Drilling fluids processing handbook

✍ Scribed by American Society of Mechanical Engineers. Shale Shaker Committee

• Publisher: Elsevier
• Year: 2004
• Tongue: English
• Leaves: 693
• Series: Chemical, Petrochemical & Process
• Edition: 1
• Category: Library

✦ Synopsis

Written by the Shale Shaker Committee of the American Society of Mechanical Engineers, originally of the American Association of Drilling Engineers, the authors of this book are some of the most well-respected names in the world for drilling. The first edition, Shale Shakers and Drilling Fluid Systems, was only on shale shakers, a very important piece of machinery on a drilling rig that removes drill cuttings. The original book has been much expanded to include many other aspects of drilling solids control, including chapters on drilling fluids, cut-point curves, mud cleaners, and many other pieces of equipment that were not covered in the original book. · Written by a team of more than 20 of the world's foremost drilling experts, from such companies as Shell, Conoco, Amoco, and BP.· There has never been a book that pulls together such a vast array of materials and depth of topic coverage in the area of drilling fluids.· Covers quickly changing technology that updates the drilling engineer on all of the latest equipment, fluids, and techniques.

✦ Table of Contents

Contents......Page 6
Biographies......Page 18
Preface......Page 24
1.2 Purpose......Page 28
1.3 Introduction......Page 29
1.4 Historical Perspective......Page 31
1.5 Comments......Page 38
1.6 Waste Management......Page 40
2.1.1 Functions of Drilling Fluids......Page 42
2.1.2 Types of Drilling Fluids......Page 43
2.1.3 Drilling Fluid Selection......Page 44
2.1.4 Separation of Drilled Solids from Drilling Fluids......Page 47
2.2.1 Nature of Drilled Solids and Solid Additives......Page 52
2.2.2 Physical Properties of Solids in Drilling Fluids......Page 53
2.3 Properties of Drilling Fluids......Page 58
2.3.1 Rheology......Page 59
2.4.1 Detection of Hole-Cleaning Problems......Page 65
2.4.2 Drilling Elements That Affect Hole Cleaning......Page 67
2.4.3 Filtration......Page 72
2.4.4 Rate of Penetration......Page 74
2.4.5 Shale Inhibition Potential/Wetting Characteristics......Page 78
2.4.6 Lubricity......Page 79
2.4.7 Corrosivity......Page 80
2.5.1 Colloidal and Fine Solids......Page 81
2.5.2 Macropolymers......Page 82
2.5.3 Conventional Polymers......Page 83
2.5.4 Surface-Active Materials......Page 84
2.6.2 Drilling Fluid Product Compatibility and Storage Guidelines......Page 85
2.6.3 Waste Management and Disposal......Page 89
References......Page 93
3 Solids Calculation......Page 96
3.1 Procedure for a More Accurate Low-Gravity Solids Determination......Page 97
3.1.1 Sample Calculation......Page 100
3.2 Determination of Volume Percentage of Low-Gravity Solids in Water-Based Drilling Fluid......Page 104
3.3 Rig-Site Determination of Specific Gravity of Drilled Solids......Page 105
4 Cut Points......Page 108
4.1 How to Determine Cut Point Curves......Page 112
4.2 Cut Point Data: Shale Shaker Example......Page 117
5 Tank Arrangement......Page 120
5.1.1 Suction and Testing Section......Page 121
5.1.3 Removal Section......Page 122
5.1.4 Piping and Equipment Arrangement......Page 123
5.1.5 Equalization......Page 125
5.1.6 Surface Tanks......Page 126
5.1.7 Sand Traps......Page 127
5.1.9 Desander Suction and Discharge Pits......Page 129
5.1.11 Centrifuge Suction and Discharge Pits......Page 130
5.2.1 Trip Tank......Page 131
5.4 Reserve Tank(s)......Page 132
6 Scalping Shakers and Gumbo Removal......Page 134
7 Shale Shakers......Page 138
7.1 How a Shale Shaker Screens Fluid......Page 140
7.2 Shaker Description......Page 143
7.3 Shale Shaker Limits......Page 145
7.3.1 Fluid Rheological Properties......Page 146
7.3.5 Solids: Type, Size, and Shape......Page 147
7.4 Shaker Development Summary......Page 148
7.5 Shale Shaker Design......Page 149
7.5.1 Shape of Motion......Page 150
7.5.2 Vibrating Systems......Page 160
7.5.3 Screen Deck Design......Page 161
7.5.4 g Factor......Page 163
7.5.5 Power Systems......Page 167
7.6 Selection of Shale Shakers......Page 170
7.6.2 Cost of Removing Drilled Solids......Page 172
7.6.3 Specific Factors......Page 173
7.7 Cascade Systems......Page 175
7.7.2 Integral Unit with Multiple Vibratory Motions......Page 177
7.7.4 Cascade Systems Summary......Page 179
7.8 Dryer Shakers......Page 180
7.9 Shaker User's Guide......Page 181
7.9.1 Installation......Page 182
7.9.2 Operation......Page 183
7.9.3 Maintenance......Page 184
7.9.4 Operating Guidelines......Page 185
7.10 Screen Cloths......Page 186
7.10.1 Common Screen Cloth Weaves......Page 187
7.10.2 Revised API Designation System......Page 194
7.11 Factors Affecting Percentage-Separated Curves......Page 201
7.11.1 Screen Blinding......Page 203
7.11.2 Materials of Construction......Page 204
7.11.3 Screen Panels......Page 205
7.11.6 Three-Dimensional Screening Surfaces......Page 207
7.12.1 Microtunneling......Page 208
7.12.4 Fiber-Optic Cables......Page 209
8.1 Settling Rates......Page 210
8.2 Comparison of Settling Rates of Barite and Low-Gravity Drilled Solids......Page 213
8.3 Comments......Page 214
8.4 Bypassing the Shale Shaker......Page 215
9.1 Introduction: General Comments on Gas Cutting......Page 216
9.3 Desanders, Desilters, and Gas Cutting......Page 219
9.5 Basic Equipment for Handling Gas-Cut Mud......Page 220
9.5.3 Impact, Baffle, or Spray Separation......Page 222
9.6 Gas Busters......Page 223
9.7.1 Atmospheric Separators......Page 224
9.7.2 West Texas Separator......Page 225
9.8.1 Commercial Separator/Flare Systems......Page 226
9.8.2 Pressurized, or Closed, Separators: Modified Production Separators......Page 227
9.9 Degassers......Page 229
9.9.1 Degasser Operations......Page 230
9.9.2 Degasser Types......Page 232
9.9.4 Magna-Vac™ Degasser......Page 234
9.10 Points About Separators and Separation......Page 236
References......Page 237
10.1 Basic Principles of Agitation Equipment......Page 240
10.2 Mechanical Agitators......Page 241
10.2.1 Impellers......Page 242
10.2.3 Shafts......Page 249
10.3.1 Design Parameters......Page 250
10.3.4 Tank Internals......Page 253
10.3.6 Sizing Agitators......Page 254
10.3.7 Turnover Rate (TOR)......Page 255
10.4 Mud Guns......Page 259
10.4.2 Low-Pressure Mud Guns......Page 260
10.4.3 Mud Gun Placement......Page 261
10.4.4 Sizing Mud Gun Systems......Page 262
10.5 Pros and Cons of Agitation Equipment......Page 264
10.5.4 Cons of Mud Guns......Page 265
10.6 Bernoulli's Principle......Page 266
10.6.1 Relationship of Pressure, Velocity, and Head......Page 267
10.7 Mud Hoppers......Page 271
10.7.1 Mud Hopper Installation and Operation......Page 273
10.7.2 Mud Hopper Recommendations......Page 275
10.8 Bulk Addition Systems......Page 277
10.9.1 Removal......Page 280
10.9.3 Suction......Page 281
References......Page 282
11 Hydrocyclones......Page 284
11.1 Discharge......Page 288
11.2 Hydrocyclone Capacity......Page 292
11.3 Hydrocyclone Tanks and Arrangements......Page 293
11.3.1 Desanders......Page 294
11.3.2 Desilters......Page 295
11.3.4 Hydrocyclone Feed Header Problems......Page 296
11.4 Median (D[sub(50)]) Cut Points......Page 297
11.4.1 Stokes' Law......Page 298
11.5 Hydrocyclone Operating Tips......Page 303
11.6 Installation......Page 305
11.7 Conclusions......Page 306
11.7.1 Errata......Page 308
12 Mud Cleaners......Page 310
12.1 History......Page 313
12.2 Uses of Mud Cleaners......Page 315
12.4 Location of Mud Cleaners in a Drilling-Fluid System......Page 318
12.5 Operating Mud Cleaners......Page 319
12.6 Estimating the Ratio of Low-Gravity Solids Volume and Barite Volume in Mud Cleaner Screen Discard......Page 320
12.7 Performance......Page 322
12.8 Mud Cleaner Economics......Page 324
12.10 Accurate Solids Determination Needed to Properly Identify Mud Cleaner Performance......Page 327
12.11 Heavy Drilling Fluids......Page 328
13.1 Decanting Centrifuges......Page 330
13.1.2 Separation Curves and Cut Points......Page 335
13.1.3 Drilling-Fluids Solids......Page 337
13.2 The Effects of Drilled Solids and Colloidal Barite on Drilling Fluids......Page 338
13.3 Centrifugal Solids Separation......Page 340
13.3.2 Centrifuge Applications......Page 343
13.3.4 The Use of Centrifuges with Weighted Drilling Fluids......Page 344
13.3.5 Running Centrifuges in Series......Page 345
13.3.7 Flocculation Units......Page 347
13.4 Rotary Mud Separator......Page 348
13.4.1 Problem 1......Page 349
13.5.3 Question 3......Page 351
13.5.8 Question 8......Page 352
13.5.10 Question 10......Page 353
14 Use of the Capture Equation to Evaluate the Performance of Mechanical Separation Equipment Used to Process Drilling Fluids......Page 354
14.1.2 Laboratory Analysis......Page 357
14.2.3 Characterizing Removed Solids......Page 358
14.3.2 Particle Size......Page 359
14.3.3 Economics......Page 360
14.4 Collection and Use of Supplementary Information......Page 361
15 Dilution......Page 362
15.1 Effect of Porosity......Page 364
15.2 Removal Efficiency......Page 365
15.3 Reasons for Drilled-Solids Removal......Page 366
15.4 Diluting as a Means for Controlling Drilled Solids......Page 367
15.5 Effect of Solids Removal System Performance......Page 368
15.6 Four Examples of the Effect of Solids Removal Equipment Efficiency......Page 369
15.6.1 Example 1......Page 370
15.6.2 Example 2......Page 371
15.6.3 Example 3......Page 373
15.6.5 Clean Fluid Required to Maintain 4%vol Drilled Solids......Page 374
15.7 Solids Removal Equipment Efficiency for Minimum Volume of Drilling Fluid to Dilute Drilled Solids......Page 375
15.7.1 Equation Derivation......Page 376
15.7.2 Discarded Solids......Page 377
15.8 Optimum Solids Removal Equipment Efficiency (SREE)......Page 378
15.9 Solids Removal Equipment Efficiency in an Unweighted Drilling Fluid from Field Data......Page 381
15.9.1 Excess Drilling Fluid Built......Page 383
15.10 Estimating Solids Removal Equipment Efficiency for a Weighted Drilling Fluid......Page 384
15.10.1 Solution......Page 385
15.10.2 Inaccuracy in Calculating Discard Volumes......Page 387
15.12.1 Drilled Solids Removal Factor......Page 388
15.13.1 Exercise 1......Page 389
15.13.2 Exercise 2......Page 391
15.13.4 Exercise 4......Page 392
15.13.5 General Comments......Page 393
16.1 Quantifying Drilling Waste......Page 394
16.1.2 Example 2......Page 395
16.1.3 Example 3......Page 396
16.1.4 Example 4......Page 397
16.1.5 Example 5......Page 398
16.2 Nature of Drilling Waste......Page 399
16.3 Minimizing Drilling Waste......Page 401
16.3.1 Total Fluid Management......Page 402
16.4 Offshore Disposal Options......Page 404
16.4.2 Injection......Page 405
16.4.4 Commercial Disposal......Page 407
16.5.1 Land Application......Page 409
16.5.2 Burial......Page 413
16.6.1 Dewatering......Page 418
16.6.2 Thermal Desorption......Page 422
16.6.3 Solidification/Stabilization......Page 424
16.7 Equipment Issues......Page 426
16.7.1 Augers......Page 427
16.7.2 Vacuums......Page 429
16.7.3 Cuttings Boxes......Page 430
16.7.4 Cuttings Dryers......Page 433
References......Page 439
17.1 Introduction to Electrical Theory......Page 440
17.2 Introduction to Electromagnetic Theory......Page 448
17.3 Electric Motors......Page 450
17.3.1 Rotor Circuits......Page 451
17.3.2 Stator Circuits......Page 452
17.4 Transformers......Page 454
17.5 Adjustable Speed Drives......Page 456
17.6.1 Ratings......Page 459
17.6.2 Energy Losses......Page 460
17.6.3 Temperature Rise......Page 461
17.7 Ambient Temperature......Page 462
17.8 Motor Installation and Troubleshooting......Page 465
17.9 Electric Motor Standards......Page 466
17.10 Enclosure and Frame Designations......Page 468
17.10.1 Protection Classes Relating to Enclosures......Page 470
17.11 Hazardous Locations......Page 471
17.12 Motors for Hazardous Duty......Page 476
17.13 European Community Directive 94/9/EC......Page 478
17.14 Electric Motors for Shale Shakers......Page 481
17.16 Electric Motors for Centrifugal Pumps......Page 486
17.17 Study Questions......Page 487
18.1 Impeller......Page 492
18.2 Casing......Page 494
18.3 Sizing Centrifugal Pumps......Page 497
18.3.1 Standard Definitions......Page 498
18.3.2 Head Produces Flow......Page 506
18.4 Reading Pump Curves......Page 507
18.5 Centrifugal Pumps Accelerate Fluid......Page 511
18.5.1 Cavitation......Page 512
18.5.2 Entrained Air......Page 513
18.6 Concentric vs Volute Casings......Page 515
18.6.1 Friction Loss Tables......Page 517
18.7.1 Friction Loss and Elevation Considerations......Page 518
18.8 Net Positive Suction Head......Page 530
18.8.2 Affinity Laws......Page 533
18.8.3 Friction Loss Formulas......Page 534
18.9 Recommended Suction Pipe Configurations......Page 535
18.9.1 Supercharging Mud Pumps......Page 537
18.9.2 Series Operation......Page 539
18.10 Standard Rules for Centrifugal Pumps......Page 540
18.11.1 Exercise 1......Page 541
18.11.2 Exercise 2: System Head Requirement Worksheet......Page 542
18.11.4 Exercise 4......Page 544
18.12.2 Answers to Exercise 2: System Head Requirement Worksheet......Page 545
18.12.4 Answers to Exercise 4......Page 547
19.1 Underbalanced Drilling Fundamentals......Page 548
19.2 Air/Gas Drilling......Page 550
19.2.1 Environmental Contamination......Page 551
19.2.2 Drilling with Natural Gas......Page 552
19.2.3 Sample Collection While Drilling with Air or Gas......Page 553
19.2.4 Air or Gas Mist Drilling......Page 554
19.3.1 Disposable Foam Systems......Page 556
19.3.2 Recyclable Foam Systems......Page 557
19.4 Liquid/Gas (Gaseated) Systems......Page 559
19.5.1 Sample Collection with Aerated Systems......Page 562
19.6 Underbalanced Drilling with Conventional Drilling Fluids or Weighted Drilling Fluids......Page 563
19.7 General Comments......Page 564
19.7.1 Pressurized Closed Separator System......Page 565
19.8.1 Shale......Page 566
19.8.4 Downhole Fires and Explosions......Page 567
19.8.6 Gaseated or Aerated Fluid Surges......Page 568
Suggested Reading......Page 569
20 Smooth Operations......Page 574
20.1 Derrickman's Guidelines......Page 575
20.1.2 Tank and Equipment Arrangements......Page 576
20.1.3 Shale Shakers......Page 577
20.1.5 Sand Trap......Page 579
20.1.6 Degasser......Page 580
20.1.7 Hydrocyclones......Page 581
20.1.8 Hydrocyclone Troubleshooting......Page 584
20.1.9 Mud Cleaners......Page 585
20.1.10 Centrifuges......Page 587
20.1.11 Piping to Materials Additions (Mixing) Section......Page 588
20.2.1 Surface Systems......Page 589
20.2.2 Centrifugal Pumps......Page 599
20.3.1 Well Parameters/Deepwater Considerations......Page 604
20.3.3 Equipment Capability......Page 606
20.3.6 Environmental Issues......Page 607
20.3.7 Economics......Page 608
Appendix......Page 610
A......Page 612
B......Page 616
C......Page 619
D......Page 627
E......Page 632
F......Page 633
G......Page 638
H......Page 640
I......Page 643
J......Page 644
K......Page 645
L......Page 646
M......Page 648
N......Page 653
O......Page 654
P......Page 655
R......Page 660
S......Page 662
T......Page 670
U......Page 672
V......Page 673
W......Page 675
Y......Page 676
Z......Page 677
A......Page 678
C......Page 679
D......Page 680
G......Page 682
I......Page 683
M......Page 684
P......Page 686
R......Page 687
S......Page 688
U......Page 691
W......Page 692
Y......Page 693