screens. The best solution is to reduce flow
rate if at all possible and to fit finer mesh screens for which
the particles will no longer be near sized.

Customer School January 2004

 Shaker Operation
Bypassing

Most header boxes (possum bellies) have a bypass

valve or valves. As the name suggests, this permits
circulation to bypass the shakers and may serve as a
dump valve to dump cuttings from the header box.

Shakers should never by bypassed when drilling. This

rapidly fills the sand trap with cuttings and leads to
overload or a blockage at hydrocyclones by coarse
solids.

Dumping of the header box can be avoided by installing

jetting lines to agitate the tank and circulate cuttings
over the shakers. Jetting should be done during
connections in order to avoid flooding of the screens and
whole mud loss.
Customer School January 2004
 Shaker Operation

Shaker Hand

Shakers should always be attended when drilling in

order that any malfunction or screen damage can be
quickly rectified.

A member of the rig crew should be assigned to the job

of “shaker hand” and should be fully trained on the
actions to be taken if problems occur.

Customer School January 2004

 Hydrocyclones

Customer School January 2004

 Hydrocyclones
Feed
Inlet Underflow Opening
Overflow Opening
(Vortex finder may be
same size or smaller)
Liquid Discharge
Feed
Opening
Inlet
(Overflow)
Feed Vortex Finder
Chamber
Working (Inside)
Diameter

Cone
Zone of
Maximum Solids
Wear Discharge
Entry

Opening
Air

(Underflow

Customer School January 2004

 Hydrocyclones
Feed Capacity Capacity Cut Point
Chamber (gpm) (m3/hr) For Solids
Diameter of 2.6sg
(inch) (micron)

4 50 11.35 20 - 25

6 100 22.71 40 - 45

8 150 34.06 70 - 75

12 500 113.55 90 - 100

Manufacturer’s figures - highly optimistic

Customer School January 2004

 Hydrocyclone Sizing
Cone Capacities

Cone Size (inch) gpm

4 50
6 100
8 150
10 500
12 500

Number of Cones

Number of cones = Max. circ. rate(gpm) x 1.25

cone capacity (gpm)

Customer School January 2004

 Hydrocyclone Sizing

Feedhead

Most manufacturers specify 75 feet of head at feed manifold.

The pressure gauge reading should therefore be:

p = 0.052 x feet of head x ppg

= 0.052 x 75 x ppg
= 3.9 x ppg
Q 4 x ppg

Customer School January 2004

 Hydrocyclone Operation

Installation

The desander should take suction from the degasser overflow tank and
overflow to the adjacent downstream tank. Desilter suction should be
from the desander overflow and again, overflow to the adjacent
downstream tank. Low level equalizers between the overflow and
suction tanks ensure a backflow of mud as described above.

Where the bottom of the cones lies several feet above the mud level in
the tanks, the overflow line may create a vacuum which sucks solids
through the overflows, thereby reducing separation efficiency. This can
be overcome by installation of a vacuum break. Installing the overflow
line at 450 may also help to alleviate this.

Customer School January 2004

 Hydrocyclone Operation

Spray Discharge

When operating at maximum efficiency, the underflow should

exit from the apex of the cone as a spray discharge.

Larger particles are thrown to the outside of the cone and

travel downwards in a spiral. When solids reach the apex,
they are more concentrated than in the feed mud due to the
smaller area available. They exit the apex as an annular ring
which forms a conical spray.

Customer School January 2004

 Hydrocyclone Operation

Spray Discharge (Cont’d)

As solids and fluid are discharged air is sucked upwards

through the center of the apex due to the creation of a low
pressure zone formed by the liquid and smaller particles
spiraling upwards in the center of the cone.

The percentage of solids in the underflow varies from around

50% for coarse sand down to around 10% for fine silt. The
underflow will be denser than the feed mud.

The overflow will be less dense than the feed mud.

Customer School January 2004

 Hydrocyclone Operation
Rope Discharge

In a rope discharge, the liquid forms 50% or sometimes less of the total
underflow. The solids concentration can increase due to faster drilling
or the sand trap being full of solids. There is insufficient room for all of
the downwards moving solids to exit from the cone apex.

The solids tend to accumulate in a dead area above the apex and the
rate of solids removal is much reduced. The solids that cannot exit
from the apex of a roping underflow cone will be swept up the center
and exit from the overflow. This includes many of the solids that would
have been removed by a spray discharge.

Customer School January 2004

 Hydrocyclone Operation

Rope Discharge (Cont.)

Since only the coarsest solids are discharged the surface area to
weight ratio is reduced and therefore less liquid is discharged.
The rope underflow will therefore have a higher density than the spray
underflow for the same mud.

The liquid returning to the tanks contains finer solids which would have
been removed by a spray discharge. It is therefore denser than the
overflow from spray discharge.

Customer School January 2004

 Rope Discharge

A typical balanced design

Solids hydrocyclone operating inefficiently
Reporting to with rope type underflow
Overflow

Rapid Cone
Wear

Dead Area - No Rotation - No

Underflow Wear
Discharge
Opening Slow “Falling” Discharge
No Air
Customer School January 2004 Entry
 Hydrocyclone Operation
Partial Feed Plugging

This is a potentially serious situation for mud loss and results

from partial plugging of the feed inlet. the result is a reduction
in the inlet velocity and a loss of separation.

•The cyclone action is lost and the mud entering spirals out of
the underflow opening in a cone shape.

• Clean mud processed by other cones on the manifold may

flow backwards into the cone and may also be lost.

• The underflow density will be equal to the feed density.

Customer School January 2004

 Hydrocyclone Operation
Partial Feed Plugging (Cont’d)

• Very high rates of mud loss can occur so the problem must
be rectified at the first opportunity, usually by replacing the
cone with a spare or removing it and blanking off the feed from
the manifold at the inlet pipe connection.

Customer School January 2004

Total & Partial Feed Inlet Plugging

Hydrocyclones with
the feed partially
Straight Down
plugged (left) and
Flow Indicates
completely plugged
All Mud Entering
(right)
Backwards Through
Overflow

The Smooth Shape

a. Coning Indicates Rotation b. Flooding
due to Due to Mud Entering Due to
Partial the Feed Inlet Complete
Plugging of Plugging of
Inlet
Customer School January 2004
Inlet
 Hydrocyclone Operation
Underflow Plugging

The underflow may become plugged for one of two reasons.

Firstly, rope discharge may have gone unchecked for so long

that plugging has resulted.

Secondly, the opening may be too small (see set up) which
results in a dry plug.

Both cases should be rectified since they reduce total capacity

and also increase the total feed concentration of solids to the
other cones. There are other serious implications of plugged
underflow.

Customer School January 2004

 Plugging of Apex
Coarse Solids Passing On To
Rig Pump Filter Cake. Annulus.

Severe Wear Inside

Fee Vortex Finder
d

A Hydrocyclone
operating with the
underflow Ring Of Severe Wear
discharge
opening plugged

Still Bed Of Very Coarse Material

Plugged Area

Customer School January 2004

 Hydrocyclone Troubleshooting
1. Low feed pressure.
a. Pump incorrectly sized.
b. Plugged pump suction - clean filter and settlement in pipe.
c. Ensure no other equipment being fed by same pump.
d. Air lock in suction.

2. No Underflow.
a. Plugged apex.
b. Aperture too small.
c. Solids all below cut point.
d. Vacuum on overflow.

Customer School January 2004

Hydrocyclone Troubleshooting Cont’d
3. Rope Discharge
a. Solids overload
b. Very high mud viscosity.
c. Undersized apex.

4. Cone Discharge - Feed partially plugged.

5. Flooded Liquid Jet Discharge - Feed completely

plugged

Customer School January 2004

Hydrocyclone Pump Sizing Procedure
1. Calculate friction head.

2. Calculate total dynamic head. T.D.H. = Inlet head + Lift +

Friction head

3. Determine pump size to be used from manufacturers tables.

4. Select pump curves and determine impeller size. Up to

1750 rpm estimate to nearest 1/4“

5. Determine horsepower required for water:

6. Calculate horsepower required for maximum mud density.

7. Choose motor size as smallest standard size equal to or

greater than minimum calculated.
Customer School January 2004
 Friction Loss in Pipe Fittings
Friction Loss in Pipe Fittings in Terms of Equivalent Feet of Straight Pipe
Swing
Gate check Angle Globe
Actual valve valve valve valve
Nom. inside Friction Close Butter- 90 welding Mitre bend
pipe diam. factor full 90 45 thru branch return full full full fly elbow
size d f open elbow elbow flow flow band open open open valve r/d=1 r/d=2 45 90
1/2 0.622 0.027 0.41 1.55 0.83 1.04 3.11 2.59 5.18 7.78 17.6
3/4 0.824 0.025 0.55 2.06 1.1 1.37 4.12 3.43 8.86 10.3 23.3
1 1.049 0.023 0.7 2.62 1.4 1.75 5.25 4.07 8.74 13.1 29.7
1 1/4 1.38 0.022 0.92 3.45 1.84 2.3 6.9 5.75 11.5 17.3 39.1
1 1/2 1.61 0.021 1.07 4.03 2.15 2.68 8.05 6.71 13.4 20.1 45.6
2 2.067 0.019 1.38 5.17 2.76 3.45 10.3 8.61 17.2 25.8 58.6 7.75 3.45 2 2.58 10.3
2 1/2 2.469 0.018 1.65 6.17 3.29 4.12 12.3 10.3 20.6 30.9 70 9.26 4.12 2.47 3.08 12.3
3 3.068 0.018 2.04 7.67 4.09 5.11 15.3 12.8 25.5 38.4 86.9 11.5 5.11 3.07 3.84 15.3
4 4.026 0.017 2.68 10.1 5.37 5.71 20.1 16.8 33.6 50.3 114 15.1 6.71 4.03 5.03 20.1
5 5.047 0.016 3.36 12.6 6.73 8.41 25.2 21 42.1 63.1 143 18.9 8.41 5.05 6.31 25.2
6 6.065 0.015 4.04 15.2 8.09 10.1 30.3 25.3 50.5 75.8 172 22.7 10.1 6.07 7.58 30.3
8 7.981 0.014 5.32 20 10.6 13.3 39.9 33.3 33.3 99.8 226 29.9 13.3 7.98 9.98 39.9
10 10.02 0.014 6.68 25.1 13.4 16.7 50.1 41.8 41.8 125 284 29.2 16.7 10 12.5 50.1
12 11.938 0.013 7.96 29.8 15.9 19.9 59.7 49.7 49.7 149 338 34.8 19.9 11.9 14.9 59.7
14 13.124 0.013 8.75 32.8 17.5 21.8 65.6 54.7 54.7 164 372 38.3 21.8 13.1 16.4 65.6
16 15 0.013 10 37.5 20 25 75 62.5 62.5 188 425 31.3 25 15 18.8 75
18 16.876 0.012 16.9 42.2 22.5 28.1 84.4 70.3 70.3 210 478 35.2 28.1 16.9 21.1 84.4
20 18.814 0.012 12.5 47 25.1 31.4 94.1 78.4 78.4 235 533 39.2 31.4 18.8 23.5 94.1
24 22.628 0.012 15.1 56.6 30.2 37.7 113 94.3 94.3 283 641 47.1 37.7 22.6 28.3 113
30 28 0.011 18.7 70 37.3 46.7 140 117 46.7 28 35 140
36 34 0.011 22.7 85 45.3 56.7 170 142 56.7 34 43 170
42 40 0.01 26.7 100 53.3 66.7 200 167 56.7 40 50 200
48 46 0.01 30.7 115 51.3 76.7 230 192 76.7 46 58 230

1/2 TO 6
L/D 8 30 16 20 60 150 =100 150 340 20 12 15 60
24 TO 48
Customer School January 2004
=50
 Pump Sizing Example
Example

Desander at 1500gpm: Fittings on discharge:

Qty
Inlet head required = 75 feet 90º elbows = 2
Lift = 10 feet 45º = 1
Pipe length = 30 feet Tee piece = 1
Pipe length = 10 feet Butt. valves = 2

Fittings on Feed:
Qty
Tee piece = 1
Butt. valve = 2

Maximum mud density = 1.6sg.

Customer School January 2004
 Mudcleaner

Mudcleaner Working Principles

Clean Mud

Mud In Hydrocyclones
(Desilters
and/or
Cone Underflow Desanders)

Reject or
Discard Fine Mesh

Screen
Solids
Screen Underflow

Customer School January 2004

Mud Return
 Mudcleaner

•Designed to recover Barite.

•Screen sized to allow material smaller than 75 microns to be

recovered.

•In 1965 Most drill solids were grater than 75 microns as only
coarse screens were available. In 2004 all solids above 75
microns are removed using the shale shakers leaving little for
the mudcleaner to do!!

•The pump action degrades solids finer.

•A mudcleaner should only be used when fine screens cannot

be fitted to the shale shakers.

Customer School January 2004

 Decanting Centrifuges

Centrifuges
An Introduction to the Working
Principles

Customer School January 2004

 Centrifugal Separation
Stokes’ Law

d 2(ρp - ρ1)
Vc = rζ2
18γ
Vc d ρp ρ1 L rw2
Centrifugal Particle Particle Liquid Liquid Centripetal
settling diameter density density viscosity acceleration
Velocity(m/s) (mm) (kg/m3) (kg/m3) (kg/ms) (m/s2)

w
Vc r
d

Customer School January 2004

 Centrifugal Separation
Stokes’ Law

Drilled Solid Barite Particle

2.6 SG 104 micron 4.2 SG 74 micron

Gravity (1G) = 9.81 ms-2 or 32 ft/s2

Equivalent Settling Rates

Customer School January 2004
Improving the gravity separation vessel

Increased efficiency.
Continuous gravity Enlarged settling area by
separation vessel means of buffer plates

Customer School January 2004

 Continuous gravity settler

Scraping device for solids discharge

Solids discharge
Feed

Liquid discharge

Customer School January 2004

 From gravity settler to centrifuge

Screw conveyor for solids discharge

2
1 Cylindrical/concial,
rotating separation
Solids discharge vessel with internal
by means of screw screw conveyor
conveyor

3
The decanter centrifuge
concept

Customer School January 2004

 Decanting Centrifuge

A machine for the continuous sedimentation of suspended

solids from a liquid by the action of centrifugal force in an
elongated rotating bowl.

Continuous unloading of solids from the bowl is made

possible by a conveyor which rotates in the same direction
as the bowl but at a slightly different speed.

PRINCIPLE COMPONENTS

1. Bowl (or drum)

2. Conveyor (or scroll)
3. Gearbox
4. Frame and collecting vessel
5. Feed inlet and distribution
Customer School January 2004
 Operational Parameters

g g
Differential speed ( ∆n )
R N

According to decanter design According to process parameters

Differential speed (∆n) Feed rate (Q)
Rotor speed (g-force) (N) Particle size (flocculation)
Pond depth (R) Viscosity (heating)
Customer School January 2004
 Bowl Cross Section

Liquid Differential speed ( ∆n )

weirs = rotor rpm - conveyor rpm Pitch
Pond
depth

Liquid level
(radius)
Solids
Pond Beach ports

Customer School January 2004

 Design Features

These are designed to give optimum performance

under the widest possible range of applications an
operating conditions encountered in drilling fluid
processing. Adjustments are easily made to
optimise performance at differing values of mud
weight, viscosity, solids distribution, etc., and to
select the particle size cut-point in classification
duties.v

Customer School January 2004

 Decanter Applications

Decanter centrifuges are specifically built for

oilfield applications, both onshore and offshore.
Adjustable operating parameters enable the
Decanters to be employed for a wide range of solids
control purposes in drilling fluid systems including.
Barite recovery from the active mud system or from
surplus mud in storage. Separation of drilled solids
from unweighted muds.

Customer School January 2004

 Construction

Decanter centrifuges and their associated drive

arrangements and electrical controls are integrated
and mounted on a typical oilfield subframe specially
designed to withstand long and hard use in the field.

The conveyor is specially designed for heavy duty,

high torque applications, with erosion protected feed
inlet. The bowl is built up in sections made of
centrifugally cast stainless steel.

Materials and bowl geometry are designed to assure

long-term continuous operation without risk of
clogging and with little need for field maintenance.

Customer School January 2004

 General dimensions

Bowl diameter 14”/353 mm

Bowl length 57½”/1460 mm
Lambda (slenderness ratio) 4.14
Volume 66 litres max.
Dependent upon liquid
radius
Max. bowl speed 4000 rpm
Normal operating range 1588-3415 rpm
Max. g-value 3157g
Normal operating g-value 498g - 2303g
Differential speed 0 to 104 rpm
Moment of inertia 9.0 kgm²

Standard seal material is nitrile, other materials can be

supplied on request.

Customer School January 2004

 Feed Rates & Additives

Solids capture can be improved by a reduction in

the feed rate.

In most cases Decanter centrifuges do a good job

of separation without benefit of chemical
additives. However, some fluids containing a high
proportion of colloidal fines, e.g. in drilling waste
applications, may need to be flocculated to make
them separable. Flocculent chemicals are
expensive, so it pays to exploit the other tuning
capabilities of the Decanter to the full in order to
minimise the dosage.

Customer School January 2004

 Barite recovery

Two-stage centrifugation, with barite recovery in the first stage

followed by clarification of the liquid phase for recycling to the
active mud system.

LGS Removal 2 Barite Rec. 1

Solids Overboard

Clean Mud to Active

Barite Flush
to Active

Feed Pump 2

Feed Pump 1

Customer School January 2004

 Bowl Cross Section

Liquid Differential speed ( ∆n )

weirs = rotor rpm - conveyor rpmPitch
Pond
depth

Liquid level
(radius)
Solids
Pond Beach ports

Customer School January 2004

 Drive System

The decanter is equipped with a hydraulic Voith

Coupling and belt-pulley for main drive and a belt
pulley system for the back drive, discharge funnels
for solids and liquid discharge as well as a gearbox
overload switch, cover open switch and vibration
switch. Fixed Speed
Electric Bowl Drive Motor

Fixed Speed Scroll

Planetary Gearbox

Customer School January 2004

 Bowl Speed

Depending on specification, DMNX Decanters are

equipped with a pulley system for a fixed speed
drive, or a variable speed turbo arrangement on
the main drive enabling the operator to adjust the
bowl speed between 1000 and 3415 rpm within a
few seconds. This option, combined with variable
conveyor speed, gives a new dimension to the use
of centrifuges for drilling fluids treatment.

The optimum speed for solids capture or for a

specified cut-point depends on the composition of
the drilling fluid and the nature of the solids.

Customer School January 2004

 Operational Parameters

g g
Differential speed ( ∆n )
R N

According to decanter design According to process parameters

Differential speed (∆n) Feed rate (Q)
Rotor speed (g-force) (N) Particle size (flocculation)
Pond depth (R) Viscosity (heating)
Customer School January 2004
 The Solids Control Layout

Equipment configuration

As important as the equipment itself.

Rules are:
• Each set of equipment takes suction from a dedicated pit.
• Discharge is to the next pit downstream
• Sandtraps are not required with good solids control and contribute
to excess waste.
• Minimise volume as much as possible. Less volume = less waste
• Pits must be agitated efficiently. Size agitators correctly
• Avoid excessive use of mud guns and circulation lines.
• Do not run pumps without reason

Some examples of configuration…

Customer School January 2004

 The Solids Control Sub-Process

Solids dump or waste treatment Decanter

Shakers

Flow
from Screened Degasser
well drilling
fluid
bore
Sand Adjust,
level
trap 1
2 3 4 5 6 control
to pits

A To Decanters
Dump/waste
B
treatment A = Desanders
(typical B = Desilters
for all tanks) C = Mud cleaners Catch
C Tank
Solids dump or waste treatment

Customer School January 2004

 Dual Decanter Installation Parallel

Shakers

Coarse solids Sand Tank 1 Tank 2 Tank 3

Trap
Fluid + fine solids
Pump
Clean fluid
Fluid +
Decanter Decanter fine
solids
Catch tank

Pump
Solids

Customer School January 2004

 Dual Decanter Installation Series

Shakers

Coarse
solids Sand Tank 1 Tank 2 Tank 3
Trap
Fluid + fine solids
Valve closed
Clean
Pump
fluid
Decanter Decanter Barite
return
Catch tank using
Jet jet
hopper hopper
Dilution
line
Clean fluid

Solids Pump

Customer School January 2004

 System for Unweighted Mud

Decanter processing
active mud. Cheap Return
to hole Low
mud with no discharge equalizer

limits.
Low
equalizer

Flowline Degasser Adjustable equalizer

normally high
Low Low Low
High
equalizer equalizer equalizer
weir

High Fluid
weir return

Sand Centrifuge
Screened
trap solids
dump Solids
discard Desander Desilter
discard
Solids discard
Customer School January 2004
 System for Unweighted Mud

Return
to hole Low
Decanter processing equalizer

mudcleaner
underflow. Low
equalizer

Flowline Degasser Adjustable equalizer

normally high
High Low Low Low
weir equalizer equalizer equalizer

Fluid
High return
Sand weir
trap Desilter Centrifuge
dump Screened
solids Solids
discard discard
Desander Underflows screened Fluid return
Customer School January 2004 Solids discard
 System for Weighted Mud

Return
Dual Decanter to hole
Low
equalizer
Installation in
Series Low
equalizer

Adjustable equalizer
Degasser
Flowline normally high

High Low Low Low

weir equalizer equalizer equalizer

High
Sand
weir
trap
dump Screened Mud cleaner Centrifuges
solids
Mud return Solids
discard
Screened Screen discard
solids underflow
discarded returned
Customer School January 2004
 Summary and Questions

So all that was Solids

Control, what about
Waste management?

Customer School January 2004

 Waste Management

What is Waste Management?

With increasing environmental legislation the
discharge from

Customer School January 2004

 Waste Management

Customer School January 2004

 Purpose of Waste Management

The primary principle of Waste

Management is the disposal of drilling
waste in a safe, economic and
environmentally responsible manner.

Customer School January 2004

 Waste Stream Identification
Sources of Contaminants Potential
Lubricants Environmental
Impacts
Crude Oil
Aquatic
Fuels
Ecosystems
Solvents
Land
Spotting Hydrocarbons
Ecosystems
Fluids
Human Health
Pseudo and
OB Air Emissions
Drilling Fluids

Customer School January 2004

 Waste Stream Identification

Sources of Contaminants Potential

Environmental
Impacts
Metals
Cuttings Chromium Aquatic
Ecosystems
Pipe Dope Cadmium
Land
Barite Lead
Ecosystems
Cr.-Lignosulfonates Barium Human Health
Hematite Mercury
H2S Scavengers
Selenium
Zinc, etc
Customer School January 2004
 The Fluid Process

ADDITIVES

SOLIDS
SOLIDS
WELL
WELL BORE
BORE MIXING
MIXING
CONTROL
CONTROL

SOLIDS + FLUID

WASTE
WASTE
MANAGEMENT
MANAGEMENT

Customer School January 2004

 Waste Management Processes

Site design
Identifying the right technology
Cuttings Handling
Cuttings Drying
Cuttings Injection
Bioremediation
Thermal Phase Separation

Customer School January 2004

 Waste Management Processes

Site design
Considerations are:
• Mud type
• Environmental legislation
• Cost
• Zero discharge, pitless or reserve pit
• Water table
• Weather
• Salinity

Customer School January 2004

 Waste Management Processes

Identifying the right technology

No environmental constraints BEM 3 Balanced Elliptical Single

Deck Shale Shakers

BEM 3 Mud Cleaner

Centrifuges, Barite Recovery,

High Dual/Single Systems, Degassers,
Efficiency Solids agitators.
Control Package
Cuttings Collection Systems,
Verti-G dryers.
Enhanced Equipment
Total containment systems
Haul away
Disposal Offsite
Dewatering
Zero Discharge/Pitless Drilling Water Purification
Site Remediation
Urban Applications Downhole Injection of Wastes

Customer School January 2004

 Waste Management Processes
Drilling
Waste Production. Fluids,
Cuttings with Drilling fluid no
longer
required

Return Water to
Site
Rain mud/mix system
Efficient water
solids
Control
Equip.

Segregation of Wastes

Old Mud, washwater, rain. all

is contained , segregated
Cuttings Waste Liquid wastes and processed through the
Dewatering unit

Transported from the shakers/

Collect
centrifuge

Contained for easy handling Dewatering unit

Liquid run off is collected
and treated by the
Dewatering unit
Segregated for best processing

solids are sent to the

cuttings treatment area
Transported

Treated for disposal

Disposal Options
Disposal
on /
Use on site or
offsite Non saline, non Oily cuttings
adjacent land
Stabilise/fix/
Only material to be Salty cutting, burry/haul
discharged is dry solids. away Stabilise, Bury,
Disposal options depends on Thermal Treatment,
Oily Cuttings,
character of material Reinjection.
Bioremediation

Customer School January 2004

 Waste Management Technologies

Waste Management Technologies

Finding the right piece of equipment for

the job!

Unlike Solids Control Equipment where

all systems look similar, waste
management has many different
technologies, each tailored fro need…

A few examples…
Customer School January 2004
 Cuttings Handling Systems

Augers
– Often the simplest
way to move
cuttings from one
location to another
– Limited by space,
rig layout and
distance

Customer School January 2004

 Cuttings Handling Systems

Typical Auger Setup:

Customer School January 2004

 Cuttings Handling Systems

Swaco Vacuum System

Advantages of Vacuum systems:

– Safer than Augers
– Able to rig up in hours
– Flexibility
– Able to be used in pit cleaning
operations

Customer School January 2004

 Cuttings Handling Systems

Typical Vacuum Setup:

Customer School January 2004

 Cuttings Handling Systems
Vacuum System Applications:

Customer School January 2004

 Cuttings Handling Systems

Swaco Cuttings Blower System

‘Clean Cut’

Advantages of Clean Cut:

– Minimize rig and boat space requirements
– Automation reduces manpower
requirements
– Expands cuttings transfer distances
horizontally and vertically
– Reduce power requirements for cuttings
transfer

Customer School January 2004

 Cuttings Handling Systems
How the Blower Works:

• Cuttings fed into the blower unit

• Cuttings are blown in pulses
• Can convey distances over 1000ft
Customer School January 2004
 Cuttings Handling Systems

Typical Blower Setup:

Customer School January 2004

 Cuttings Dryers

Vertical Dryers Drying Shakers

Customer School January 2004

 Cuttings Dryer Function

Process wet cuttings discharge from

shale shakers to reduce oil content and
return reclaimed drilling fluid to active
system

Customer School January 2004

 Verti-G Dryer

Description:
• Incorporates a high speed
rotating vertical basket
• Cuttings are separated by a
combination of centrifugal force
and screening
• The Dryer works on-line and
handles the entire shaker
discharge
• Cuttings dryness typically
averages between 4 and 6
percent by weight

Customer School January 2004

 Verti-G Flow Diagram

Material Feed

Screen
Basket Effluent Wet drill cuttings enter
into the top of the dryer
Cone

Rotor Dry drill cuttings exit out the

bottom of the dryer

Recycled drilling fluid is

recovered out the side ports

Dry Cuttings Discharge

Customer School January 2004
 Dryer Schematic

1
1 Feed
2
2 Charging Hopper
3 Cone Cap 7
4 Cone
8
5 Flights 3
6 Rotor
7 Screen Basket Detail of Basket
8 Screen & Screen
9 Motor 7 7
10 Drive Belts 8 8
11 Liquid Effluent Discharge 5 4
5
12 Dry Cuttings Discharge

Feed Material 6
Liquid Effluent
Dry Cuttings
9

11
10
12

SW 00014 P

Customer School January 2004

 Dryer Screen/Basket

Customer School January 2004

 Liquid / Solids Separation

Effluent Dry Cuttings

Customer School January 2004

 Typical Dryer layout

1 Flow Line Shaker

2 Mud Cleaner
3 Screw Conveyor
1
4 VERTI-G Cuttings Dryer
5 Cuttings Discharge
1
6 Recovered Mud
7 Catch Tank
8 Centrifuge Feed Pump
2 9 Centrifuge
10 Solids Discharge
3 11 Clean Mud to Active

11

10
8

6
7
5

Customer School January 2004

SW 00044 C
 Typical Offshore Installation

Customer School January 2004

 Cuttings Re-Injection

Purpose of CRI:
• It provides a solution for the
disposal of drilling waste material

• Compliance with environmental

regulations

• Can provide true zero discharge

Discharge

Customer School January 2004

 Cuttings Re-Injection

Description:
• Mechanical degradation of drill cuttings to form a slurry suitable
for re-injection
• Treatment of the cuttings slurry by dilution and chemical additions
to achieve the required density, viscosity and rheology for re-
injection

• To inject the slurry down suitable casing annuli, casing or tubing

and into a chosen formation sequence

• To ensure the long term containment of the slurry beneath a

suitable “Cap Rock” and to prevent propagation to surface The
Surface.
Customer School January 2004
Cuttings Re-injection
Annular Re-Injection Philosophy
Cuttings Separated,
Slurrified & Injected Platform
from the Surface

Wellhead Wellhead

Cuttings Slurry
Produced Oil Riser Riser
Drilling Fluid

30 inch Conductor 30 inch Conductor

Production and New Well being

900 metres

Re-injection Well Drilled

13 3/8 inch Casing 13 3/8 inch Casing

Impermeable Cap Rock Formation

Injection Zone

9 5/8 inch Casing 9 5/8 inch Casing

Reservoir
Drill Bit
7 inch Liner SW
Customer School January 2004
Cuttings Re-Injection
The Options

1 2 3 4 5
Existing Existing Drill & re-inject Existing Dedicated
production well production well simultaneously redundant well re-injection well

Injecting into Injecting into Re-inject above Injecting inside Injecting inside
20 x 13 3/8 inch 13 3/8 x 9 5/8 inch reservoir, then drill 9 5/8 inch redundant dedicated
annulus. annulus. to TD and produce. well. well.

20" 20" 20" 20"

Injection
Zone

13 3/8" 13 3/8" 13 3/8" 13 3/8" 13 3/8"

Injection Injection
Depleted
Zone Zone
Reservoir

9 5/8" 9 5/8" 9 5/8" 9 5/8" 9 5/8"

Injection Injection
Reservoir Zone Zone

Cement 7"

SW 97058 C
Customer School January 2004
 Dual Tank Slurry Unit

• Length 6000mm (19’ 8”)

• Width 3000mm (9’ 10”)
• Height 2700mm (8’ 9”)
• Dry Weight 19,000 kgs
• Wet Weight 45,600 kgs
• 4 x 75HP Shear Pumps
• 2 x 50bbl tanks
Customer School January 2004
 Slurry Process

Customer School January 2004

 Particle Reduction / Slurry
Slurry Characteristics
– Reduce sand and surface gravel (and sometimes
clay balls) to an injection grade size
– Reduction devices include: horizontal ball mills,
vertical and horizontal crushers and multi-shear
technology.

Slurry Characteristics
• Weight: 9.5 – 12 ppg
• Viscosity: 60 – 90 sec/quart
• Solids Content: 20 – 30%
• Max. Particle Dist. (D90)< 300 µm

Customer School January 2004

 Tungsten Carbide Impeller

Customer School January 2004

 Classifying Shaker

• Insures limitation of
particle size in slurry
• Directs oversized
particles to reduction or
storage loop
• Directs undersized
particles to injection
holding tank
• Protects well and
pumping equipment

Customer School January 2004

 Typical CRI Layout

1
1 Rig Shaker
2 Cuttings Ditch
3 Centrifuge Underflow 12
4 SlurrificationUnit 1
3
18 18
5 Coarse Tank
1 9
6 Coarse Tank Circulating 4
Pump
7 Fines Tank 1
8 Fines Tank Circulating Alternative Feed to
Pump Coarse Tank using Augers 5
1
9 Agitator
10 Seawater Supply 2
11 Drain Water & Slops
9
12 Classifying Shaker 12
13 Batch Holding Tank
17
14 Holding Tank Pump
15 H.P. Injection Pump
9 13
16 ReinjectionWellhead
17 Flushing Line 9 14 15 16
18 Screw Conveyor 4

7
8
11 5
8
10 6

SW 01088

Customer School January 2004

 Bioremediation

What is Bioremediation?

A natural process where adapted

microorganisms degrade hydrocarbon to a
more elementary chain that can be easily
reduced to environmentally acceptable
Carbon compounds

Customer School January 2004

 Bioremediation

Bioremediation Options
• Land Farming
• Phytoremediation
• Biopiles
• Slurry phase bioreactors
• Aerated Biopiles/composting
• Worm driven waste management
(Vermiculture)

Customer School January 2004

 Land Farming

A
Eq cce
u ip s s
m e fo r
nt

1
LL
CE
50
m

Dump Truck

3
LL
CE Back Hoe

2
LL
CE
Tractor m
with Disc 50
Hay Bales
t
to en
te r s tm a l
W a A d j u is p o s
Water al D
Ditch F in a n d

Pump

O il Skimmer

Customer School January 2004

Typical Land Farming Site Layout
 Biopiles

Moisture and additional nutrients added (if required) via perforated plastic pipe
Cover

Temperature
logging points

Cuttings + Bulking agent (straw/woodchips) + Nutrients (manure)

Humidified air via perforated plastic pipe buried in pea gravel

(NB a pile 2m high may require another layer of aeration pipe at 1m)

Impermeable liner + leachate collection/treatment system

Customer School January 2004
 Vermiculture
• Vermiculture = Worm Driven
• Initial results (below) look very
Waste Management
promising, more field tests
• Used in New Zealand (Shell currently underway
Westech + Swift Energy) to
Total hydrocarbons by GC-FID (OIEWG carbon bands; mg/kg dry wt)
remediate PARALAND drill Cuttings + Sawdust 0 4 10 13 19 21 28 Days
Carbon No
cuttings and incorporate them C7-C9
C10-C14
<600
41300
<80
4600
<50
2700
<8
140
<7
127
<7
82
<20
<30
<20 mg/kg dry wt
<40 mg/kg dry wt
into fertilizer C15-C36
Total
<2000
41000
<300
4600
<200
2700
<30
150
40
170
<30
110
<60
<100
<80 mg/kg dry wt
<100 mg/kg dry wt

Total hydrocarbons by GC-FID (OIEWG carbon bands; mg/kg dry wt)

5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
0 5 10 15 20 25 30
Days

Customer School January 2004

 Slurry Phase Bioreactors
• Cost effective,
transportable high Bacteria, pH, Nutrients

efficiency bioreactor
based on application of Principal
Bioreactor

waste water treatment Holding

Holding Tank
Pre-
Treatment

technology to create a
Partial Reuse of

highly aerated fluidised Water and Re-

Inoculation of

bed reactor in a barite silo Bacteria Aeration

or similar tank Secondary

De-watering Bioreactor or

• Bioreactors give better

Land Farming
if Required

Oily Cuttings
process control than with or Sludge

existing biological
Clean Soil / Cuttings

methods

Customer School January 2004

 Thermal Phase Separation

Description
•A process which uses indirectly
applied heat to vaporize and remove
hydrocarbon contaminants and water
from OBM cuttings or oil contaminated
soil.
•The indirect heating of oily cuttings
and waste to remove through
volatilisation the water and oil in gas
form, then to cool and condense the
gases into liquids for recovery.
•Typically treated cuttings will contain
less than 1.0%hydrocarbons and are
often as low as 0.05%.

Customer School January 2004

 TPS Process Overview

HX RB I

OWS

W O
HX
HX – Heat Exchanger
RB – Roots Blower
I – Impinger
OWS – Oil/Water Separator
W – Recovered Water
O – Recovered Oil January 2004
Customer School
Thermal Phase Separation
Extraction Chamber Schematic Diagram
7
7

5
6

2 2

1 1

4
3

6 1
6 5

2
1
1 Oil Contaminated Cuttings 2
2 Screw Conveyor 1
3 Burner
4 Firebox 4
3
5 Extraction Chamber
6 Vapours
7 Exhaust Gas

SW 0109
Customer School January 2004
 Air emissions are limited to the Separated H2O is pumped through a
combustion of fuel gas surge tank to a cooler unit prior to
discharge or re-circulation to the Quench
Header

Feed up to
60% liquid

Volatilized hydrocarbons
forced into the overhead
Condensate is pumped Quench Header
to the Oil/Water
Separator where Passes through a rotary paddle airlock
recovered hydrocarbons to the indirectly heated Extraction
are drawn off Chamber
Customer School January 2004
Treated Solids are discharged with <0.1%TPH
 Waste Management / Solids Control
Summary

• Solids Control: Primary purpose is to

maintain fluid properties while
minimising dilution

• Waste Management: Concerns the

processes used to handle and treat
solid and fluid waste generated by the
drilling process for environmental and/or
economic reasons

Customer School January 2004