Drilling Waste Management

Sometimes, clients or users may contact GN Solids Control to ask for assistance on GN equipment operation.

Recently, a client show own GN Solids Control decanter centrifuge at their rigs sites contact GN and ask GN to help with some technical assistance. The VFD decanter centrifuge is used at their drilling mud solids control system. They said it is related to a small issue on GNLW363CG-VFD Decanter Centrifuge. They said their issue is that the set RPM Bowl speed is reached very slow, about 3 – 5 minutes to reach high speed RPM.

They want to know is that normal to take such time to achieve the set high speed? They want to know what is the reason to cause the slow speed-up? Is it caused by some safety settings? They also want to know is there any way to improve the VFD response?

GN Solids Control gave reply to the client that, the pre-setting of GN Solids Control on VFD control panel is 5 minutes to reach 3200rpm. The slow speed-up is to avoid trip off during running. In this case, it should take around 3 minutes to reach 2000RPM. If the time is too long, it is abnormal. The parameter can be set on the VFD drives. If clients want more assistance on the VFD drive parameters settings, they can send photos of the decanter centrifuge VFD panel nameplate. GN Solids Control will check the original parameter settings before delivery from GN Solids Control factory, and give clients instruction about how to process.

The clients give their thanks to GN Solids Control about the the prompt answer. They accept the time. They said all fine if everything is made to protect the system from overloading. They are just a little bit worry not to be some safe limitation caused by a failure or so.

Besides decanter centrifuge, GN Solids Control also make shale shaker, mud cleaner, desander, desilter, jet mud mixer, vertical cuttings dryer, etc…

GN Solids Control makes a large quantity of Screw Conveyor and Screw Pumps for a Drilling Waste Management Company in African. There are 10 sets Variable Speed Screw Conveyor and 8 sets Variable Speed Screw Pump are included in the project.

The 10 sets of screw conveyor are equipped with 12 inch auger diameter. There are quantity 7 screw conveyors model GNSC12B-12V and and quantity 3 screw conveyors model GNSC12B-24V. The model code GNSC means GN Solids Control brand Screw Conveyor. 12B means version B 12 inch diameter. 24V means 24 ft transfer length and variable speed screw conveyor. If the final no. is 24 without V, it means 24 ft transfer length fixed speed screw conveyor.

GN Solids Control uses manual adjustable speed gearbox to adjust conveyor speed. The gearbox box and electric driven motor can be connected by coupling which are connected in-line. The gearbox and motors can also be connected by pulley and belt per jobsite request. There are also L-type connection gearboxes for GN Solids Control screw conveyor.

The 8 sets Variable Speed Screw Pump is with quantity 6 model GNG30B-075V and quantity 2 model GNG10B-040V. It is German brand NETZSCH pump which are mainly used as decanter centrifuge feeding pump. The rotor and stator of NETZSCH pump are made in German and assemble in China.

All the screw conveyors and screw pumps are equipped with electrical control panel for start, stop and E-stop.

Besides 12 inch auger diameter, GN Solids Control can also make other sizes screw conveyors, includes: 10 inch diameter, 12 inch diameter, 14 inch diameter, 16 inch diameter, and 18 inch diameter. And the transfer length includes. The auger length is 12 ft and 24 ft per order request.

Besides screw conveyor and screw pump, GN Solids Control also makes centrifugal pump, solids and sludge vacuum pump for transfer. GN Solids Control major products are separation equipment for drilling mud and drilling cuttings, like various sizes decanter centrifuge, vertical cuttings dryer, High G drying shaker, dewatering unit, full package solids control system, drilling cuttings management system, oil sludge separation system, slurry dewatering system,desanding plant, etc…

GN Solids Control finished a package of drilling waste management equipment for a regular client in Nigeria. The equipment will be used by a service company for drilling mud solids control and drilling waste management.

The drilling waste management package includes following items:

1) 3 sets VFD decanter centrifuge. The model is GNLW363C-VFD.

It is a 14 inch high speed decanter centrifuge with positive pressurized VFD control panel. GN Solids Control is the few centrifuge supplier who is capable to make positive pressurized VFD panel. The VFD panel is equipped with vortex cooling system, which is specially designed for high temperature area. Operators can setup the temperature inside the VFD control panel to be around 25C degree. It can protect the components. Moreover, there are touch screen and PLC programme for smart control.

While most other centrifuge supplier make normal flameproof VFD control panel. And they use fan for cooling. It does not suit for high temperature area.

2) 2 sets of vertical cuttings dryer. The model is GNCD930F.

Vertical cuttings dryer is also called as vertical centrifuge. It is mainly used for oil based mud and oil based cuttings. It can reduce the OOC (oil on cuttings) to 3% ~ 5%.

Clients can also choose bigger opening screen basket for water base mud treatment.

3) Telescopic skids to hold decanter centrifuge and vertical cuttings dryer.

The telescopic skid is designed to hold the decanter centrifuge, VFD control panel and feeding pump. During shipment, the skid can be felt down to 2500mm. During working, the centrifuge skid can be lift up to designed height. Currently, GN Solids Control makes skid with height to 2800 to 4200mm.

Besides VFD centrifuge, GN Solids Control can make fixed speed centrifuge and FHD centrifuge. And GN Solids Control makes centrifuge with bowl size 9 inch, 14 inch, 18 inch, 22 inch and big bowl decanter centrifuge 30 inch.

GN Solids Control also makes other drilling waste management equipment, including screw conveyor, dewatering unit, high G drying shaker, disc centrifuge, etc…

GN Solids Control just finished a job site training via internet for a client in South America. The training is for number 2 decanter centrifuge GNLW363C-VFD. Now the decanter centrifuge start to running well at rig site. It is a 14inch high speed decanter centrifuge with variable frequency drive (VFD) control panel. The 2 decanter centrifuges are used at the drilling rig mud system in South American.

GN Solids Control 14 inch decanter centrifuge is widely used for various applications. The decanter centrifuge can be used in oil and gas drilling solids control system, used in HDD mud recycling system, used in drilling waste management fine solids separation, used in slurry separation treatment, it can also be used in dewatering treatment system, etc…

GN Solids Control major business is for drilling mud solids control and drilling cuttings treatment. Most decanter centrifuge is designed for drilling mud solids control. GN Solids Control decanter centrifuge is designed and made for both drilling mud solids control and drilling waste management.

Unlike drilling mud treatment decanter centrifuge, drilling waste treatment centrifuge requests better wearing-resistance of the equipment. In this case, the centrifuge centrifuge and vertical cuttings dryer used for waste management must have high material standard:

1) The bearings brand of GN Solids Control decanter centrifuge is international leading brand SKF and FAG. As there are big bearings in the machines.

2) GN Solids Control decanter centrifuge bowl material is SS2304 Duplex made by centrifugal casting.

Besides offering variable speed variable frequency drive (VFD) control panel, GN Solids Control is also capable to offer fixed drive control panel, and full hydraulic drive (FHD) control panel for the 14inch high speed decanter centrifuge. For the fixed speed decanter centrifuge, GN Solids Control can also offer other sets of pulley and belt. The clients can change the pulley and belts to get another fixed speed. The optional speed is 3200rpm, 2800rpm and 1800rpm.

Besides the number 2 decanter centrifuge, there are 2 screw pumps which are used to feed for the 2 decanter centrifuge.

 

GN Solids Control makes various sizes of screw conveyor augers for the oil gas industry. The screw conveyor augers are widely used for transfer the drilling cuttings to feed to the cuttings dryer,and cuttings collection box.GN designed 3 size of diameter, 10inch, 12inch, 14inch, 18inch, each size has 4 different length for option according to the drilling site of the customer.GN Solids Control can offer fixed speed gearbox drive and manual adjustable speed gearbox for each size of gearbox.

Some clients want to use Standard Bearing with seal (if possible double bearings) instead of Middle Hanging Bearing core in the hanger bearing for the connection of each auger sections. GN Solids Control does not recommend this design.

Firstly, standard bearing and seal design are costly. Plus it is more complicated to install.

Secondly, the bearing at this location is easy to be worn out,especially be worn out by drilling mud and drilling cuttings. If the seal is not good enough at this location, the bearing will soon be broken.

Moreover, it is inconvenient to replace the bearing and seal after wear. The operators need to fully dismantle the auger for replacing new ones. As far as we know, there are no suppliers in China use standard bearing at this position. Their popular design is using copper sleeves at this location.

GN Solids Control use hanger bearing which are made of alloy materials to fit for oil field drilling waste transfer. Alloy material is more wear-resistant than copper. Plus, GN Solids Control makes the hanger bearing in the form of a separate unit. The parts can be quickly replaced by removing the bolts and mounting brackets in case of needed.

GN Solids Control use helical gear reducer (speed adjuster). It is more stable and less maintenance.
Besides, clients will want there are clear separation between the electric motor and manual speed adjuster (gearbox or reducer) to enable job site operators to remove the electric motors for repair without affecting the gearbox (speed adjuster or reducer). GN Solids Control connect the driven motor and gearbox (speed adjuster reducer) by flange. It is easy for installation and dismantle.

ViST is Vacuum Shaker Screen Technology which is developed and designed by GN Solids Control. The shaker screen vacuum unit is to work with shale shaker to reduce drilling waste and recycle drilling fluids. At some jobsites, clients use screen vacuum unit to replace drilling waste high G drying shaker.

There are insert type screen vacuum unit and external mounting type screen vacuum unit. For GN own design shale shaker and some other shaker model which use frame screens, if there is space to insert the catch pan (tray) under the outside discharge end shaker screen, we call it insert type screen vacuum unit. It is relative small modification on job site shale shaker. If for GN brand shale shaker, all shaker models reserve the design to add screen vacuum unit directly.

For insert type vacuum screen unit, the catch pan is fixed directly under the discharge side shaker screen. The screen API size depends on the shale shaker API screen, or the high G drying shaker API screen.

But for the external type screen vacuum unit, the client will use a small screen after the shale shaker or high G drying shaker.
Some clients want to use very fine screens, like API-230,270 and 325 while they add the external screen vacuum units to the shale shakers on offshore drilling rig mud system.

GN Solids Control does not recommend clients to choose such fine screens for external screen vacuum unit after solids control shale shaker. As solids control shale shaker does not use very fine screens. The high G drying shale shaker may use fine screens. But API 230, API 270 and API 325 are not used by solids control shale shaker. The small screen API size should be similar to the shale shaker screen. It cannot be too fine. Otherwise, it may cause block.

In other job site while clients use the screen vacuum unit for GN shale shakers, the max. shaker screen API size they use is API 120 and API 140. Hardly over API 140.

A drilling waste dewatering unit and a solidification unit is finished the installation at job site in Africa. The client start to use the dewatering unit and the drilling cuttings solidification unit to treat the waste slurry.

It is a 20ft containerized dewatering unit used at this job site. There is a 3-tank automatic polymer dosing system and a single tank PE tank for liquid chemical. The single PE tank is for manual operation. Client can choose to use both dosing system or either of them.

A 14 inch decanter centrifuge is used together with the chemical dosing system for dewatering treatment. Normally, there will be a shale shaker or high G drying shaker used before decanter centrifuge for reducing the solids content and remove the big size solids. But at this job site, there is no big size particles, and the solids content is small. The client does not need to use shale shaker separater, but use dewatering centrifuge separation directly.

After decanter centrifuge dewatering treatment, the client will use the solidification unit to make the solids waste dry. GN Solids make automatic drill cuttings solidification unit, all auger inside the solidification unit are equipped with VFD control panel. The operators can set up feeding speed before start the solidification unit.

Besides the containerized dewatering dosing system, GN Solids Control offers different sizes of 3-tank automatic polymer dosing system and single tank liquid chemical dosing unit. Clients can choose different models and modular to use it separately, or use more sets for bigger capacity.

GN Solids Control makes various sizes dewatering centrifuge, the bowl size is varying from 9 inch, 14 inch, 18 inch, 22 inch and up to max. 30 inch. And GN Solids Control offers fixed speed control, VFD control and FHD control to various size centrifuges to meet clients’ demands.

GN Solids Control also makes screw conveyor, sludge and solids vacuum pump, vertical cuttings dryer, oil sludge separation unit and waste oil/water treatment unit to meet different applications.

In April, a full set of drilling cuttings washing system is ready for commissioning for a China client at client’s job site. The drilling cuttings washing system is used to wash and separate oil base drilling cuttings and oil sludge generated from oil and gas drilling, and refinery.

There are 7 treatment modular in this drill cuttings treatment washing system:
1.Pre-treatment: A set of coarse shale shaker is used in this modular for crushing the big rocks and for pre-seperation. It is the pre-treatment before all separation steps.
2.Screening separation modular. There is a high G drying shale shaker used in this step to remove the big size particles.
3.Washing modular with static mixing for mixing and preparing solids and liquid mixture. After that, the liquid mixture can be separated by next step separation equipment.
4.Liquid and Solids separation modular with decanter centrifuge for 2-phase separation. It is the 1st time liquid and solids separation.
5.The 2nd time washing modular with dewatering treatment to remove the fine solids in the liquid.
6.The 2nd time 2-phase decanter centrifuge separation unit for ultra fine solids separation.
7.The liquid recovery modular.

It is a a full function oil based drilling cuttings washing and separation system with a full set of separation and treatment equipment. Below list is the major treatment equipment used in this oil based drill cuttings washing system:
1.A Drum shale shaker is used in the pre-treatment unit to crush the big rocks and remove it.
2.A high G drying shale shaker is used in the screening separation modular to remove the big size particles. It is the most hot sale shaker model GNZS594F which is widely used in oil and gas drilling solids control systems.
3.2 sets of static mixing unit are used in the 2 stage washing modular.
4.A inclined plate clarify is used for soil settle down in the oily liquid, which is discharged from decanter centrifuges.
5.Screw conveyor and belt drive conveyor are used in the system to feed for shaker and for solids discharge from decanter centrifuges and shale shakers.

High G drying shaker and vertical cuttings dryer are the major products for drilling cuttings treatment. This week, some sets of high G drying shaker are vertical cuttings dryer are packed for shipping to an offshore drilling company. The high G drying shaker are installed on a small holding tank. There is a centrifugal pump used as transfer pump to transfer mud out from the small holding tank.

The different is that, high G drying shaker is mainly used to separate water base mud and water base cuttings. While vertical cuttings dryer are used to treat oil base mud and oil base cuttings. In some cases, vertical cuttings dryer can be used to treat water base cuttings. But it is easier to be blocked than high G drying shaker.

High G drying shale shaker utilize API RP13C complied shaker screen. Operators can choose suitable API screen to reach the expected cut point. But vertical cuttings dryer use screen basket. Most supplier can only offer 2 sizes of bigger opening screen baskets. GN Solids Control offers 3 options of screen basket: 0.25mm, 0.35mm and 0.5mm. Operators can choose the suitable size per his job site situation and their performance demands. Generally speaking, the fine opening can get more clean liquid, and it may cause more block than big size screen opening. And the more the feeding flow rate, the wetter in the solids discharge.

Vertical cuttings dryer itself cost higher than high G drying shaker. And its motor power is much higher than high G drying shale shaker. But while be used to treat oil base mud, Vertical cuttings dryer can reduce the oil on the cuttings to 3% ~ 5%. But the high G drying shaker can only reduce oil on cuttings to 10% ~ 15%. There is a much difference.

Normally, water base mud is used at the the early drilling sections, and oil based mud is used at deeper drilling. In this case, some clients will choose both high G drying shaker and vertical cuttings dryer to treat WBM and OBM separately. Clients can also choose neither high G drying shaker or vertical cuttings dryer per their job site situation.

As the oil sludge treatment is a new trend. It means a new business scope for many companies. Many clients do not have much experience before they run GN waste management plant.

In order to ensure they have enough knowledge to operate the unit and reach good performance, GN Solids Control will send engineer to job site to help for the first time commissioning. GN engineer will support to test the treatment unit with real oil sludge and to train their stuff about how to adjust the system based on the material situation in order to reach a good performance. And GN engineer will give training about normal maintenance and trouble shooting if requested by clients.

Recently, GN Solids Control engineers just finished the commissioning job of an oil sludge treatment plant. The treatment plant is for a China domestic client which is used in China. It is a middle size oil sludge treatment system with 14inch centrifuges to treat oil contaminated wastes. And it is also the most popular size oil sludge treatment plant.

It is a complete oil sludge treatment plant for 2-phase and 3-phase separation. Below is the major separation plant of the oil sludge treatment plant for this project:

1) The 1st modular of the oil sludge treatment plant is premixing and heating tank package. The solids and liquid inside the raw oil sludge is not equal. Or some time, the solids control is too much high. The first stage is to prepare the sludge and make it suitable for separation. The processes which maybe be used in this stage are: mixing, dilution, heating, chemical dosing. Clients and chose 1 or more process based on the material situation.

2) The 2nd modular is drying shaker tank unit for coarse separation. The drying shaker is customized with rubber sealing cover and steam nozzle pipelines for heating. Clients choose the right API shaker screen to remove particles above a certain sizes.

3) The 3rd modular is decanter centrifuge C/W a holding tank for 2-phase separation.

4) The 4th modular is 3-phase centrifuge C/W holding tanks

5) The 5th modular is containerized dosing system to supply chemicals for the whole treatment process.