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It is now commonly understood that effective removal of drilled solids from drilling fluid is fundamental to jobsite performance. In fact, it is rare to see drilling rigs operating without some form of solids control system in place. This has been driven by the growing number of benefits that a well-designed solids control system provides. Including but not limited to,
By and large, increased drilled solids removal equates to lower drilling costs and lower long-term maintenance costs. However, in order to achieve those benefits, today&#;s drilling fluid reclamation systems must first rely on a quality vibratory shaker.
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Otherwise known as shale shakers, shakers are the first line of defense for a properly designed solids control system. Shakers have been used on conventional drilling rigs since the s and are a significant part of the drilling process. Choosing the right shaker for your operational needs is crucial in maximizing solids control operations. However, making the right choice can be a confusing, and in many cases, frustrating experience. Key variables that should be considered include:
When drilling fluid, laden with drilled solids, flows across the shaker screen, residence time plays an important factor in liquid/solid separation. Shaker inclination influences the time the fluid stays on the screen. Further, when a positive deck angle is selected, pooling of the drilling fluid is allowed to occur on the shaker screens. This allows for a higher head pressure across the screen surface and can improve the hydraulic capacity of the shaker. Typical shakers feature leveling jacks that allow the deck to be adjusted to a declined (downward or negative), horizontal (flat) or inclined (upward or positive) position.
New innovations in shaker design offer single point jacking systems that can operate via electric motor, gear-driven assembly or pneumatic operation. These new actuation systems allow the operator to adjust the deck inclination with minimal effort during operation (a.k.a. AWD, &#;adjustable while drilling&#;) quickly and efficiently.
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Early shaker designs featured a single motor mounted either away from the center of gravity or at the center of gravity section of the shaker basket. These two positions produce orbital / circular motion. Such designs produced poor results as they were limited to coarse screens and provided for limited solids conveyance.
In the late s, the introduction of linear motion technology allowed operators to utilize a wide range of screens to effectively process material across the entire screening surface. Consequently, linear motion presents conveyance challenges with a positive deck inclination and when the drilling solids include clay. In addition, it has been found that linear motion imparts a relatively &#;violent&#; response at the top and bottom of its motion range. Thus, in the s, balanced elliptical motion was introduced.
Balanced elliptical motion (and its variant, progressive linear motion) reduced the &#;violent&#; response at the top and bottom the shaker&#;s movement. This ultimately proved effective in dealing with clays and provided evidence that screen life could be extended. Consequently, balanced elliptical motion came at a financial cost and a hydraulic throughput cost. Such vibrator motors are more expensive to deploy and presented slightly less G-force at the screen surface, therefore reducing the overall hydraulic capacity of the shaker.
Traditional shaker manufacturers offer either linear motion or balanced elliptical motion configurations. However, in recent years, new innovations in vibrator motor design have introduced shakers to the market that feature dual-motion options. This technology allows the operator to adjust the shaker motion during operation without having to shut down the system.
In addition to choosing the right shaker motion for your operations, the available G-force is equally important. Shaker motors come in a variety of horsepower configurations that generally range in G-force from 3 to 8 Gs. The higher the G-force, the more effective liquid/solid separation occurs. However, it is important to remember that with higher G-force, the shorter the screen life.
Traditional shakers on the market require the operator to shut down the shaker and manually adjust the concentric weights inside the motor to either increase or decrease the applied G-force. This procedure is time consuming. New innovations in shaker control systems adopt a variable frequency drive (VFD) that allows the operator to easily adjust the imparted G-force without having to shut down the shaker.
Currently, there are several different screen designs on the market and most of today&#;s manufacturers focus on the frame structure and shaker fastening applications. Traditional screens are constructed using a rigid steel frame and perforated plate; in which layers of woven wire cloth are bonded with powder-coating. New technology has advanced shaker screen construction using composite materials, therefore improving durability and performance.
Composite screens can provide higher surface tension. As such, the wire mesh experiences less fatigue wear. This translates to a more precise cut point and a longer service life.
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One of the most important variables is total screen surface area deployed. Maximizing surface area can be achieved by increasing the number of screen decks and/or providing corrugated wave screens. Corrugated wave screens feature up to 50% more screen surface area. This maximizes liquid/solid separation per square foot of screen deployed.
Even when it comes to securing screens, there are a variety of available configurations, each with their own advantages and disadvantages. Wedge fastened screens provide an easy and low-cost option but tend to be more time consuming. Conversely, hook strip screens provide a less time-consuming alternative, but present a much higher price point.
Choosing the right shaker is a long-term investment. Since shakers are constantly exposed to highly abrasive solids and constant G-force thrust, it is important to select a shaker that is rugged and durable. The thickness of the steel used, use of full seam-welded construction vs. huck-bolt construction, and the use of powder-coat or wet paint are all factors worthy of consideration when selecting a shaker.
Today&#;s shakers start at a cost ranging from $15,000 up to $40,000 depending on size, number of screen panels and available options. The average monthly consumables can range from $500 up to $2,500 a month when operating on a full-time basis. The benefits of deploying the right shaker yields significant jobsite operational cost savings. Recovery of lost drilling fluid reduces the cost associated with make-up water. Additionally, the right shaker and screen selection can yield a drier solid waste cutting, which reduces the material disposal costs. With the proper selection, a properly design shaker system can pay for itself within 12 to 18 months.
When choosing the right shaker for your operational needs, it is important to fully evaluate all features offered to maximize drilling fluid recovery and minimize waste disposal. Making the wrong choice will impact rig site performance and result in higher operational costs.
SRK Shale saker screen
In the realm of oil and gas drilling, the wire mesh utilized in shale shakers holds critical importance in the solid control process. These meshes, integral components of shaker assemblies, play a meticulous role in filtering drilling fluids and are also employed for extracting sizable solid cuttings from the drilling fluid known as mud and separate solids from liquids and ensuring the efficiency of drilling operations. However, amidst the myriad choices available, selecting the ideal wire mesh can be an overwhelming task. Fear not! Let&#;s embark on a comprehensive journey to unravel the complexities involved in choosing the perfect wire mesh for shale shaker screens.
Before delving into the nuances of mesh selection, comprehending the primary role of a shale shaker screen is vital. This pivotal piece of equipment forms the core of the solid control system. Its primary function involves sieving drilling fluids and extracting solid particles while enabling the purified fluid to circulate seamlessly, thereby optimizing the drilling process.
Wire mesh for shale shaker screens comes in varied types, each tailored to specific functionalities. Some prominent types include:
Hook Strip shale shaker screens: Known for their hassle-free installation and removal, these meshes are a preferred choice across diverse drilling operations.
Composite Frame Shale Shaker Screens: These screens combine a steel frame with a composite material. They offer increased longevity, improved resistance to corrosion, and often have higher conductance.
Metal-backed shale shaker screens: Featuring a metal structure like stainless steel wire mesh and other metals, for instance, added support, these screens are durable and provide better resistance against wear and tear, enhancing their lifespan.
The mesh rating system is crucial in the oil and gas industry, particularly in shale shaker screens used for solids control. The size of the required wire mesh is based on the size of the particles that can pass through a screen. Here&#;s a table showcasing mesh ratings with micron sizes, API designations, and corresponding API D100 separations. The API is adhering to standards set by the American Petroleum Institute (API). These meshes are categorized based on mesh size and conductance.
This table shows the relationship between mesh ratings, API designations, and the corresponding API D100 separation sizes in microns, which helps in selecting the appropriate screen for effective solids control in shale shakers within the oil and gas drilling process.
MESH RATING
(BASED ON TOP LAYER MESH)
API DESIGNATION API D100 SEPARATION(MICRONS)
10 Mesh
API &#; 10
> 1,850.0 to 2,180.0
12 Mesh
API &#; 14
> 1,290.0 to 1,550.0
16 Mesh
API &#; 16
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> 1,090.0 to 1,290.0
24 Mesh
API &#; 20
> 780.0 to 925.0
30 Mesh
API &#; 25
> 655.0 to 780.0
38 Mesh
API &#; 35
> 462.5 to 549.0
50 Mesh
API &#; 50
> 275.0 to 327.5
70 to 75 Mesh
API &#; 60
> 231.0 to 275.0
80 to 90 Mesh
API &#; 70
> 196.0 to 231.0
100 to 120 Mesh
API &#; 80
> 165.0 to 196.0
130 to 140 Mesh
API &#; 100
> 137.5 to 164.9
150 to 175 Mesh
API &#; 120
> 116.5 to 137.5
180 to 190 Mesh
API &#; 140
> 98.0 to 116.5
200 to 210 Mesh
API &#; 170
> 82.5 to 98.0
220 to 250 Mesh
API &#; 200
> 69.0 to 82.5
270 Mesh to 280 Mesh
API &#; 230
> 58.0 to 69.0
325 Mesh
API &#; 325
> 41.5 to 49.0
Determining the appropriate mesh size is pivotal. Mesh size signifies the number of openings per linear inch and directly influences the mesh&#;s ability to filter particles. Finer mesh sizes effectively filter smaller particles, while larger mesh sizes enable the passage of larger particles.
The size chart of wire mesh serves as a valuable guide, offering a standardized classification system. It simplifies the selection process based on mesh sizes and conductance, aiding in choosing the right wire mesh.
Drilling Fluids and Flow Rate: Varied drilling fluids necessitate specific mesh configurations. Grasping the composition and viscosity of fluids is pivotal in selecting a mesh capable of handling them effectively. Additionally, considering the flow rate aids in determining the mesh&#;s capacity to process fluids efficiently.
Mesh Longevity and Efficiency: The durability and lifespan of a mesh, often termed its &#;screen life,&#; are critical considerations. Opting for a durable mesh ensures cost-effectiveness and minimizes downtime due to frequent replacements. Furthermore, prioritize meshes designed for high efficiency to enhance the solid control process.
Cost of the mesh: While cost is a significant factor, striking a balance between quality and price is essential. Multiple manufacturers offer wire meshes for shale shaker screens at varying price points. Assessing their reputation, product quality, and after-sales support is imperative to making an informed decision.
What is a Shale Shaker Wire Mesh?
A shale shaker The wire mesh is a pivotal component of the shale shaker that separates solid particles from drilling fluids.
What is the function of a shaker?
The primary function of a shaker is to filter drilling fluids, extracting solid particles to ensure smooth drilling operations.
What size mesh is ideal for a shale shaker screen?
Shale shaker screen wire meshes come in various sizes, ranging from coarse to fine, and are designed to filter different particle sizes.
What SS grades are we generally using for shale shaker screens?
Shale shaker screens vary in design and functionality. Common types include hook strip wire meshes and API RP 13C wire meshes.
What types of features can you avail of in wire mesh for shale shaker screens?
Selecting the right wire mesh for shale shaker screens is a multifaceted process that demands a comprehensive understanding of drilling requirements, mesh types, sizes, and manufacturers. Prioritizing factors such as drilling fluids, flow rates, mesh longevity, and efficiency ensures an optimized solid control system, contributing to a smoother and more efficient drilling process.
In essence, the crux lies not only in choosing a mesh but also in identifying the perfect match for your specific drilling needs a choice that withstands high performance, durability, and cost-effectiveness. Delve into the specifics, explore the array of options, and make an informed decision that paves the way for an efficient drilling operation.
Enhance your drilling operations with precision and efficiency. Explore our premium range of wire mesh for shale shaker screens at SRK Metals. Our comprehensive guide on selecting the ideal mesh ensures optimized solid control systems for your specific drilling needs. Contact us today to discover the perfect match that promises durability, high performance, and cost-effectiveness for a seamless drilling process.