Mud Processing System

Mud Processing System
© 2022 Derrick Corporation

Addition Removal Well
Suction
Removal Section: The tanks and equipment used for the separation of drilled solids and gas from the drilling fluid.
Addition Section: The equipment and tanks utilized in the addition and blending of mud additives.
Suction Section: The tank(s) from which the rig pumps take suction, and any associated pumps or mixing equipment.
Circulation volume : Usually consists of 1.5 a Hole Volume
Additional components : Flow Line, Active tanks, Reserve tanks, Trip tank(s), Agitators, Pumps, Motors, Solids and Gas removal
devices, mixing and shearing devices, and associated piping.
Surface Mud Systems
The size of each section

depends upon the size
of the hole being drilled
and the depths of these
holes.
7
Agitation
Rectangular with flat bottom

11
Rectangular with
concave bottom
Vertical
cylindrical
with concave
bottom
Rectangular with sloped
bottom
• Create an upward velocity within the
mud tanks that is greater than the
settling velocity of the suspended
solids.
• Maintain a homogenous mixture

throughout the surface system.
Common Types of Mud Agitators
Vertical Mud Agitator Horizontal Mud Agitator
Agitator Flow Patterns
Fluid travels in a horizontal,
Radial Flow circular fashion and only moves
upward when it hits the side
wall of the tank compartment.
Impeller blades are
vertically mounted, in
line with the agitator
shaft.
Turbine Impeller
5 Ft. Depth or Less
Axial Flow
Impeller blades are

slanted at 45°
Canted Impeller
5 Ft. Depth or Greater
Combination Flow
▪ Contoured (swept-faced)
impellers promote both radial
and axial flow patterns
depending on the inclination
and pitch of the impeller.
▪ This type of blade requires

less horsepower but does not
impart near the shear forces
of the other types of blades.
Therefore, they are mainly
used in large volume holding
tanks.
Dual Impellers
Recommend Dual Impellers

for tanks greater than 9 Ft.
Mud Depth
Required Information for Sizing
Rectangular Tank, Flat Bottom
Tank Dimensions:
-Length, 30 ft. -Width, 10 ft. -Height, 10 ft.
1. Tank/Compartment Volume, gallons = Length × Width × Height × 7.4805

2. If Length is 1.5 times the Width, then divide the tank into equal
compartments.
Height, 10 ft.
22,224 Gallons
483 barrels
Length, 30 ft.
Rectangular Tank, Concave Bottom
Gallons per
Tank Dimensions: cubic ft
‒ Length, 10 ft. ‒ Top Height, 8 ft. ‒ Top Width, 10 ft.
‒ Concave Depth, 2 ft. ‒ Radius, 5 ft.
1. Tank/Compartment Volume, gallons = Length × Width × Height × 7.4805
2. Concave Volume, gallons = (3.1416 × Radius2 × Length × 7.4805) × (2 ÷
(Radius × 2))
3. Total Volume, gallons = #1 + #2
Width, ft.
End View.
Height, ft.
5,984 gals (top section)
1,175 gals (concave section)

Depth, ft.
Length, ft.
Vertical Cylindrical Tank, Concave Bottom
Radius, ft.
Tank Dimensions:
▪ Radius, 5.0 ft.
▪ Cylindrical Depth, 8.0 ft.
▪ Concave Depth, 2.0 ft.
Height, ft.
4,700 gals
1. Cylindrical Volume, gallons =
3.1416 × Radius2 × Height ×
7.4805
2. Concave Volume, gallons =

3.1416 × Radius2 × Height ÷ 2 ×
Height, ft.
7.4805
1,175 gals
Rectangular Tank, Sloped Bottom
Tank Dimensions:
-Length, 10 ft. -Top Width, 10 ft. -Top Depth, 6 ft. -Sloped Depth, 4ft.
- Bottom Width, 2 ft.
1. Tank/Compartment Volume, gallons = Length × Width × Depth × 7.4805

2. Sloped Volume, gallons = (Length × Depth) × (Top Width + Bottom Width) ÷ 2)) ×
7.4805
3. Total Volume, gallons = #1 + #2
Top Width, ft.
Top Depth, ft.

End View.
4,488 gals
1,795 gals
Sloped Bottom
Depth, ft. Width, ft.
Length, ft.
Horizontal Cylindrical Tank Part 1
Tank Dimensions:
-Length, 10 ft. -Radius, 5 ft. -Mud Depth, 8 ft.
1. 100% Tank Volume, gallons = 3.1416 × Radius2 × Length × 7.4805 (5,875 gals)
2. Ratio of Tank Depth = (Mud Depth ÷ (Radius × 2)) × 100 (80)
3. Obtain tank percentage from curve chart
End View.
Radius, ft.
Length, ft. Mud Depth, ft.
Curve for Cylindrical Tank in a Horizontal Position
100
95
90
85
Ratio of Liquid Depth to Diameter
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
% of Total Volume
Horizontal Cylindrical Tank Part 2
Tank Dimensions:
-Length, 10 ft. -Radius, 5 ft. -Mud Depth, 8 ft.
1. 100% Tank Volume, gallons = 3.1416 × Radius2 × Length × 7.4805 (5,875 gals)
2. Ratio of Tank Depth = (Mud Depth ÷ (Radius × 2)) × 100 (80.00 %)
3. Obtain tank percentage from curve chart (76.00 %)
4. Actual Tank Volume, gallons = Chart % × 100% Volume gallons (4,465 gals)
End View.
Radius, ft.
4,465 gals
Length, ft. Mud Depth, ft.

Required Information for Sizing
Blade Displacement
QGPM =

 (L )R
1
2 2

− (R − L2 ) (RPM )(# Blades)
231
Where; L1 = bladewidth  sin( )
*Units are in Inches
L1 
L2 R
Turnover Rate (TOR) The time it takes to circulate the entire pit one time.
Vt
TOR =  60
D
Where: Vt = Tank Volume (gallons) and D = Impeller Displacement (gpm)
SOLIDS
COMPARTMENT SUCTION RESERVE SLUG/PILL
CONTROL
RECOMMENDED TOR
50 TO 75 65 TO 80 50 TO 80 40 TO 60
(SECONDS)
HP Calculations
Impeller Power
Required to Size Motor

➢ Function of Power Number, RPM, Diameter, SG of Fluid
where N P  SG  RPM 3  D 3 and N p = 1.37  C  Cn  CW  CC

HP =
1.5241013
 sin  
2.08
• Blade Angle Correction Factor C =   

 sin 45 
n
• Blade Number Correction Factor Cn = 1.0 + 1.34 log 
4
0.68
W D 
• Blade Width Correction Factor CW =  
 0.2 
−0.25
C
• Impeller Clearance Correction Factor CC =  
D
Horsepower Calculations
Agitator Models
Displacement/Horsepower Values for all Derrick Impellers
Impeller R60 Hz R50 Hz V60 Hz V50 Hz
Size Canted Dual Canted Turbine Canted Dual Canted Turbine Canted Dual Canted Turbine Canted Dual Canted Turbine
5 HP 5 HP 5 HP 3 HP 3 HP 3 HP 5 HP 5 HP 5 HP 3 HP 3 HP 3 HP
20" 1,487 GPM 2,973 GPM 1717 GPM 1240 GPM 2481 GPM 1432 GPM 1313 GPM 2627 GPM 1517 GPM 1096 GPM 2192 GPM 1265 GPM
5 HP 7.5 HP 7.5 HP 5 HP 7.5 HP 7.5 HP 5 HP 7.5 HP 5 HP 5 HP 7.5 HP 5 HP
7.5 HP 15 HP 10 HP 7.5 HP 10 HP 7.5 HP 5 HP 10 HP 7.5 HP 5 HP 10 HP 7.5 HP
10 HP 20 HP 15 HP 7.5 HP 15 HP 10 HP 7.5 HP 15 HP 10 HP 7.5 HP 15 HP 7.5 HP
46" 11,102 GPM 22204 GPM 12820 GPM 9158 GPM 18315 GPM 10574 GPM 10888 GPM 21776 GPM 12572 GPM 9067 GPM 17962 GPM 10370 GPM
48" 12,723 GPM 25445 GPM 14691 GPM 10494 GPM 20989 GPM 12118 GPM 12477 GPM 24955 GPM 14408 GPM 10292 GPM 20584 GPM 11884 GPM
30 HP 30 HP 25 HP 25 HP 25 HP 30 HP 30 HP 25 HP 25 HP 25 HP
50" 13,768 GPM 15897 GPM 11356 GPM 22713 GPM 13113 GPM 13502 GPM 15591 GPM 11137 GPM 22275 GPM 12860 GPM
18 PPG 16 PPG 14 PPG 12 PPG 10 PPG 8.33 PPG

Agitator Sizing Program
Baffles
Baffles may be installed around each mechanical stirrer to prevent air vortices and settling in corners.
T = Tank Diameter
Baffle Types
Works Best
Installation & Parts
Suction Line Placement
2 x Pipe
Diameter Away
Agitator Impeller Placement
Impeller placement:
• Turbine - (depth < 6 ft.)

12 in from tank bottom
• Canted - (depth > 6 ft.)

Primary – 75% of
impeller diameter off
tank bottom
• Canted - (depth > 6 ft.)

Secondary – 67% of
mud depth off tank
bottom
Agitator Shaft Size Shaft Length = Tank Depth – Gearbox Stub
Shaft Size = 3.25 in
In/MM In/MM In/MM

Addition & Suction Tanks
Centrifugal Pump
Kinetic Energy Expressed
Fluid accelerates
to a velocity near
that
Vm------------ Vr of the tips of the
-------
impeller.
Vt
H = V²
2g
Feet of Head H = V²
2g
H = Vertical Fall Distance (ft)
V = Vertical Velocity (ft/sec)
g = Gravitational Constant (ft/sec2)
Impeller Velocity = 80.2 ft/sec
(80.2)² Tip speed

H=
2(32.2)
H = 100 feet of head

Head is the height --------------------------------------
at which a pump
can raise fluid up
resulting from the
kinetic energy the
pump gives to the
liquid
Head vs Pressure
Centrifugal pumps are constant head devices, not constant pressure or output devices.
The main reason for using head instead of pressure to measure a centrifugal pump's energy is that the pressure
from a pump will change if the specific gravity (weight) of the liquid changes, but the head will not change.
Mud Density 12 ppg Mud Density 15ppg

PSI = 46.8 PSI = 60.0
75 ft. 75 ft.
Slurry Density,
Head, & Pressure
Pressure (psi)
– Head (ft) =
Slurry Density (lb./gal) X .052
– Pressure (psi) = Head (ft) X .052 X Slurry Density (lb./gal)
– Pressure (psi) Rule of thumb = Approx. 4 X Mud Weight in

lb./gal at 75’ Head
75fH x .052 = 3.9 x lb./gal

100
Fluid Density, ft/hd
Head, & Pressure
75 ft/hd
4 x Mud weight(ppg)
10 ppg
1.2 SG
Net Positive Suction Head
A centrifugal pump cannot “suck” fluids into the

housing. Fluid must flow into the housing because
of a positive pressure. A low pressure exists at the
center of an impeller.
Atmospheric pressure must push the fluid into the

pump. If the pump suction requires that the fluid
be lifted up into the pump housing, the head
available many be insufficient. Pressures in the
center of the impeller are measured from absolute
zero pressure.
Any pressure above absolute zero is called a net

positive suction pressure.
Cavitation
The formation of vapor cavities,("bubbles" or "voids"), in a liquid.
When subjected to higher pressure, the voids become
unsustainable and implode generating an intense shock wave.
Cavitation Forming
Impeller Veins Cavitation

Cavitation
Anything below is
Inlet in. by Discharge in. by Impeller Housing in.
a 50 Hz
Fh = 75 + Lift + Friction Loss Total Semi- Vertical Line is :

Net Positive Suction Head
Friction Loss = each turn or fitting add 1 ft The head at the suction of the pump
above absolute zero.
PSI = Fh x .052 x ppg or ( 4 x mud weight) The tank depth required to flood the
suction
Curved Line is
Motor Efficiency
Dark Black Line is

Impeller Dia
Increase by .25”
Dashed Black Line is Basic

Horsepower for water
If you know your mud weight, then
calculate by:
GPM x Fh x SG ÷ 2772
Removal Section
Dilution: Refers to the process of adding drilling fluid to maintain a targeted drilled-solids
concentration.
Low Gravity Solids

• Drilling rigs with good
solids removal systems
can comfortably maintain
high removal efficiency
with minimum losses.
• It is always best to
remove drilled solids at
the flow line because
they will never be that
large again.
Solids Control Equipment is the
most cost effective way to
eliminate the detrimental effects
of solids contamination
Recommend Minimum of 1” Drop per Foot

70
Flowline
If circulation stops, this whole section of the

flowline would potentially remain full of liquid
which would eventually harden and cause
blockage. At this point, if circulation were to
start again, it’s very likely that the bell nipple
would overflow.
Flowline
Correction to shaker or flowline placement
Flo-Divider
Stage 1 for circulation,

evenly disperse your flow rate between shale
shakers
Uneven Flow Distribution
75 micron
Solids Classification
API CLASSIFICATION SIZE RANGE (MICRONS) COMMON TERM API SCREEN
Coarse >2000 Gravel 10
Intermediate 250 - 2000 Dirt 60 - 10
Medium 73 - 250 Sand 200 – 60
Fine 44 - 73 Silt 325 - 200
Ultra Fine 2 - 44 Clay NA – 325
Colloidal 0-2 Clay NA

Removal Section
Sand Gas Fines Ultra-fines Colloidal Colloidal

Stage 2 for circulation,
use mechanical agitation to keep the solids in
suspension.
•The sand trap is the only settling compartment
Sand Trap = 45° Sloped
Bottom in the surface mud system. It should not be
stirred nor should any pump take its suction
from the sand trap.
•The outlet valve should be large, non-plugging,
and quick opening and closing.
High Weir
Sand Trap
Typical Sand Trap
Equalization Quick Guide
Sand Trap Exit High
Degasser High
Desander Low
Desilter Low
Centrifuge Low
Solids Removal – Addition High *(Adjustable)
Addition - Blend Low
Blend - Suction Low
𝑀𝑎𝑥 𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑅𝑎𝑡𝑒

Pipe Diameter =
15
Flo-Divider
Stage 3 for circulation, ensure proper

equalization lines.
High Weir High Weir
Sand Trap
Stage 1 for Solids Removal.
Shale Shakers process 100% of the flow.
High Weir High Weir
Sand Trap
Shaker Motion
Center of Gravity (CG):

Balances basket to
provide consistent
motion
Conveyance SIN (450) × 0.16” × 1755rpm ÷ 60 sec.
Conveyance = 3.30926 in/sec
1755
rpm
450
0.16”
Screen Purpose
Remove Drill Solids While Saving Drilling Fluid
Screen Performance
The size of solids moving through a screen depend on:
• Thickness of the wire

• Shape of the opening
• Layers of the screen
NON-BLANKED OPEN AREA
The area of cloth that is

not blocked by any
supporting structure
.75 in. 1.5 in.

Mud Properties affect screen cloth!
Cyclic Checking
Failure & Changing screens
Holes
93
Confidential © 2014 Derrick Corporation
Shaker Performance
Fluid Capacity and Circulation
Shaker capacity is determined

by:
Solids Capacity Limit: the

maximum amount of solids that
a device will convey.
Liquid limit: the maximum gpm

capacity for various drilling
fluids.
Particle Plugging
Screen Blinding
Screen Label
• The API Screen Designation
API screen number; 2 x font
size
– D100 separation in microns
– Non-blanked area in square
feet or square meters
– Conductance in
kilodarcies/millimeter
– Manufacturer's Designation
/ Part Number
– Statement of conformance
to ISO 13501 (API RP 13C)
Fluid End Point
Hyperpool
Basket Angle Adjustment Alternate Adjustment
Pond Configuration
Correct Basket Angle

Correct Flow Rate
Increase Flow rate

Decrease Basket Angle
Screen Finer
Decrease Flow rate

Increase Basket Angle
Screen Coarser
POND AREA OPEN SCEEN AREA

Fluid End Point
504 / 514
Basket Angle Adjustment Alternate Adjustment
Pond Configuration
Correct Basket Angle

Correct Flow Rate
Increase Flow rate

Decrease Basket Angle
Screen Finer
Decrease Flow rate

Increase Basket Angle
Screen Coarser
POND AREA OPEN SCEEN AREA

Oil Rig Tender Specifications for Shale Shakers
 Tender 1 (Algeria)
 Tender 2 (India)
 Tender 3 (Ukraine)
Tender 1

106
Tender 2

107
Tender 3
36 l/s x 15.85 = 570 GPM

108
Stage 4 for circulation, ensure proper
connection and operation of a degasser if
needed.
High Weir High Weir
Sand Trap
• When either a desander, a desilter, or both are
mounted over the top of a shale shaker basket,
the device is called a mud cleaner.
• Shale shakers were first combined with

hydrocyclone units to solve the problem of
excessive loss of barite and excessive drilling
fluid loss in the discard stream from the cones.
• When drilling with weighted muds or muds with

expensive base fluids, mud cleaners should be
run preferentially rather than desanders or
desilters by themselves.
Principle of Operation
• A hydrocyclone is a device that

separates particles in a liquid
suspension based on the ratio
of centripetal force to fluid
resistance
Spray Discharge
Hydrocyclone Operation
Pressure
• Hydrocyclones require 75 Feet of

Head (Fh) at feed inlet
• 75 Fh at feed inlet is essential for:
• Proper operation
• Efficient separation
• Pressure at the feed inlet is
measured with a pressure gauge
and can be converted to a Feed
Head Reading
Stage 2 for Solids Removal
Operate a Desander if screens are API 140 or smaller.
Stage 3 for Solids Removal ,
Operate a desilter in unweighted mud
Efficiency
____ gpm ÷ 1200 gpm x 100 = = ____ % Efficiency
20 cyclones
______ gpm
75 fh
1,200
GPM ___
gpm
1,200
GPM
Mud Cleaner Economics
– Collect sample from screen discard
– Perform gravimetric retort test for
solids concentrations (per API RP
13C)
– If % volume HGS > % volume LGS,
then the mud cleaner may not be
economical
• Detailed economic analysis
– Compare mud and barite discarded
versus dilution needed to control
percent drilled solids
Mud Cleaner vs. Centrifuge
• Mud Cleaner:
– Designed to process 100% of active system
– Discards larger drilled solids (> 75 microns)
• Centrifuge
– Normally processes 10-20% of active system
– Remove smaller solids (< 20 microns)
They complement, not replace, each other!

Stage 4 for Solids Removal,
Operate a centrifuge for fine/ultrafine particles.
Solids
Stage 4 Option for Solids Removal
Operate dual centrifuges for high density mud.
Sand Trap
Solids
Solids Control Equipment
Un-Weighted System
Micron Size Range

Colloidal
Medium, Intermediate, & Coarse Sand
Ultra Fine & Fine - Clay, Silt & Sand Clay
925 184 154 120 104 83 76 65 50 43 30 20 10 5 2 1

D50 cut point
D50 cut point (48 microns) (10 microns)
D50 cut point (87 microns)
API 140
API 170
API 200
API 230
API 270
API 325 Desander and /or Desilter Centrifuge
processes 120% of shale shaker Primary
underflow Application: Un-
weighted and
Closed Loop
Shale Shaker processes 100% of the flow and discards System
the largest cuttings of the size spectrum
Solids Control Equipment
Weighted System
Micron Size Range
Colloidal
Medium, Intermediate, & Coarse Sand Ultra Fine & Fine - Clay, Silt & Sand
Clay
Barite
925 184 154 120 104 83 76 65 50 43 30 20 10 5 2 1

76 Microns (API 200)
API 140
API 170
API 200
Centrifuge
High G’s
Centrifuge 600 to
Secondary
900 G’s
Desander/Desilter Application:
Primary
process rate should be Weighted Mud,
Application:
120% of shale shaker process of primary
Weighted Mud
underflow centrifuge effluent
System, Barite
Shale Shaker processes 100% of the flow Recovery
discarding the largest cuttings of the size
spectrum with minimum Barite Loss
We are a Global Family® focused on Pioneering Technology®.
© 2023 Derrick Corporation. All rights reserved. Derrick and all its products indicated by trademark symbols are trademarks and/or registered trademarks of Derrick Corporation.

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© 2022 Derrick Corporation

Circulation volume : Usually consists of 1.5 a Hole Volume

The size of each section

© 2022 Derrick Corporation

• Maintain a homogenous mixture

Impeller blades are

▪ This type of blade requires

Recommend Dual Impellers

1. Tank/Compartment Volume, gallons = Length × Width × Height × 7.4805

1,175 gals (concave section)

2. Concave Volume, gallons =

1. Tank/Compartment Volume, gallons = Length × Width × Depth × 7.4805

Top Depth, ft.

Length, ft. Mud Depth, ft.

*Units are in Inches

Required to Size Motor

where N P  SG  RPM 3  D 3 and N p = 1.37  C  Cn  CW  CC

• Blade Angle Correction Factor C =   

18 PPG 16 PPG 14 PPG 12 PPG 10 PPG 8.33 PPG

• Turbine - (depth < 6 ft.)

• Canted - (depth > 6 ft.)

• Canted - (depth > 6 ft.)

Shaft Size = 3.25 in

In/MM In/MM In/MM

Impeller Velocity = 80.2 ft/sec

(80.2)² Tip speed

H = 100 feet of head

Mud Density 12 ppg Mud Density 15ppg

– Pressure (psi) = Head (ft) X .052 X Slurry Density (lb./gal)

– Pressure (psi) Rule of thumb = Approx. 4 X Mud Weight in

75fH x .052 = 3.9 x lb./gal

A centrifugal pump cannot “suck” fluids into the

Atmospheric pressure must push the fluid into the

Any pressure above absolute zero is called a net

Impeller Veins Cavitation

Fh = 75 + Lift + Friction Loss Total Semi- Vertical Line is :

Dark Black Line is

Dashed Black Line is Basic

Low Gravity Solids

© 2022 Derrick Corporation

If circulation stops, this whole section of the

Stage 1 for circulation,

Coarse >2000 Gravel 10

Intermediate 250 - 2000 Dirt 60 - 10

Medium 73 - 250 Sand 200 – 60

Fine 44 - 73 Silt 325 - 200

Ultra Fine 2 - 44 Clay NA – 325

Colloidal 0-2 Clay NA

Sand Gas Fines Ultra-fines Colloidal Colloidal

𝑀𝑎𝑥 𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑅𝑎𝑡𝑒

Stage 3 for circulation, ensure proper

High Weir High Weir

High Weir High Weir

Center of Gravity (CG):

• Thickness of the wire

The area of cloth that is

.75 in. 1.5 in.

Shaker capacity is determined

Solids Capacity Limit: the

Liquid limit: the maximum gpm

Correct Basket Angle

Increase Flow rate

Decrease Flow rate