Other than the drill floor itself, the solids control system requires more attention than any other single rig system whether onshore or offshore. For that reason, it is most important that the solids control system is designed to be as efficient and as maintenance free as possible. This section will discuss that pan of the mud system extending from the bell nipple (or diverter housing outlet) to the mud pump suction piping.
A large percentage of the solids generated in the drilling process must be removed from the drilling mud so that the mud properties can be controlled. Solids control equipment can be used to remove a portion of the solids generated. If the equipment cannot remove a sufficient percentage of the drilled solids for mud control, then discarding of whole mud is required to achieve adequate solids removal. One way to look at solids removal effectiveness for a drilling mud/solids control system is
to determine the efficiency of removal of drilled solids by the system.
This handbook describes the method and mechanical systems available to control drilled solids in drilling fluids used in oil well drilling. System details permit immediate and practical application both in the planning/design phase and in operations.
Good solids-control programs are often ignored because basic principles are not understood. This book explains the fundamentals of good solids control. Adherence to these simple basic principles is financially rewarding.
This American Society of Mechanical Engineers (ASME) textbook/handbook is a revision of the American Association of Drilling Engineers (AADE) Shale Shaker Handbook, which was a revision of the International Association of Drilling Contractors (IADC) Mud Equipment Manual. Many of the authors of this book were authors of those books as well. Patience, dedication, many long hours of work, and evaluation of the latest technology have been required of all members of this committee. Ten years were required to write the IADC Manual;
7 years were required to write the AADE Handbook; and 2 years were required to write this textbook.
None of the authors of any of the three books have received any compensation for their work and writing. The group was dedicated to providing the drilling industry with the best technology available, and many hours of discussion were frequently required to resolve controversial issues.
Fallacious arguments persist that drilled solids are beneficial. Drilled
solids are evil and insidious. Increases in drilled-solids concentrations
generally do not immediately reveal their economic impact. Their
detrimental effects are generally not immediately obvious on a drilling
rig; so skeptics fail to believe that drilled solids foster the havoc that they
truly do. The secret to drilling safely, fast, and under budget is to remove
drilled solids. Drilled solids increase drilling costs, damage reservoirs,
and create large disposal costs. Specific problems associated with drilled
. Filtrate damage to formations
. Drilling rate limits
. Hole problems
. Stuck pipe problems
. Lost circulation problems
. Direct drilling-fluid costs
. Increased disposal costs
These bad effects of drilled solids are explored in greater detail here
and in the rest of the book. The eradication of these effects is discussed
in great detail in this book. The book may be used for planning and
designing a drilling-fluid processing system, improving current systems,
troubleshooting a system, or improving rig operations. Drilled solids are
evil, and this is the theme of this Handbook.
The effects of drilled solids on the economics of drilling a well are
subtle. Increasing drilled-solids content does not immediately result in
disaster on a drilling rig. When a drill bit ceases to drill and torque
increases, a driller knows immediately that it is time to pull the bit.
When drilled solids increase, the detrimental effects are not immediately
apparent. Decreasing drilled solids is analogous to buying insurance for an event that will not happen. Proving that something will not happen—
like stuck pipe—is difficult to do. This is somewhat like the story of
Salem, who was walking down Main Street snapping his fingers. Friend
asks, ‘‘Why are you snapping your fingers?’’ Salem: ‘‘Keeps the tigers
away.’’ Friend: ‘‘There are no tigers on Main Street.’’ Salem: ‘‘Yeah,
works doesn’t it?’’ No drilling program calls for stuck pipe or fishing
jobs even if they are common in an area with a particular drilling rig.
The evil effects of drilled solids are real. Acknowledging that fact and
preparing to properly handle them at the surface will result in much
lower drilling costs.
Good drilled-solids removal procedures start at the drill bit. Cuttings
should be removed before another drill bit cutter crushes rock that has
already been removed from the formation. These cuttings should be
transported to the surface with as little disintegration as possible. In
addition to the cuttings produced by the drill bit, slivers or chunks of
rock from the well-bore walls also enter the drilling fluid stream. Large
drilled solids are easier to remove than small ones. After the cuttings
have reached the surface, the correct equipment must be available to
handle the appropriate solids loading, and the processing routing must
be correct. Surprisingly, after all these years of using drilling fluids, the
simple principles of arranging equipment are seldom practiced in the
field. Some drilling rigs, particularly offshore ones, have a complex
manifold of plumbing in the surface drilling fluid pits. The concept is
that any one of the centrifugal pumps can pump from any compartment
to any other compartment by adjusting valves. This concept is incorrect
and detrimental to proper drilled-solids removal. Generally, arranging
the complex routing for correct solids-removal processing is so
unobvious that all of the drilling fluid is not processed by the equipment.
Also, valves can leak in this system and go undetected for many wells.
Better to follow the rule, One pump/one purpose. Add additional
plumbing or pumps but do not use solids-removal equipment feed
pumps for anything but their stated purpose. This book shows how the
equipment works and how it should be plumbed.
While drilling wells, drilling fluid is processed at the surface to remove
drilled solids and blend the necessary additives to allow drilling fluid to
meet specifications. Drilling-fluid processing systems are described in
this book from both a theoretical point of view and practical guidelines.
It will be as useful for a student of drilling as for the person on the rig.
Drill bit cuttings and pieces of formation that have sloughed into the
well bore (collectively called drilled solids) are brought to the surface by
the drilling fluid. The fluid flows across a shale shaker before entering the
mud pits. Most shale shakers impart a vibratory motion to a wire or
plastic mesh screen. This motion allows the drilling fluid to pass through
the screen and removes particles larger than the openings in the screen.
Usually drilled solids must be maintained at some relatively low
concentration. The reason for the need for this control is explained in
the next section. The shale shaker is the initial and primary drilled-solids
removal device and usually works in conjunction with other solidsremoval
equipment located downstream.
Solids-control equipment, also called solids-removal equipment or
drilled-solids management equipment, is designed to remove drilled
solids from a circulating drilling fluid. This equipment includes gumbo
removers, scalper shakers, shale shakers, dryer shakers, desanders,
desilters, mud cleaners, and centrifuges. These components, in various
arrangements, are used to remove specific-size particles from drilling
fluid. Knowledge of operating principles of auxiliary equipment, such
as agitators, mud guns, mud hoppers, gas busters, degassers, and
centrifugal pumps, is necessary to properly process drilling fluid in
surface systems. All of this equipment is discussed in this book.
However, the best equipment available is insufficient if it processes only
a portion of the active drilling fluid coming from the well.