March 2024

The evolution of solids control in industrial equipment has seen significant changes as drilling becomes more challenging and environmental concerns grow increasingly paramount [1]. This progression has been crucial in maintaining the efficiency and environmental compliance of operations across various sectors, such as HDD, dewatering, construction projects, and especially in the oil drilling rig landscape. Advances in solid control equipment, including desanders, shale shakers, mud tanks, and centrifuges, have been pivotal in refining processes and reducing the negative impact of drilled solids on drilling costs and performance [1].Understanding the intricacies of solids control management, from employing shale shakers and desilters in solids control oilfield operations to optimizing shaker screens for better fluid recovery, is more than just an operational necessity; it’s an economic strategy [1]. Our article delves into the technological advancements in solids control, best practices for its management, and the undeniable economic and environmental benefits. We explore how innovations in solid control jobs and equipment have reshaped the landscape of the oil industry and beyond, ensuring more sustainable and cost-effective outcomes [1].Overview of Solids Control EquipmentIn our exploration of solids control equipment, it’s crucial to understand the components that play pivotal roles in the process:Shale Shakers and Screens: Acting as the first line of defense, shale shakers remove large solids like rocks and cuttings from the drilling fluid, while screens, adhering to the new API RP 13C labeling procedure, fine-tune this process by filtering finer solids [10][12][15][5].Hydrocyclones (Desanders and Desilters): These convert pressure into centrifugal force, effectively separating suspended solids from the drilling mud. Desanders focus on particles sized 47-74μm, and desilters further refine the process [4].Vacuum Degassers and Centrifuges: Vacuum degassers ensure the drilling fluid’s density by removing gas, whereas centrifuges tackle heavy solids and lighter components of the liquid, utilizing centrifugal force for a more detailed separation [10][14][4].These components, from the initial separation by shale shakers to the fine-tuning by centrifuges, underscore the sophistication of modern solids control systems. They not only enhance drilling efficiency but also contribute to the environmental and economic benefits by optimizing the reuse of materials and minimizing waste [2][3].Technological Advancements in Solids ControlIn the realm of solids control, Here are some key developments:High ‘G’ Force Linear Motion Shakers: These shakers are adept at handling various ground conditions, making them a versatile choice for solids control. Their high ‘G’ force effectively separates solids from drilling fluids, optimizing the drilling process [5].Automated Monitoring Systems: The integration of instrumented surface measuring technology allows for real-time monitoring of the circulating system and solids control equipment. This automation ensures optimal performance and adherence to environmental standards [9].Equipment Evaluation through Material Balance Studies: Conducting material balance studies is essential for assessing the efficiency of solids control systems. This evaluation helps in identifying areas for improvement, ensuring the equipment operates at its best [10].Advancements in Horizontal Directional Drilling (HDD) technology also play a crucial role in the evolution of solids control. Innovations such as self-contained drilling rigs, advanced navigation systems, and the use of fusible pipes enhance the effectiveness and efficiency of HDD projects [11]. These technological advancements not only improve operational performance but also contribute to the environmental and economic benefits of solids control in industrial equipment.Best Practices for Solids Control ManagementIn managing solids control effectively, several best practices stand out for their critical role in enhancing drilling operations while minimizing environmental impact and operational costs [14].Equipment Efficiency: Ensure all solids removal treating equipment can process at least 100-125% of the mud circulation rate. This capacity is pivotal in preventing the accumulation of unremoved solids, which become increasingly difficult to remove with each circulation cycle [15].Screen Selection and Maintenance:Utilize the smallest mesh screen possible on shale shakers, adapting to different formations as necessary [15].Maintain a comprehensive inventory of recommended spare parts and screens to facilitate timely replacements [15].Operational Best PracticesAssign certified rig personnel specifically for the operation and maintenance of equipment to ensure expertise and accountability [15]Ensure the system is hydraulically balanced, capable of making both scalp and fine cuts, and has adequate drilling fluid mixing and re-circulating capacity [15].Avoid bypassing shale shakers or other solids control equipment during drilling to ensure maximum efficiency [15]Advanced Techniques and Regular MonitoringImplement decanter centrifuges for achieving extremely fine cut points, allowing for rapid settling of solids under controlled conditions [15].Conduct regular testing for viscosity, mud weight, sand content, pH, and total hardness to monitor the health of your drilling fluid effectively.By adhering to these best practices, operations can significantly enhance the effectiveness of their solids control management, leading to improved efficiency, reduced costs, and a lesser environmental footprint.Economic and Environmental BenefitsWhen we delve into the economic and environmental benefits of effective solids control in industrial equipment, the advantages are both broad and significant. Here’s a closer look:Lower Operational Costs:Reduced fluid dilution rates mean less need for expensive fluid replacements, directly lowering operational expenses [36][37].Efficient removal of solids leads to a decreased volume of required additives, translating into cost savings [36][37].Enhanced Drilling Fluid Properties:Improved properties of drilling fluids allow for higher flow rates and extended fluid life, optimizing the drilling process and reducing the need for new fluids [36][37].Waste Management and Environmental Protection:Reduced waste management costs are achieved through compliance with environmental and regulatory standards, minimizing the financial burden associated with waste disposal [36][37].The adoption of a closed-loop system minimizes environmental risks and spills by eliminating the need for conventional reserve pits [36][37].Closed-loop systems also play a crucial role in reducing the risk of drilling fluid spills, further safeguarding the environment [36][37].Additional Economic and Environmental Benefits:The implementation of solid control systems not only extends fluid life but also minimizes water usage and transport needs. By returning solids-free liquid back into the fluids system, it contributes to operational efficiency and environmental sustainability [7].These benefits highlight the importance of solids control not just from an operational standpoint but also in promoting environmental stewardship and economic efficiency. By investing in properly maintained equipment, companies can significantly reduce the cost of drilled solids removal, making it a wise and necessary investment for modern drilling operations [10]. References[1] – https://drillingfluid.org/drilling-fluids-handbook/historical-of-economics-solids-control.html[2] – https://www.thedriller.com/articles/92916-solid-control-equipment-types-and-usage[3] – https://www.linkedin.com/pulse/solid-control-equipment-ensuring[4] – https://trenchlesspedia.com/definition/4351/solids-control-equipment-drilling-fluid[5] – https://trenchlesstechnology.com/good-practices-in-solids-control/[6] – https://supplychaingamechanger.com/why-solids-control-is-a-game-changer-for-the-oil-industry/[7] – https://diamondtservices.com/blog/top-3-ways-solids-control-can-help-the-environment/[8] – https://www.linkedin.com/pulse/solid-control-equipment-market-trends-f5ucf[9] – https://www.thepanthercompanies.com/blog/solids-control-understanding-critical-components-to-improve-the-drilling-process[10] – https://drillingfluid.org/solids-removal-equipment-operation-guidelines/solids-control-economic-evaluation-mechanical-equipment.html[11] – https://solidscontrolworld.com/blog/advancements-in-hdd-technology-how-new-equipment-is-changing-the-industry/[12] – https://www.slb.com/products-and-services/innovating-in-oil-and-gas/drilling/drilling-fluids-and-well-cementing/solids-control[13] – https://www.gilmore.com/well-completions-technology-product-advancements/[14] – https://diamondtservices.com/blog/maintenance-and-best-practices-for-solids-control-equipment/[15] – https://trenchlesstechnology.com/the-principles-of-effective-solids-control/[16] – https://elginseparationsolutions.com/wp-content/uploads/2018/09/Principles-of-HDD-Solids-Control-and-Buyers-Guide-7-25-2018.pdf

March 2024

The Evolution of Solids Control in Industrial Equipment