Drilling mud Equipment

GN Solids Control made an oil-based drilling cuttings treatment system for a CNPC company. GN Solids Control made and designed and system per client’s job site situation. So it can suit for the clients’ situation well. Clients are happy with the performance of the OBM treatment system. Both the team leader and job site workers are satisfied with the system, and they said that, after applying GN waste management system. They can recovery more usable drilling mud. Their drilling waste and their drilling cost are both reduced. And they can save cost and manpower on the waste material shipment.

The oil based mud treatment system made for CNPC is a complete package. It is a skid mounted cuttings drying system with processing equipment, mud and cuttings transfer equipment, and electric control system.

Below is the major equipment included in the skid mounted oil based mud cuttings drying system:

Firstly, there is a vertical cutting dryer. The vertical cuttings dryer is mounted on a separate skid. VG dryer is also called VG centrifuge, it is the major equipment to treat the oil based mud and cuttings discharged from shale shaker. GN high quality vertical centrifuge can reduce the oil on cuttings to as low as 3% ~ 5%. In many countries and regions, less than 3~5% OOC can be discharged directly. Even not, it is already very dry like powders. It is easy for movement and for next process treatment.

Secondly, there is a 14 inch decanter centrifuge in the oil base mud cuttings drying system. The decanter centrifuge is used after the vertical centrifuge to reduce the mud weight. Enable the recovered mud qualified for drilling activity.

3 sets screw conveyors are equipped in the system. One screw conveyor is located under the shale shaker to collect drilling cuttings discharged from shale shakers. Another screw conveyor is located inclined to transfer the cuttings from shale shaker and feed to the vertical cuttings dryer. The 3^rd screw conveyor is inclined and under the vertical cuttings dryer. It is used to transfer the drying cuttings from VG dryer to the cuttings containers.

Mud agitator is one of the most popular equipment for drilling mud systems. It is mainly used to keep both the mud uniformity and the suspension of solids. The mud agitator is used to agitate the mud consecutively and reliably. This agitator agitates the mud to make the cuttings silt and sand pass the solids control system without being precipitated onto the tank bottom.

According to the different types of gearbox design, the mud agitators can be divided into 2 kinds:
The most popular design is worn and gear reducer mud agitator.

The worn and gear reducer mud agitator is an economic standard mud agitator. The mud agitator is equipped with explosion proof motor, worn and gear reducer. The worn and gear reducer is working stable and cost effective. It is also easy for maintenance.

Another kind of agitator is equipped with heavy duty helical bevel gearbox. We call it helical bevel agitator.

The mud agitator is equipped with heavy duty helical bevel gearbox. Compared with traditional worn and gear gearbox, the helical bevel agitator is with a bigger torque. It is more powerful for heavy mud. The heavy duty helical bevel mud agitator save also power, for the same motor power, the helical bevel mud agitator is with a big torque compared with worn gearbox. So a smaller power helical bevel mud agitator can reach the performance of a bigger power worn gearbox agitator.

There are 2 ways for the connections of motor and agitator gearbox.
The motor and gearbox can be connected by flange directly. It is with small footprint.
The motor and gearbox can also be connected by coupling, and fixed on the small skid. Clients can choose the suitable one per his job site situation.

Other accessories for drilling mud agitator:
1) Shaft: The shaft length of mud agitator should be customized per clients’ mud tank size.
2) Impeller: There are double layer and single layer impeller for mud agitators. The impeller size is also designed to suit for the tank depth and width for a better agitating performance.
3) Tank bottom stabilizer to fix the shaft. For mud tank depth over 1800mm. GN will recommend Tank bottom stabilizer to fix the shaft and avoid is swaying during rotating.

A few weeks ago, GN Solids Control had a shipment for some solids control equipment to a client in Uzbekistan. Soon, the equipment will be used in extreme cold regions of Uzbekistan. The lowest ambient temperature in the area can be below minus 50 degrees Celsius.

This is not the first time that GN Solids Control has sent equipment to the extremely cold regions of the Commonwealth of Independent States (CIS).  4 years ago, in 2014, some package of drilling cuttings drying system was dispatch to Baker Hughes in Russian. The systems were running from 2014 till now. End users are very happy with GN products quality and GN services. Since they have other Chinese brand equipment in other jobsites, after comparison, end users said GN vertical cuttings dryer and decanter centrifuges are the best from China.

The solids control equipment will be used in clients’ drilling rig mud system for mud processing, the shipment is including following processing equipment:
1) Some linear motion shale shakers. It is the first stage solids control equipment in drilling rig mud system.
2）Some Mud cleaners. In rig mud system, mud cleaner is used after shale shaker. The desander can clean the mud to 50 microns, while the desilter separator can separate the drilling fluids to 27 microns.
3）Some Decanter centrifuge. There will be at least 2 sets decanter centrifuges in a complete drilling mud processing system. Firstly, a middle speed decanter centrifuge at 1800 rpm will be used to recovery the barite. After some circulation, there will be too much ultra fine solids inside the drilling mud, a high speed decanter centrifuge can be used to reduce the mud weight.

Furthermore, GN Solids Control is with rich experience to offer processing equipment for high temperature areas in Middle east and Africa, like in UAE, Kuwait, Iraq, Qatar, Yemen, Oman, Saudi, Algeria, Egypt, Ukraine, etc…In these areas, the highest temperature can up to +55 degrees Celsius. GN Solids Control is capable to make solids control and drilling waste management equipment for cold temperature areas to minus 50 degrees Celsius and to high temperature areas up to +55 degrees Celsius.

An electric motor will generator big electric current during starting; the sudden current may cause sudden voltage drop down, and cause other unexpected bad effects, or damage the equipment. So it’s important and necessary to choose the suitable starting method for functional and cost-effective control system.

Direct online (DOL) starter
Direct online starter is the simplest and cheapest way of electric motor starting. Magnetic starter control panels is the post popular type of Direct online starter. DOL starting is simply switching the motor on in one operation, with a direct connection from the power source. But it can only be used for small motors. For oil and gas drilling mud systems, only the motors less than 30kw will use DOL starting. For big power motors, if there is already an effective control to start and stop the motor, a DOL starter can be used as the second control.

Star-delta starting
In oil and gas drilling field, start-delta starting are normally used for motors between 30kw to 75kw, like for pumps. When we mentioned star-delta starter, the motor is first connected in ‘star’ configuration, which allows the motor to gather speed without drawing excessive current. Once the motor is up to speed (or a preset time is elapsed) it is then connected in the normal ‘delta’ configuration. This method can reduce the starting current demand by 30%, but is only suited to applications where the motor is starting without load .

Soft starting
Soft starters are more expensive than DOL and star-delta. A soft starter is an electronic components which controls the voltage flowing to the motor when startup. Soft starter can slowly increase the supply voltage to the motor, and start the motor smoothly without overcurrent.

Variable frequency speed drives (VFD control)
A variable frequency speed drive (VFD), also known as a VSD or VVVF, which allows complete control of the motor speed including starting and stopping. It operates by changing the frequency of the power supplied to the motor. And the motor can be run at any speed, so VFD drive control can save power, and control the driving speed. Variable frequency drives are the most expensive method for motor starters. And it can be used to control running speed of the machine, like for decanter centrifuges, vertical cuttings dryers, screw conveyors, etc…

Recently a customer has some questions about GN Electric Ignition Device. They contacted GN people and GN replied. Below are the major communication between GN and operator of the ignition device.

Client’s Questions 1: I presume the solenoid valve will close once the ignition is activated or should we close it on remote. This is for preserving the gas for future use. ( we may have to ignite several times during well kill operation as we get gases intermittently-H2s Laden gas)
Reply from GN Solids Control: Once you start up the igniter and it is firing stably, the solenoid valve can be closed for saving gas. As the gas tank is small size. It is only 5kg. You can ignite again in case you need with the wireless controller.

Client’s Questions 2: As the vent line is from the top of gas buster and then connected to the igniter which will be about 6 to 8 ft high. This forms a “U” section for the vent line and liquids remaining cannot be cleared out, which gives resistance for any gas vented out and blow back into gas buster. Any solution for this. Any bypass is recommended to drain out these fluids?
Reply from GN Solids Control: What kind of gas buster you used? Mostly, the igniter is connected to mud gas separator. The vent line on top of the mud gas separator. Liquid is impossible to go inside.

Client’s Questions 3: As the igniter is kept in open position, we may also end up with sand and also rain water ( in deserts) inside the igniter. Can we intermittently flush the system with water. Is it safe for the system electrics. In case we flush, then we will definitely have a reservoir of water in the vent line and adding up sand will only plug the system.
Reply from GN Solids Control: You do not need to flush the igniter. It will not be blocked. There is a screen on top of the Igniter burner pipe to prevent big sizes blocks or stuffs fall inside.
There is a drain port with ball valve (JB/T 308 PN16DN20QB) at the bottom point of the Igniter elbow connection pipe. You should open the ball valve to drain the pipe timely to release sands/rain.

Client’s Questions 4: What would you recommend to avoid getting into critical situations at the Rig.
Reply from GN Solids Control: If you will not use the Igniter for a longer time. It is better to close all valves, and cover the Igniter burner with rainproof cloth or plastic bag, to prevent it from rain/sands.

GN Solids Control makes different sizes of decanter centrifuge:

1) The 9 inch mini size decanter centrifuge: GNLW223, GNLW224 series. It is mainly for waste water and mining industry separation.

2) The 14 inch most popular size decanter centrifuge: GNLW363 series. The size is widely used in oil and gas drilling and for industry separation.

3) The 18 inch big bowl centrifuge for bigger capacity: GNLW452 series low speed big bowl and GNLW453 series high speed centrifuge.

4) The 22 inch big bowl centrifuge for waste management and industry waste application: GNLW553 and GNLW554 series

5) The largest size GN Solids Control does make is 30 inch: GNLW764 series.

GN Solids Control offers different design for centrifuge driving systems: fixed speed motor drive system, variable frequency drive system (VFD centrifuge), and full hydraulic drive system (FHD centrifuge). No matter what kind of driving system, GN Solids Control will include the pump driving control inside the centrifuge control panels.

But sometimes, clients want to use their existing pumps, if they use the pump control inside GN centrifuge control system, it will be fine. In some cases, clients use their old pump control panel with their own pump. In will cause overload of the centrifuge. It is not recommended. Why the centrifuge feeding must be inside the centrifuge control panel?

There is safety protection inside the centrifuge control system. If the pump control is related to the centrifuge control (main motor drive and back drive motor), in case the centrifuge is overload, and the current will be increased. When the current increase over the setup data, centrifuge control system will adjust its control: to reduce the pump speed to reduce the feeding. When the pump feeding capacity to centrifuge is smaller, the current increasing will be reduced. When the current drop down to a setup safety data, the centrifuge control system will increase the pump speed to increase pump feeding, the centrifuge can handle a bigger capacity that it can do.

If clients want to use their own pump to feed the centrifuge, it must be for sure to relate and interlock their pump control to the centrifuge control. It can avoid overload and protect the centrifuge well.

There are many parameters to judge a shaker screen performance, like non-blanked area (usable screen area), conductance, API size (screen opening), mesh size, etc… All these parameters will caused different performance of the replacement screens and the effect the shale shaker performance. There are so many manufacturers for replacement screens, how the users select the right screens for his applications?

API RP 13C is the international recognized standard for replacement shaker screen manufacturing. It means that, if the replacement screens are made per international API RP 13C standard, it ensures that, for the same screen models, the same API size of from different suppliers are all interchangeable.
Why it is the same API size screens are interchangeable for the same screen model? We will be clear after we know the definition of the screen parameters.

1) Mesh size: the size is only determine the hole quantity per square inch on the screen mesh. It depends more on the technology of screen making and the wire cloth size.

2) Conductance (unit: kd/mm). It defines the ability of fluids can go through the screen wiremesh. For the same screen, a bigger conductance means bigger capacity to handle drilling fluids.

3) The non-blanked area of a screen means the usable area of the screen to allow the drilling fluids going through. Generally speaking, the more non-blanked area, the better of the screen handling capacity.

4) The API size of the screen: As per API RP 13C Standard, if the Cut Point is within the same range, it will be defined as the same API size. It can be used as equivalent screen. Like all screens with cut point bigger than 165 microns but smaller than 196 microns can all be defined as API 80.

So the screen manufactured by different suppliers, no matter Chinese maker or U.S maker, no matter GN Solids Control,  Swaco, Derrick or Brandt, the same API screen will all be replaceable even if the Mesh size , or Part No is different.

GN Solids Control is the world’s leading manufacturer of solids control equipment and mud recovery systems. As a leading manufacturer of shale shakers, mud cleaners, decanter centrifuges, cutting dryers, centrifugal pumps, etc., GN’s brands and products are available. More and more international customers are recognized. The GND system consists of a two-layer mud shaker, two hydrocyclones, a centrifugal pump, a tank and an electrical control system. The system can effectively separate solids and liquids, reduce the solid waste content in the drilling mud, make the cuttings drier, easy to transport, environmentally friendly and easy to handle. The entire system is very compact and armored, very economical and value for money.

We have been working hard to develop different markets for our Oil Sludge processing systems. The scope comes from waste management companies, drilling waste treatment companies, and oil companies and oilfield service companies. The first stage separation of the system is a two-layer mud vibrating screen. When the mud enters the lower layer of the screen, large solids will be separated from the mud. Fine solids and mud will fall into the tank, and the mud will pass through the centrifuge. The pump draws in two hydrocyclones that work like a sand remover to separate the solids size to 40 microns. The solids separated by the hydrocyclone will fall onto the upper deck of the shale shaker and the solids will be further dried for disposal. The clean mud separated by the hydrocyclone will fly back to the tank and be pumped back to the wellbore for reuse and recycling. The basic configuration of the mud recovery system is a two-layer mud shaker, two hydrocyclones for sand removal, a centrifugal pump, a mud tank and some other components. Visit our website at www.gnsolidsamerica.com for more information, please send your questions to USA@gnsolidscontrol.com

GN Solids Control is one of the largest solids control and waste management companies specializing in the production of related equipment such as shale shakers, desanders, desilters, mud cleaners, vacuum degassers, mud gas separators, sedimentation centrifuges Machine, agitator, centrifugal pump, cutting dryer, screw pump, shear pump, mud gun, etc. After 10 years of development, GN has promoted its products to more than 60 countries and now has two overseas subsidiaries in the US and Russia.

Of all the products in the range, the decanter centrifuge is one of the most popular products for GN customers. Now GN can not only manufacture the traditional 363 centrifuge with a 14-inch bowl, but also make a larger bowl size GNLW553 with a bowl size of 22 inches. The equipment can be used to process water-based mud, oil-based mud systems, dewatering and recovery of barite. This device also has some great features: it is VFD controlled and offers operators a variety of solutions to adapt to changing field operations. The duplex stainless steel bowl is centrifugally cast and has good centrifugal balance and corrosion resistance. The surface of all screw conveyors is protected by tungsten carbide bricks that protect the entire length of the screw conveyor. They can work in a super hot desert environment. The VFD control system is provided by SIEMENS or ABB. All bearings used in the centrifuge are made of SFK quality bearings to ensure longer life and more reliable operation. All motors and control panels are explosion-proof and certified for use in Zone 1 and Zone 2 hazardous areas. The 553 decanter centrifuge will be a star product for handling large volumes of liquid and solids separation work. More and more customers are showing great interest in this. This is a basic introduction to the large bowl type decanter centrifuge 553.

I hope it will be useful to you. We will do our best to help your business succeed. Welcome to www.gnsolidsamerica.com and send your questions to USA@gnsolidscontrol.com

The intelligent control variable frequency positive pressure cabinet is integrated with HMI, PLC and frequency converter. It can realize the frequency conversion control mode of the mud centrifuge, which makes the operation more humanized. The customer can select different speed and difference speed according to the material conditions on site.

 

The automatic control makes the equipment more widely applicable to the site. The customer sets the centrifuge main engine speed 0-3200r/min according to different materials, and the differential speed is adjusted at 10-45r/min. The state screen automatically reminds the centrifuge maintenance parts to be regularly maintained. The alarm compensates for the damage caused by the negligence of the staff; the alarm screen shows the fault alarm when the electrical equipment has a problem, and the user can better find the problem in time.

Positive pressure control cabinet operation has more clean instrument air than previous explosion-proof frequency conversion cabinets. For most customers, it seems more troublesome than the explosion-proof control cabinet. It is more reasonable from the following points:

1. Performance and heat dissipation of the inverter (take ABB inverter as an example)

Because of the working principle, the inverter needs to dissipate a large amount of heat during normal operation. Under normal circumstances, the inverter works best at a constant temperature (generally 40-50 °c). How is this heat in a closed space? In order to pass, there are usually two ways; a) heat exchange b) cooling by the outside world.

 

A), explosion-proof inverter for heat exchange:

 

Explosion-proof inverter

B), positive pressure ventilation type control cabinet

 

Positive pressure ventilation type control cabinet

 

2. We are in terms of explosion-proof performance
3. A) Explosion-proof type explosion-proof:

 

In the case of this explosion-proof mode, the explosive gas can enter the casing, but the flame gas cannot propagate to the outside through the joint surface in the event of an explosion, that is, the explosion-proof body can prevent the flame in the box from spreading outward after the explosion, but Explosion inside the cabinet can damage the components and is also a loss.

 

B), positive pressure type explosion-proof control cabinet

 

Through this method, the pressure of the internal instrument to enter the clean instrument gas is higher than the outside, that is, the pressure inside the box is higher than that outside the box, and the explosive mixture of the outside can not enter the tank or the concentration of the explosive gas entering the explosion limit. , so there will be no bad explosion at all.

 

The total positive pressure explosion-proof control cabinet seems to be more troublesome than the explosion-proof control cabinet, but it is safe and reasonable.

Engineers can choose according to different equipment use site requirements

More question,welcome contact GN solids control