IDEC Solid Control 2
IDEC Solid Control 2
Warehouse
Environment
Wellbore
Health, Safety and the Environment
High solids content can have an adverse impact on health, safety, and the
environment:
●
Health and Safety
■
Higher swab and surge pressures
■
Higher ECD
■
Gas-cut mud
●
Environment
■
Increase in volume discharged or carried off for disposal
■
Higher material consumption
■
Increase in fluid transportation, storage, and reconditioning
Types of Solids
●
High Gravity Solids ( HGS )
■
Weighting materials added to increase density (SG > 3.0 )
●
Low Gravity Solids ( LGS )
■
All other solid material ( SG < 3 )
●
LGS may be intentional solids such as:
■
Viscosifiers
■
Fluid Loss Additives
■
Shale Stabilisers
●
Or unintentional drilled solids
Solids Classification
Table: Solids Classifications
Category Size (m) Types of Particles Solids Control
Equipment
■
The increased hydrostatic head may
also result in differential sticking
0
0 3 6 9
●
API have introduced new classification: A x B ( C x D, E)
A = number of openings per inch in the flow direction
B = number of openings per inch perpendicular to flow
C = Opening size in the flow direction (microns)
D = Opening size perpendicular to flow (microns)
E = Percent of open area of the screen
For Example: 60 x 60 (234 x 234, 30.5)
●
This system cannot be applied to complex weaves
Screen Motion
Three types of motion
●
Conveys solids to the solids discharge
end
Linear
●
Allows liquid to pass through the
screen
●
Creates a limited amount of G-forces Elliptical
●
For solids conveyance
■
Linear motion is considered best Circular
■
Elliptical is second best
■
Circular motion is considered worst
Screen Capacity
Capacity depends on: Screen Plugging
●
Screen size, surface area and condition
●
Amount, size and type of solids in fluid
●
Solid layer permeability
●
Fluid type and properties (density,
viscosity, surface activity)
●
Screen angle, motion and vibration
amplitude
Screen Capacity
2,000
1,000
0
0 10 20 30 40 50 60 70 80
100
200 Square Mesh Screen
SHAKER A
60
40
SHAKER B
20
0
20 30 40 50 100 120 160 200 300
Particle size in microns
Screen Cut Point
100
120 Mesh - WBM, 9.0 ppg, 10 cP
60
40
20
0
20 30 40 50 100 120 160 200 300
Particle size in microns
Operational Remarks
NEVER by-pass the shale shakers If screens plug try finer screens first
ALWAYS use the finest mesh possible Keep a complete range of screens - spares should
be at hand to make quick screen changes
Regulate the flow over the shakers The best screen repairs are made with Devcon -
silicon sealant can also be used but does not last
Monitor the shakers and screens continuously If > 10% of the screen has been repaired, use a new
screen
Choose screens and adjust angle to keep fluid covering Ensure maintenance program is followed
2/3 of the screen
Keep record of screens in use and hours run Keep a record of which screens are in use close to
the shakers for all to see
Switch shakers off during trips to prolong screen life Keep old screens well stacked and labelled
Use only one shaker when RIH When using OBM clean screens with high pressure
base oil - not water
Advantages and Disadvantages
Simple to operate Flow rate dependent on mud properties
Reliable Constant shaker watch required
Cut point is independent of mud properties Expensive, relatively high running costs, large
footprint
If screen aperture is known the cut point is defined Screens may develop tears (especially fine screens)
Able to process relatively large volumes Bottom screen of double deck shaker difficult to
inspect
Easy to inspect (except for bottom screen on double deck Screens may plug with near-sized particles (sand,
shaker) LCM, ...)
Solids can be removed before mechanical degradation Screens may blind (active clays, polymers, water-
occurs wet solids in OBM)
Mechanical failure or rig movement may cause
excessive mud loss
Adjustments to drilling parameters or screen size
are required when mud temperature, weight,
viscosity, or solids loading changes
Installation
●
Cascade System - The fluid goes over a conventional circular motion shaker
(scalping shaker) to remove the larger particles prior to going over a linear motion
shaker.
●
Mud-Cleaner - The shaker can also be used as a mud cleaner when desilting cones
are mounted above the shaker.
●
Access - The shakers should be installed such that the screens can be changed easily,
both the actual replacement and the tensioning of the screens.
●
Ventilation - Required (either natural or forced ventilation) in the shaker-house to
prevent the accumulation of vapors. Ventilation is especially important with OBM.
Sand Trap
The sand trap in a drilling rig is a device used in the solids control system to remove sand and other
heavy particulates from drilling fluid before it is recirculated back into the well. It helps protect
downstream equipment like mud pumps, shale shakers, and desanders from excessive wear and damage
caused by abrasive particles.
●
The sand trap is a gravity settling pit
●
Due to short residence time and small particle size in underflow - not very effective during normal
drilling conditions
●
If the shale shaker screens never ripped then the major justification for a sand trap would disappear
●
Fluid should exit trap at opposite side via an overflow gate
●
Sand trap should have a sloping bottom and dump valve to discharge solids without discharging
excess fluid
●
It should not be dumped during mud circulation
●
It should be by-passed when weighted muds or OBM are used
●
Dump valve should be locked shut if OBM is used
Degasser
The degasser is a critical piece of solids control equipment used to remove entrained gases, such as
methane (CH₄), hydrogen sulfide (H₂S), and carbon dioxide (CO₂), from the drilling mud. Removing
these gases is essential for maintaining mud density, preventing blowouts, and ensuring safety on the
rig.
●
The shale shaker and circulating system are not very effective at removing gas from the mud,
especially at higher mud weights
●
Centrifugal pumps, hydrocyclones and the rig pumps loose efficiency if the mud is gas cut
●
The degasser should be installed between the sand trap and the first hydrocyclones
●
When the degasser is not in use its suction pit should be kept empty to prevent blocking of the
suction line due to solids settled from the mud
Equalization
●
Each piece of equipment, except the centrifuge, is (normally) able to process a
volume larger than the circulating rate
●
Equalising gates between the pits prevent any one pit from sucking dry
●
The equalizers are positioned in the separating pit walls at either a high or a low
position (over and under flow)
●
An overflow from one tank to the other ensures:
■
Sufficient suction for pumps
■
Constant volume level (required for kick detection)
●
An underflow from one tank to the other ensures:
■
Prevention of solids accumulation on the bottom of the pit
Separation Efficiency
The separation efficiency of hydrocyclones depends on four general
factors:
●
Hydrocyclone design
●
Flow parameters
●
Fluid properties
●
Particle properties
Hydrocyclone Design
The main design variables that control the hydro cyclone
performance are:
●
Cone diameter
●
Cone angle
●
Cylinder length
●
Feed inlet diameter
●
Apex (underflow) diameter
●
Vortex finder
●
Cone material
Flow Parameters
●
Underflow opening on most hydrocyclones can be adjusted to obtain optimum feed
head
■
Apex diameter is increased to correct for excessive feed head
(lowers balance point reducing centrifugal force and in turn lift force)
■
Apex diameter is decreased to raise the balance point to correct for low feed head
●
Excessive feed head will give rise to
■
Reverse flow above the apex causing dryer cuttings liable plug the unit
■
Increased bowl wear
●
Low feed head will cause balance point to fall outside cone
■
Excessive liquid exiting the apex, characterised by rope discharge
■
This is an inefficient condition for hydrocyclones in normal use
Particle Properties
●
Particle characteristics are important in separation efficiency
■
Particle size and shape
■
Particle density
■
Solids concentration
●
Effect of particle density and size on settling velocity is clearly shown by
Stoke's law
●
Particle shape also influences its settling behaviour
■
Oblong shaped particles, because of their high drag coefficients, will be retarded
more than spherical shapes
●
Fine particles will carry more liquid than an equal volume of coarse
particles
Particle Properties
●
Volumetric concentration of solids can pose settling problems
■
Viscosity increase
■
Particle-to-particle interference
■
Overloading
●
Overloading occurs when
■
Solids concentration in feed is too high
■
Solids are coarse enough to settle
■
As a result more particles are delivered to apex than can be discharged
●
Overloading is characterised by
■
Rope discharge
■
Increase in median cut point
Desilter Cut Point
100
WBM - 8.6 ppg, 12 cP
40
20
0
20 30 40 50 100 120 160 200 300
Particle size in microns
Cut Point Comparison
100 0
90 3” - Spray 10
4” - Spray
50 50
40 60
30 70
API 200 MESH
20 80
10 90
100
0 10 20 30 40 50 60 70 80 90 100
Equivalent mean particle size diameter (micros)
Cut Point and Feed Solids
100
90
80
70
Separation Efficiency (%)
Total Solids 2% 4% 8% 16 % 16 %
60 in feed (% v/v)
50
D50 Cut Point
17 30 60 85 160 4” Hydrocyclones
40 (microns) 50 gal/min, 75 ft of head
30
Particle size distribution
20 of feed solids held constant
10 1 10 100 1000
0 Particle Size (Microns)
Adjustable Parameters
●
Only variable is apex diameter which should be adjusted to obtain spray
discharge
●
Operating feed "pressure" and cone capacity remain relatively constant
(around 75 feet of head)
●
Some manufacturers’ cut-point data was determined during tests using
water, thus published figures are better than one would expect with mud
Liquid level
(radius)
Solids
Pond Beach ports
Decanter Centrifuge
Solids Solids discharge with
absorbed liquid only
Colloidal
liquid
discharge
Feed inlet
Gearbox
Colloidal
liquid
discharge
Pool level controlled Feed ports Beach
by weir settings
Centrifuge
Centrifuge efficiency and capacity depend on its design features
and operating parameters
●
Design Features
■
Bowl diameter
■
Bowl shape
■
Conveyor design
■
Torque protection and metering
●
Operating Parameters
■
Feed rate
■
Bowl and scroll speed
■
Pool depth
■
Mud characteristics
Feed Rate
●
Feed rate can be readily adjusted - it should remain constant at the
selected capacity
●
To prevent solids degradation centrifugal pumps should not be used
●
Positive displacement pumps driven by a variable speed motor to
adjust the feed rate are most commonly used
●
Feed rate determines the residence time - high feed rate will result in:
■
Shorter residence time
■
Poorer cut point
■
Larger solid recovery in mass per unit time
Bowl and Scroll Speed
●
Bowl speed controls the centrifugal force - it can be altered on many centrifuges
(1,500 - 3,500 RPM)
●
Scroll rotates in same direction as bowl but at lower RPM (on some machines the
scroll rotates faster than the bowl)
●
Scroll speed is controlled by differential speed selector which operates the gear
box - typical gear box has a ratio of 80:1
●
Slower conveyance results in:
■
Increased torque
■
Drier cuttings
■
Greater risk of plugging the centrifuge
●
Faster conveyance results in:
■
Reduced torque
■
Wetter cuttings
■
Bigger pool disturbance resulting in poorer cut points
Advantages and Disadvantages
Advantages
●
Low cut point
●
Removes solids in the driest possible form
Disadvantages
●
Complicated operations, especially start-up and shut-down procedures
●
Fine HGS and coarse LGS may be separated simultaneously resulting in recycling of
LGS during barite recovery or removal of HGS in solids removal
●
Removal of essential mud solids such as viscosifiers and excess lime
●
Limited throughput (this may be an advantage if mud properties are severely
affected by removal of essential solids)
●
High rental and purchase cost
●
High operating costs due to wear
Installation
●
To make best use of the centrifuge, use the following as feed:
■
Returns to the active
■
Mud cleaner underflow
■
Mud from active pit
■
Mud from reserve system
(Last two options required to centrifuge the mud system during trips or other times
when mud not circulating)
●
Divert the solid and liquid effluent to either the dump-chute or active
system. The following is required for the dump-chute:
■
True vertical drop (preferably with flushing system)
■
If not true vertical, at least 45° (must be fitted with a flushing system)
■
Sufficient diameter
■
No 'crooked' lines or sharp bends
Installation
●
When solids are diverted back to active, sufficient energy
should be available to re-suspend the solids into the liquid
■
Installing a strong agitator in the receiving pit
■
Installing a hopper underneath the solids discharge (similar to the
mixing hopper) - this could be fed from the desilter overflow
●
Oil recovery centrifuge installations
■
Normally have less versatility
■
Require special feed pump
■
Units should be skid mounted
■
Normally returned to base when not required
The
Equipmen
t!
Solids Control System
Solids Control Overview
Waste Stream
Decanter Decanter
Shakers
Degasser
Waste Stream
Mudcleaner
• The design objective of any solids control system should be to achieve step-
wise removal of progressively finer drilled solids.
• This allows each piece to optimize the performance of downstream
equipment.
Solid control optimum cut points
High Speed
Centrifuges
Low Speed
Centrifuges Mud Cleaners and
Desilters Desand
% ers
High Performance Shale
Shakers
Barite
3% > 74 Microns
5% > 44 Microns
Drille
d 1000 Micron = 1 Millimetre = 1/40 inch
Solids
Particle Size (microns) 44 74 150 300 1000
Specific Surface Area 23 13 6.7 3.3 1
Ultra-Fine Fine Medium Intermediate
Solid Control and Mud treatment Services
Why choose IDEC for solid control and mud treatment services?
• IDEC’s solids control equipment enhances drilling
Drilling Efficiency and fluid quality, reduces mud dilution, and improves
Environmental cuttings drying—essential for environmental and
Compliance economic demands.
5 - 10
Mud Cleaners
5 - 10
Desanders
10 - 15
Desilters
30 - 40
Decanting Centrifuges
D96!!!!
Barite
3% > 74 Microns
5% > 44 Microns
Drilled Solids
1000 Micron = 1 Millimetre = 1/40 inch
The IDEC 2080 ‘ECHO’ VFD Decanter Centrifuge has been designed to
process large volumes of fluids, improve barite recovery and produce solids
that meet environmental regulations for disposal.
The 2080 ‘Echo’ decanter centrifuge is manufactured utilizing the highest quality
materials and state of the art manufacturing techniques.
The 20”x 80“rotating assembly is constructed entirely of 2205 Duplex stainless steel and
is dynamically balanced to the applicable ISO standards to ensure reliable operation in
demanding high speed applications.
IDEC 1456 VFD Decanter Centrifuge
The 1456 decanter centrifuge is manufactured utilizing the highest quality materials and state of the art manufacturing
techniques.
The 14"x 56" rotating assembly is constructed entirely of 316 stainless
steel and is dynamically balanced to the applicable ISO standards to
insure reliable operation in demanding high speed applications.
FEATURES:
Dynamically balanced 316 Stainless Steel Rotating Assembly
VFD/ HMI Control Panel
No A/C or Purged Air Required
PLC Real Time Controller
C1/ Zone 1- 15” Cooler Touch Screen
Optional Communication Package with Remote Accessibility
Optional Communication Package with Remote Accessibility
through Secured
IDEC 1656 VFD Decanter Centrifuge
The 1656 decanter centrifuge is manufactured utilizing the highest quality materials and state of the art
manufacturing techniques.
The 16"x 56" rotating assembly is constructed entirely of 2205 Duplex stainless steel and is dynamically
balanced to the applicable ISO standards to insure reliable operation in demanding high speed applications.
PERFORMANCE SPECIFICATIONS: FEATURES:
Dynamically Balanced 2205 VFD/ HMI Control Panel
Duplex Stainless Steel Rotating
Assembly
Max Bowl Speed of 3700 rpm. No A/C or Purged Air Required
IDEC 18-inch (450mm) decanter centrifuge is an economic centrifuge, popular for drilling mud
treatment.
FEATURES:
Duplex Stainless Steel Grade 2205 made by centrifugal casting as Bowl
Material
Stainless Steel 316 conveyor and main body resist corrosion and
prolong service life.
Tungsten alloy tile protects conveyor from wearing and increases solids
conveying efficiency.
Replaceable tungsten carbon allay ring protects solids discharge port.
75
Solid Control and Mud treatment Services-Degasser
78
Vertical Cuttings Dryer
The IDEC Vertical Cutting Dryer uses centrifugal force to dry drilled
solids in oil or synthetic base fluids. A stainless-steel screen bowl
traps “wet” solids and accelerates them up 900 RPM with G force
to 420G
The liquid is forced through the screen bowl openings, while “dry”
solids are extracted by the angled flights attached to the cone,
which rotate slightly slower than the bowl. Tungsten carbide
protects the flights from abrasive solids and ensures long
operational life. This aids in maintaining a constant gap between
the scroll and screen bowl, which is crucial for proper operation.
Features:
•More Application: Working for OBM and SBM
•High G Force: Normal 420G @ 900RPM, optional to drive by VFD with variable speed.
•FAG Brand premium bearing.
•The Flights on the rotor is hard facing to HRC 65, longer life than our competitors.
•Special high-pressure air knife design to clean the basket screen automatically to avoid the
screen blinding especially for high viscosity mud and water-based mud.
79
Solid Control and Mud treatment Services-Dewatering
FEATURES
• Recovered Water from the Dewatering process may be
recycled or re‐used for the following:
• Returned direct to the active mud system, as dilution
83
Screen Technology
Different Types of IDEC Screens
IDEC Shaker Screens
Replacement Screens Available for the
following Models:
Various oil smudges come from different areas; the sludge conditions may be different from each other. For a
suitable solution for recovering the valuable liquid from the sludge, the following questions need to be clear
for IDEC to provide the best proposal for your oil sludge treatment Plant.
IDEC Contract History
Description Contract (1) Contract (2) Contract (3) Contract (4) Contract (5) Contract (6) Contract (7) Contract (8) Contract (9) Contract (10)
d) Date of Commencement 5/2/2015 5/5/2014 1/3//2013 2/9/2013 30/11/2015 2016 2017 2017 2020 2019
e) Date of Completion 20/10/2015 30/1/2016 28/2/2016 1/9/2015 31/3/2016 2017 2019 2019 2022 2025
IDEC Contract History
Description Contract (11) Contract (12) Contract (13) Contract (14) Contract (15) Contract (16) Contract (17) Contract (18) Contract (19) Contract (20)
UAQ Petroleum
Ltd./Arawak
ADNOC Drilling
a) Client DNO Pearl (Dana Gas) HKN Energy Genel Energy Rosneft Western Zagros Energy ADNOC Offshore ADNOC Offshore
Services
International
Limited
United Arab United Arab United Arab United Arab
KURDISTAN KURDISTAN KURDISTAN KURDISTAN KURDISTAN KURDISTAN
b) Location/Country Emirates Emirates Emirates Emirates
REGION OF IRAQ REGION OF IRAQ REGION OF IRAQ REGION OF IRAQ REGION OF IRAQ REGION OF IRAQ
Umm Al Quwain Abu Dhabi Abu Dhabi Abu Dhabi
THE PROVISION THE PROVISION THE PROVISION THE PROVISION THE PROVISION THE PROVISION THE PROVISION THE PROVISION THE PROVISION THE PROVISION
OF DRILLING OF DRILLING OF DRILLING OF DRILLING OF DRILLING OF DRILLING OF DRILLING OF SOLIDS OF FILTRATION OF SOLIDS
FLUIDS, SOLIDS FLUIDS, SOLIDS FLUIDS, SOLIDS FLUIDS, SOLIDS FLUIDS, SOLIDS FLUIDS, SOLIDS FLUIDS, SOLIDS CONTROL EQUIPMENT & CONTROL,
CONTROL CONTROL CONTROL CONTROL CONTROL CONTROL CONTROL EQUIPMENT & SERVICES FOR FILTRATION &
EQUIPMENT, EQUIPMENT, EQUIPMENT, EQUIPMENT, EQUIPMENT, EQUIPMENT, EQUIPMENT, SERVICES THE WASTE
WASTE WASTE WASTE WASTE WASTE WASTE WASTE COMPLETION MANAGEMENT
Contract Brief Scope of MANAGEMENT MANAGEMENT MANAGEMENT MANAGEMENT MANAGEMENT MANAGEMENT MANAGEMENT EQUIPMENT &
c) service
SERVICES SERVICES SERVICES SERVICES SERVICES SERVICES SERVICES SERVICES FOR
ONSHORE &
OFFSHORE
d) Date of Commencement 2017 2018 2016 2020 2021 2022 2016 2017 2019 2021
e) Date of Completion 2018 2019 2019 2022 2022 2025 2017 2023 2023 2024
f) Contract Value in USD 4 4 9 15 4 12 3 5.8 M 5M 8.2 M
IDEC Contract History