GN Solids Control can design and make various type of mud cleaning system to suit for various applications.

Drilling mud solids control system for Oil and gas drilling is the multi-tank mud system, like Silting mud tank ( Shaker Tanks), Active Mud Tank, Suction Mud Tank, Mixing Mud Tank, Storage Mud Tank. GN Solids Control can offer complete turn key solution. Drilling mud solids control system is also called solids control system, or mud circulation system for the oil gas drilling rigs. GN Solids Control makes oil drilling mud system available for different oil drilling rig sizes from small rig 250HP to deep drilling rigs up to 3000 HP with various capacity.

GN Solids Control can design and manufacture hydrovac slurry processing system, which is also called as Slurry Dewatering System, in some countries, like in U.S.A, Canada, Australia, New Zealand, it can also called as hydrovac slurry waste treatment or waste slurry management system.

GN Solids Control can design and manufacture Mud Recycling System for water well drilling, Horizontal Directional Drilling (HDD) and CBM drilling rig.

GN Solids Control is a top manufacturer of Horizontal Directional Drilling (HDD) Mud Equipment / HDD Mud Recycling System. GN Solids Control drilling mud recycling system has been applied in many countries for HDD and CBM drilling operation. Especially popular in Singapore, Indonesia, India etc. GN Solids Control can offer Self-Contained Mud Recycling System with model as below: GNMS-200B for 200GPM capacity, GNMS-400B for 400GPM capacity, GNMS-600B for 600GPM capacity, GNMS-800B for 800GPM capacity.

GN Solids Control can design and manufacture efficient TBM slurry separation plant. It is the basis for the successful use of slurry-supported tunnel boring machines(TBM). GN Solids Control Slurry separation plant is popular for project of AVN Machines, Mix shields  or Shaft Sinking Machines . GN Solids Control use double deck shale shakers, desander desilter separators, as well as decanter centrifuges to separate and remove the excavated solids from the bentonite suspension.

GN Solids Control finished a package of Oily soil leaching solid-liquid separation system. The separation package is sold to customer in the Middle East for the contaminated soil treatment. The system is designed to treat the oily sludge and oily soil.

Below are the major separation modules included in the contaminated Soil Washing and Separation system:

Module 1: The vacuum transfer unit. There is a solids and sludge vacuum pump used for transferring the waste material from waste pit. The vacuum pump is a 100% air driven device, there is no electrical components. Hence, there is an air compressor to feed air for the vacuum pump. And there is an air tank equipped after the air compressor and before feeding air for vacuum pump.

Module 2: The pre-mixing and washing unit. There is a tank with heating pipes. The vacuum pump transfer oily sludge or oily soil into the tank. Water will be feed into the tank to dilute the sludge and oily soil. After this stage, there will be oil, water and sand mixture.

As the viscosity and density of oil sludge is normally high. It is very difficult or nearly impossible for separation. There is a heating system used for together with the heating pipes for heating the oily sludge. The most suitable temperature is 70℃ ~ 80℃, which is the most suitable temperature to keep the activity of chemicals.

Module 3: Coarse shake separation unit. The coarse shale shaker is to pre-separate the big particles and sands from the oily sludge. As the solids contents are very high. The big opening PU screens are used in the shaker for longer service time.

Module 4: The decanter centrifuge separation unit. It is used for liquid and solids separation.

Module 5: The 3-phase separation unit for oil, water and solids separation. 3-phase centrifuge are used in the unit.

Module 6: Chemical dosing module. Chemicals are used nearly in all process. There is a skid mounted chemical dosing unit in the system to supply chemicals.

If the oil sludge discharged from oil sludge treatment is directly discharged without treatment, it will not only occupy a large amount of land, but also contain a large amount of heavy metals and bacteria, which will produce foul odors and cause serious pollution of water, soil and atmosphere.

At present, there are many treatment technologies for oily sludge, in accordance with the requirements of reduction, harmlessness, resource utilization and comprehensive utilization.

The main treatment methods of oily sludge waste in oilfields are as follows:

1. Incinerate in a high temperature incinerator. Oilfields often use thermal desorption unit (TDU). The sludge is incinerated to recover clean oil and water, and the oil content in the solid waste is reduced to less than 0.5%. The products that meet the standard will be landfilled or fired bricks. This treatment method is costly and causes coking, which affects the normal operation of the incinerator. And energy cannot be recovered efficiently. If the oily sludge has a high moisture content, the temperature in the incinerator will decrease after entering the incinerator, and the pollutants after incineration will not be able to reach the standard stably, which will lead to air pollution and dust pollution.

2. Treat oily sludge by drying ordinary sludge. Because of the particularity of oily sludge, common processes and machines are not suitable for the treatment of oily sludge, which leads to agglomeration and coking of oily sludge in the equipment, making the equipment scrapped. In addition, the oily sludge treated by the ordinary sludge drying process cannot meet the standard. For example, equipment such as rotary kiln sludge dryers will form coking inside the equipment in a short period of time during the process of processing oily sludge, causing the equipment to fail to operate normally.

3. GN Solids Control Use chemical hot washing to treat and recycle oily sludge. As far as China’s current situation is concerned, chemical hot washing is mostly used for oil recovery from oil sludge, with the purpose of recovering oil. Therefore, the oil sludge after hot washing is a non-standard product and still needs to be treated. Therefore, the hot washing method can only be used as an auxiliary method for reduction, and cannot be used as a direct oil sludge treatment method.

GN Solids Control finished the final inspection and assembly of 5 packages of solids control equipment. They will be equipped for 5 sets new 2000 HP deep oil drilling rigs. The solids control equipment will be shipped to the client soon to commission together with their new drilling rigs.

All the equipment are customized for an old client from Nigeria. Since the first time they bought from GN Solids Control in 2012, till now, they deal with GN Solids Control over 10 years. And up to now, the all their deep drilling rigs are all running with GN Solids Control equipment for drilling mud and drilling cuttings treatment. For each 2000HP deep drilling rig, the client uses a fixed speed decanter and a VFD centrifuge for drilling mud treatment. And a vertical cuttings dryer for drilling cuttings treatment, and other accessories equipment.

The 5 packages solids control equipment include following items:

1) 5 sets fixed speed decanter centrifuge. Each fixed speed centrifuge will come together with another set of pulley and belt. While changing the pulley and belt, clients can run the centrifuge at another fixed speed. Normally GN Solids Control offer 3200 RPM and 2700RPM pulley and belt for high speed decanter centrifuge. Clients can contact GN Solids Control in case they need other speeds.

2) 5 sets VFD centrifuge. The VFD panel are equipped with Air conditioner cooling system for high ambient areas. And there are 3 VFD control inside the VFD control panel for variable speed control on main drive motor, back drive motor, as well as pump motor.

3) 5 sets vertical cuttings dryer for oil base mud treatment.

4) 40 sets screw conveyors. It is 10 inch diameter augers to fit for drilling mud solids control equipment and drilling waste management equipment.

5) Various screw pump to feed for decanter centrifuges and as flush pump for vertical cuttings dryers.

6) All above equipment will come together with relative control panels.

The transmission structure of drilling mud agitator is mainly composed of driven motor, reducer gearbox, connecting device and mixing shaft assembly. There are not many forms of drilling fluid agitators commonly used in drilling fluids solid control systems. Among them, there are worm gear direct transmission and worm gear coupling transmission.

Mud agitator is used at trip tank, pill tank, desilter tank, mud suction tank, mud reserve tank, mud mixing tank. It is also used under the decanter centrifuge to avoid the mud settle down.

Mud agitators are normally used together with mud guns. Normally a mud agitator with a mud gun. The mud gun is used to support the 4 corners of mud tanks. GN Solids Control mud guns have 3 nozzles. Each nozzle]of GN mud gun can cover 120 degree, the 3 nozzles can cover totally 360 degree of the mud gun. The mud agitator is driven by electric motor. While the mud gun is driven by centrifugal pumps which are used for mixing or mud discharge.

 

Some manufacturers have also used worm gear and worm coupling drive. Worm gear drive is widely used in drilling fluid agitator due to its simple structure, large speed ratio and high reliability. Early drilling fluid agitators were almost all directly driven by worm gear. Although the worm gear coupling drive and belt drive are large in size, they have the characteristics of soft motion, which is good for protecting the overload of the motor. Therefore, some manufacturers will choose them.

The most commonly used agitator transmission mode is the gearbox reducer. The advantages of gear reducer agitator are high transmission efficiency and less maintenance. The disadvantage is large volume. Gear driven agitators are also divided into direct drive and coupling drive. The direct drive mud agitator is the most commonly used agitator drive form at present because of its simple structure and convenient maintenance.

GN Solids Control just finished a full package drilling mud solids control equipment for an Africa client. The equipment will be used for a new rig mud system.

There are 4 stage solids control equipment included in the package.

1) Firstly, there are 3 sets solids control shale shaker. The shaker model is GNZS594F-SHBF. It is a 4-panel linear motion shale shaker which is widely used in oil rig mud system.

Besides the 4-panel shale shaker, GN Solids Control also make other sizes liquid and solids separation equipment, includes single deck shale shaker with 2-panel shale shaker, 3-panel shale shaker, and 5-panel shale shaker. GN Solids Control also makes double deck shale shaker with 5-panels and 6-panels screen deck.

2) After the 3 shale shakers, it is a 3-in-1 mud cleaner, which is composite of a single deck shale shaker, a desander separator assembly and a desilter separator assembly. There are 3 no. 10 inch desander and 12 no. 4 inch desilter cone which are combined with a 4-panel big flow shale shaker to reach 1500GPM flow capacity.

3) After mud cleaner, there are 2 no. Decanter centrifuge. It is a high speed centrifuge model GNLW363D. One centrifuge is used with middle speed for recovery the usable particles inside the drilling mud and reuse it in case of in need. After some circulations, there will be more and more ultra fine solids which cannot be removed by shale shaker and desander / desilter separator,

The other centrifuge is used with high speed for ultra fine solids separation, it is to reduce the mud weight.

4) There is a mud mixing unit in the package. It is to prepare qualified new mud to feed for the oil rigs.

If clients are interested in any other models or other sizes drilling mud recovery system, welcome you contact GN Solids Control to ask for support.

Oilfield drilling Mud gas separator is also named as poor boy degasser. It is used to remove air or gases (methane, H2S, CO2 and others) from drilling mud. It is mainly used to remove the big bubbles with the diameter of about ≥Φ3 mm. Most of these bubbles are the expanded gas filled in the drilling mud in annular of wellbore. It would cause well kick if the gas not to be removed timely.

Besides mud gas separator, there is another degasser equipment in drilling mud solids control system: vaccuum degasser. It is used after shale shaker and before hydrau cyclone separators. It is used to remove the fine bubbles inside the drilling mud.
ZYQ-1000 and ZYQ-1200 Mud gas separator are the 2 popular models for drilling mud system. Mud gas separator is located before drilling mud system. It is used after BOP choke manifolds and before solids control shale shaker.

The model ZYQ-1000 means that, the tank inside diameter of the mud gas separator is 1000mm. The tank wall of the mud gas separator is 10mm. While plus the 10mm tank inner depth, the external diameter of the tank is 1020mm.

If for model GNZYQ-1200, it means the inside tank diameter is 1200mm, the outside tank diameter after adding the 10mm tank wall is 1220mm.

The Inlet line, outlet line, vent line and solids discharge pipe size can be customized per order request. The mud gas separator design pressure is 1.6 Mpa. It is with side connection It is Atmospheric during working. There is a pressure gauge equipped on the mud gas separator. 0 ~ 140 Psi (0 ~ 1 Mpa) Pressure gauge is matching for the pressure.

Some clients may ask for 0 ~ 500 Psi gauge, which equals to 0~3.5Mpa. The measurement range is too large for mud gas separator. It will affect the accuracy of the pressure values.

There is a release value on the outlet pipe of the mud gas separator. It is butterfly value, the size of the valve can be customized per order request.

There is also a 4 inch butterfly valve on the solid discharge pipe. The valve size can be customized per order request.
The capability of lowering the Mud gas separator to a horizonal position for transporting between locations with necessary supports.

 

According to the motor mounting type, there are 2 types of drilling mud agitators for mud system: Direct connection mud agitator and Coupling connection mud agitator.

Type 1: Direct connection mud agitator. The motor is mounted on a mounting plate with flange to gearbox reduce. It is the most popular type. The design is sample, but reliable. Most agitator supplier utilize direct motor connection design.

Type 2: Coupling connection mud agitator. The motor and connected to gearbox reduce via a coupling set. So the motor is not direct connected to the gearbox reducers.

The Coupling connection mud agitator has a coupling to protect the reducer and motor. In normal situation, clients only need to check and maintain the coupling set. However, there are additional wearing parts of the coupling. The disadvantage of the coupling agitator is that the coupling and its accessories need to be regularly checked on the drilling mud system. Once the coupling or accessories are damaged, they should be replaced in time, otherwise the motor and reducer will be damaged quickly.

The advantage of the direct agitator is that it is less maintenance as long as the gear oil is added. The disadvantage is that once damaged, either the reducer is damaged or the roller key of the motor shaft is damaged. It is difficult to repair. And the repair cost is high.

However, the probability of such a failure is very low and it belongs to an abnormal situation. According to the feedback records on the site, the damage probability of the agitator caused by not replacing the coupling parts in time is much higher than that of the direct connected agitator. Therefore, GN Solids Control recommended direct connect agitators. GN Solids Control standard agitator models are direct motor connection type. And most popular agitator brands provide direct connection agitator. They do not offer coupling connection agitators.

This week, GN Solids Control is assembling 2 sets of mud cleaning system for SINOPEC HDD rigs. The 2 mud cleaning system are designed for different size HDD rigs, one system is with 1000GPM handling capacity, while the other one is designed for 500GPM handling capacity.

500GPM mud system is the most popular size SINOPEC bought from GN Solids Control. Till now, they have over 30 sets mud recycling system from GN Solids Control for their international HDD and piling projects.

The 2 mud recycling system are painted with clients’ special requested color. GN Standard color is green, while the SINOPEC system is yellow. The 500GPM mud system is equipped with very high standard. It is composite with all the 4-stage solids control equipment for drilling mud treatment.

1. The 1st stage solids control equipment shale shaker. There is a 3-panel shale shaker which is with big screen areas for capacity up to 500GPM. The shaker model is GN703F, which is the most hot sale shale shaker made by GN Solids Control.

2. The 2nd stage solids control equipment desander, and the 3rd stage solids control equipment. It is a 3-in-1 mud cleaner which is composite of a big area underflow shale shaker GNZS703F, and 1×10 inch desander cone plus 8×4 inch desiltere cone.

3. The 4th stage solids control equipment decanter centrifuge. There is a 18 inch middle big bowl centrifuge. The centrifuge model is GNLW452D. It is a big bowl centrifuge but it is middle speed, The GNLW452D is an economic centrifuge model with big bowl but middle speed. So it is widely used in HDD, CBM, water well drilling and other trenchless rigs.

Besides mud recycling, GN Solids Control 500GPM mud recycling system also have the function of mixing. It can continue prepare quality new mud for the mud system. The mixing pipelines are connected to all mud tank compartments. So operators can choose to mixing from any of the tank compartment.

GN Solids Control makes linear motion or dual motion shale shaker for onshore and offshore drilling rigs. This week, GN Solids Control finished 2 shale shakers for an offshore drilling company.

The 2 shale shakers are the most popular models made by GN Solids Control GNZS594. It is a 4-panel single deck shale shaker. It can either make as linear motion or dual motions while apply various vibrating motors.

GN Solids Control shale shaker is equipped with heady duty design shaker deck. The whole shaker deck of GN Solids Control shale shaker is treated by heat treatment. It enable GN shale shakers to suit for G force up to 7.5 G. If for high G drying shaker model, the G force can up to 8.0G.

The shaker deck of GN shale shaker is sealed with patent design sealing rubbers to avoid fine solids bypass and to protection the shaker deck and shaker screens during vibrating. And the patent design shaker deck sealing rubber is easy for installation and replacement.

Another big advantage of GN Solids Control shale shaker is equipped with mechanical deck angle adjustable device. Operators can adjust shaker deck angle while the the shaker is running. They do not need to stop the shakers. And plus, the shaker deck adjustment device is GN Solids Control patent design technology. It is a Synchronous lifting system, it means the shaker users can change shaker deck at either side of the shaker deck, both side with change with the same angle.

And plus, GN Solids Control is also capable to make other separation equipment for offshore drilling, like mud cleaner, decanter centrifuge, degassers, etc…

Besides shale shaker for drilling rig mud system, GN Solids Control is also capacity to make high capacity dewatering vibrating screen shaker, Classification Vibrating Screen shaker and mining vibrating screen shakers with different capacity. For more details, please contact GN Solids Control system branch: GN Separation.