Section 1100

SOLIDS CONTROL HANDBOOK

January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 1 of 18

Tank Design and Equipment

Arrangements
1 Tank Design.........................................................................................................................1
1.1 Compartment Equalization.............................................................................................2
1.2 Sand Trap......................................................................................................................3
1.3 Slug Tank ......................................................................................................................3
1.4 Equipment Arrangement................................................................................................4
1.5 General Guidelines for Surface System Arrangements..................................................5

2 Equipment Arrangements...................................................................................................6
2.1 Unweighted Mud - Centrifuge Processing Active System...............................................6
2.2 Unweighted Mud - Centrifuge Processing Hydrocyclone Underflow ...............................8
2.3 Unweighted Mud - Centrifuge Processing Mud Cleaner Underflow .............................. 10
2.4 Weighted Water-Based Mud - Single-Stage Centrifuging (Barite Recovery) ................ 12
2.5 Weighted Mud - Two-Stage Centrifuging ..................................................................... 14
2.6 Complete System Layout For Both Weighted and Unweighted Mud ............................ 16

3 Summary............................................................................................................................ 18
FIGURES
Fig. 1. Unweighted mud - centrifuge processing active system. ..............................................7
Fig. 2. Unweighted mud - centrifuge processing hydrocyclone underflow................................9
Fig. 3. Unweighted mud - centrifuge processing mud cleaner underflow. .............................. 11
Fig. 4. Weighted water-based mud - single-stage centrifuging (Barite recovery) ................... 13
Fig. 5. Weighted mud - two stage centrifuging. ..................................................................... 15
Fig. 6. Generic - complete system. ....................................................................................... 17

1 Tank Design
The surface pits that comprise the active circulating system should be
designed to contain enough usable mud to maintain mud properties and to
fill the hole during a wet trip at the rig’s maximum rated depth. Usable mud is
defined as the mud volume which can be pumped before suction is lost. For
example, a typical 10,000 ft well will normally require a minimum active
system tank volume of 500 bbls.

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 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 2 of 18 Arrangements Dowell

The active surface system can be divided into two sections: Solids Removal
and Addition-Suction. All solids removal equipment and degassing occurs in
the Solids Removal section. The Addition-Suction section is used to add
fresh mud to the circulating system and provide sufficient residence time for
proper mixing to occur before being pumped downhole. A slug tank is usually
available to pump small “pills” such as LCM or barite slugs for tripping.
Each section must be further divided into enough compartments to efficiently
carry out its designed function. The number of compartments needed will
depend upon the amount and type of solids removal equipment, system size
and circulation rate. Each compartment must have enough surface area to
allow entrained air to break out of the mud. A rule of thumb for the minimum
surface area is calculated by:
Area (sq ft) = Maximum Circulating Rate (GPM)/40
To maximize solids suspension and usable volume, the best tank shape is
round with a conical bottom. Next best is a square or rectangular shape with
a V-bottom. The least-preferred shape is the square or rectangular box with
a flat bottom. The ideal tank depth is equal to the width or diameter of the
tank. This design provides sufficient pump suction head and is best for
complete stirring.

1.1 Compartment Equalization

Equalization height between compartments will depend upon the duty of the
compartment. As a rule, an adjustable equalizer is needed only between the
Solids Removal section and the Addition-Suction section. An adjustable
swing-arm equalizer is recommended. Normally, the equalizer will take mud
from the bottom of the last solids removal compartment and discharge mud
near the top of the first compartment in the Addition-Suction section (high
equalization). This keeps the fluid level high in the Solids Removal section to
maintain sufficient suction head for the centrifugal pumps, prevents vortexing
by the stirrers and provides sufficient mixing volume in barite-recovery
operations. In emergencies, the swing-arm can be lowered to provide access
to the full surface volume.
High equalization between the Solids Removal and Addition-Suction sections
also increases the ability to detect volume changes due to influx or losses to
formation. Because the volume of the Solids Removal Section remains
constant, any volume change is apparent as a liquid level change in the
Addition-Suction section only. This increases the sensitivity to volume
fluctuations since the change in fluid level will be more pronounced per unit
volume.
The minimum equivalent diameter of the equalizer for adequate flow
between compartments can be estimated by the following calculation:
1/2
Diameter, in. = (Qmax, gpm/15)

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 3 of 18

Recommended equalization between specific compartments is summarized

below:

Location Equalization
Sand Trap Exit High
Degasser High
Desander Low
Desilter Low
Centrifuge Low
Solids Removal - Addition High (Adjustable)
Addition-Blend Low
Blend-Suction Low

1.2 Sand Trap

A sand trap is the settling compartment located downstream of the shale
shakers. It should be the ONLY settling compartment and should not be
used in closed-loop systems. Its main function is to remove large solids
that might plug the downstream hydrocyclones. With the fine-screen
capabilities of today’s shale shakers, the sand trap mainly serves as a
backup should the shakers be bypassed or operated with torn screens. The
sand trap should be the first compartment the mud enters after passing
through the shaker screens. Since it is a settling tank, it should not be stirred
and the mud should exit the sand trap over a high weir.
The sand trap floor should have a 45° slope to its outlet. A 20 to 30 bbl
volume is sufficient. A quick opening solids dump valve that can be closed
against the mud flow is recommended to reduce mud losses. The sand trap
should be dumped only when nearly filled with solids, since whole mud is lost
when the sand trap is dumped.

1.3 Slug Tank

A slug tank is a small compartment (10-50 bbls) isolated from the rest of the
active system in the Addition/Suction section. Slug tanks provide the ability
to mix small volumes of specialized fluids and materials. The mud pump
suction is manifolded to provide access to the slug tank. The slug tank is
routinely used to mix small slugs of material to be pumped directly downhole,
such as high density pills for placement in the drill pipe prior to tripping. It is
also commonly used for preparation of LCM pills, spotting fluid for differential
sticking, and viscous sweeps. The mixing hopper must be manifolded to
permit isolation of the slug tank for mixing these pills.

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 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 4 of 18 Arrangements Dowell

1.4 Equipment Arrangement

The solids removal equipment should be arranged to sequentially remove
finer solids as the mud moves from the flowline to the suction pit. The
purpose of this arrangement is to reduce the solids loading on the next piece
of equipment. Each device must take mud from an upstream compartment
and discharge into the next compartment downstream. This applies to both
unweighted and weighted mud equipment arrangements. The amount and
type of equipment required will depend upon the drilling conditions and
economics specific to each well. Unless a detailed economic analysis is
made, it is usually better to overestimate solids removal equipment
requirements. Underequipping the rigs will usually result in more dire
consequences, such as low penetration rates, differential sticking, high
material consumption and excessive dilution and disposal volumes.
Proper routing of fluids through the solids removal system is essential to
achieve maximum solids removal efficiency. Mistakes in fluid routing can
drastically reduce separation performance by causing a large percentage of
the circulation rate to be bypassed. These errors are most commonly
associated with mud cleaners and hydrocyclones. In addition to suction and
discharge routing, overflow discharges to mud ditches and mud gun use are
other common sources of routing errors.
Ideally, each piece of solids control equipment should be fed by a single-
purpose pump with no routing option. Mud cleaners, desilters and desanders
should not, under any condition, require multiple suction locations. In
practice, complex routing with multiple suction options is the rule rather than
the exception. When this is the case, the internal configuration of the mud
tanks during rig up must be inspected to trace all lines. Do not rely on “as
built” schematics; they are usually incorrect. Color-coding of the correct
routing schematic to correspond with color-coded valves on the manifolds
can greatly assist rig crew members in making correct routing decisions.
“Hard-plumbed” routing errors should be corrected as soon as possible.

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 5 of 18

1.5 General Guidelines for Surface System Arrangements

The following guidelines are common to all equipment arrangements.
1. All removal compartments except the sand trap should be well-agitated
to ensure even solids loading.
2. Mechanical stirrers are recommended. Check that they are properly-
sized and installed correctly.
3. Mud guns are not recommended for the Solids Removal section.
4. When installed, the degasser should be located immediately
downstream of the shale shaker and upstream of any equipment fed
from a centrifugal pump.
5. Use a high equalizer between degasser suction and discharge.
6. All solids removal equipment should discharge immediately
downstream of their suction compartments.
7. All equipment except the centrifuge should process at least 100% of the
circulation rate. Backflow should be observed in these compartments.
8. Low equalization between suction and discharge for all solids removal
equipment.
9. Different solids control devices must not share suction compartments or
share discharge compartments unless they are making the same cut.
For example, two desilters may share the same fluid routing, but a
desander and desilter should not.
10. Adjustable equalizer between Solids Removal section and Addition-
Suction section. This equalizer should normally be high except when
access to the additional volume in the solids removal section is desired.
11. No solids removal equipment should discharge into the suction pit.

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 6 of 18 Arrangements Dowell

2 Equipment Arrangements

2.1 Unweighted Mud - Centrifuge Processing Active System

This arrangement may be used with unweighted muds having low
formulation costs, where liquid disposal costs are negligible. Some whole
mud is discarded with the hydrocyclone underflows. Typically used with
environmentally benign water-based muds. A mud cleaner should be used
only if there are insufficient desilter cones to process the entire circulation
rate; it should be run in parallel with the desilter. Blank off the screen and
discharge underflow. Use of a centrifuge will depend on the economics of the
specific application.

Equipment Median Comments

Separation

Shale Shakers < 147 mm Capable of running 100 mesh (d50=147 microns)
at maximum circulation rate.
Degasser na If required.
Desander 70 mm Processing Rate = 110% of maximum circulating
rate.
Discard Underflow.
Mud Cleaner 25 mm Use as a desilter if required to achieve 110% of
circulation rate.
Run in parallel with other desilter manifolds.
Desilter 25 mm Total Processing Rate (including mud cleaner
cones) = 110% of maximum circulating rate.
Discard Underflow.
Centrifuge 4 mm Process at least 25% of maximum circulating
rate. High G, high capacity machine.
Discard Cake (Solids).

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 7 of 18
Fig. 1. Unweighted mud - centrifuge processing active system.
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 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 8 of 18 Arrangements Dowell

2.2 Unweighted Mud - Centrifuge Processing Hydrocyclone

Underflow
Used to reduce liquid discharged with cuttings while maintaining high
separation efficiency. This arrangement is preferred when the liquid phase is
expensive or when free liquid discharge must be limited. Hydrocyclones
concentrate solids to centrifuge. Use caution when processing abrasive
desander underflow; it may cause premature centrifuge wear. Centrifuge
should process in excess of hydrocyclone underflow rate, with makeup mud
from the active system. Refer to the centrifuge chapter for details of feed
compartment design and routing.

Equipment Median Comments

Separation

Shale Shakers < 147 mm Capable of running 100 mesh (d50=147 microns)
at maximum circulation rate.
Degasser na If required.
Desander 70 mm Processing Rate = 110% of maximum circulating
rate.
Underflow to Centrifuge.
Desilter 25 mm Processing Rate = 110% of maximum circulating
rate.
Underflow to Centrifuge.
Centrifuge 4 mm Processing Rate > Hydrocyclone underflow rate.
High G, high capacity machine.
Feed from hydrocyclone underflows, plus active
system.
Cake (wet solids) are discarded.

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 9 of 18
Fig. 2. Unweighted mud - centrifuge processing hydrocyclone underflow.
CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 10 of 18 Arrangements Dowell

2.3 Unweighted Mud - Centrifuge Processing Mud Cleaner Underflow

Recommended when large sections of sand are expected and free liquid
must be recovered from desander underflow. The mudcleaner screen
receives desander underflow. Sand is removed by the mud cleaner screen.
Screen unders are processed by the centrifuge. Best alternative is to provide
enough shale shakers to screen down to desander separation efficiency
(74 microns) or use full size shaker to process cone unders.

Equipment Median Comments

Separation
Shale Shakers 147 mm Capable of running 100 mesh (d50=147
microns) at maximum circulation rate.
Degasser na If required.
Desander 70 mm Processing Rate = 110% of maximum
circulating rate.
Underflow to mud cleaner screen.
Mud Cleaner 25 mm Total processing rate should exceed maximum
circulating rate.
Both desander and mud cleaner cone
underflows screened before processing by
centrifuge.
Centrifuge 4 mm Processing Rate > Hydrocyclone underflow
rate.
High G, high capacity machine.
Feed from hydrocyclone underflows, plus active
system.
Discard Cake (wet solids) are discarded.

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 11 of 18
Fig. 3. Unweighted mud - centrifuge processing mud cleaner underflow.
CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 12 of 18 Arrangements Dowell

2.4 Weighted Water-Based Mud - Single-Stage Centrifuging (Barite

Recovery)
This is the standard equipment arrangement for weighted water-based muds
when fluid costs are low and liquid discharge is permitted. The mud cleaner
may be used when the shakers cannot screen down to 200 mesh, but
monitor barite losses. The centrifuge removes liquid and colloidal solids
while recovering barite. Low centrifuge feed rates at high g-force and
continuous processing are recommended to maximize barite recovery.

Equipment Median Comments

Separation
Shale Shakers > 74 mm Capable of screening to 200 mesh at
maximum circulation rate.
Monitor solids discharge for barite content.
Degasser na If required.
Mud Cleaner 74-100 mm Run only if insufficient shaker capacity.
150 mesh screens recommended.
Monitor screen discharge for barite content.
Centrifuge 4 mm Process 10-15% of circulation rate.
Return solids to well-agitated compartment,
upstream of addition section.
Dilute feed.
Discard centrate.

Note: Refer to the Dewatering chapter for addition of chemically-enhanced

dewatering unit to this system.

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 13 of 18
Fig. 4. Weighted water-based mud - single-stage centrifuging (Barite recovery)
CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 14 of 18 Arrangements Dowell

2.5 Weighted Mud - Two-Stage Centrifuging

This arrangement is used when liquid discharge must be minimized. The first
centrifuge operates as a barite recovery unit. The second centrifuge,
operating at maximum g-force, processes the centrate (overflow) from the
barite recovery centrifuge. The solids are discharged and the centrate is
returned to the active system. Colloidal solids are not removed.

Equipment Median Comments

Separation
Shale Shakers > 74 mm Screen with finest mesh possible, down to 200
mesh (d50=74 microns) at maximum
circulation rate.
Monitor solids discharge for barite content.
Degasser na If required.
Mud Cleaner 74-100 mm Run only if insufficient shaker capacity.
150 mesh screens recommended.
Monitor solids discharge for barite content.
Centrifuge #1 Barite recovery mode, high capacity machine.
Return barite to well-agitated compartment
upstream of addition section.
Dilute feed.
Run at highest G-force conditions will allow.
Centrate to centrifuge #2.
Centrifuge #2 4 mm Run at maximum rpm, high-G machine.
Discard solids.
Return centrate to active system.

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 15 of 18
Fig. 5. Weighted mud - two stage centrifuging.
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 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 16 of 18 Arrangements Dowell

2.6 Complete System Layout For Both Weighted and Unweighted

Mud
In many cases, multiple suction and discharge locations cannot be avoided.
For example, centrifuges that will process both unweighted and weighted
systems must be located to permit routing both the cake and centrate
streams to either the active system or to discharge. The following
schematics show the fluid routing requirements for a solids removal system
which must process either unweighted or weighted mud.
Note: The centrifuge to be used for barite recovery must be positioned so
the solids may be routed either to discharge (unweighted) or returned
to the active system (weighted mud). Use a high capacity machine
for treating out coarse desilter underflows or recovering barite. The
second unit should be a high-G machine capable of removing fine
solids. If only one machine is used, it should be a high-G unit.

CONFIDENTIAL
 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Dowell Arrangements Page 17 of 18
Fig. 6. Generic - complete system.
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 Section 1100
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Tank Design and Equipment
Page 18 of 18 Arrangements Dowell

3 Summary
· The mud pits must contain enough usable mud to maintain mud
properties and to fill the hole during a wet trip at maximum depth.
· The active circulating system is divided into two sections: Solids
Removal and Addition-Suction. The purpose of each is self-explanatory.
Each section is further divided into enough compartments to carry out
its designed function. Additional tankage includes the slug tank for
mixing and pumping small pills, the trip tank for accurately metering
pipe displacement during trips, and the premix tank discussed in
Chapter 10, Addition/Mixing Systems.
· The best compartment shape is round with a conical bottom, followed
by square with a V-bottom. Each must have enough surface area to
allow entrained air to break out.
· Equalization height between compartments will depend upon the duty of
the compartment. Refer to the discussion in this chapter for specific
recommendations.
· The sand trap, located under the shale shakers, is the only settling
compartment and should not be used in closed loop systems.
· Equipment arrangements for a variety of unweighted and weighted
muds are illustrated in this chapter. Also included is a complete system
arrangement when both unweighted and weighted muds must be
processed during the course of the well.

CONFIDENTIAL