Shale shakers

Typical shale shakers on a drilling rig

Shale shakers are components of drilling equipment used in many industries, such as coal cleaning, mining, oil and gas drilling.They are the first phase of a solids control system on a drilling rig, and are used to remove large solids (cuttings) from the drilling fluid ("mud").

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Drilling fluids are integral to the drilling process and, among other functions, serve to lubricate and cool the drill bit as well as convey the drilled cuttings away from the bore hole. These fluids are a mixture of various chemicals in a water or oil based solution and can be very expensive to make. For both environmental reasons and to reduce the cost of drilling operations, drilling fluid losses are minimized by stripping them away from the drilled cuttings before the cuttings are disposed of. This is done using a multitude of specialized machines and tanks.

Shale shakers are the primary solids separation tool on a rig. After returning to the surface of the well the used drilling fluid flows directly to the shale shakers where it begins to be processed. Once processed by the shale shakers the drilling fluid is deposited into the mud tanks where other solid control equipment begin to remove the finer solids from it. The solids removed by the shale shaker are discharged out of the discharge port into a separate holding tank where they await further treatment or disposal.

Shale shakers are considered by most of the drilling industry to be the most important device in the solid control system as the performance of the successive equipment directly relates to the cleanliness of the treated drilling fluid.

Mudloggers usually go out and check the shakers for rock samples that have circulated from bottom. They separate the rock from the drilling fluid and take it into an onsite lab where they dry out the samples and label them according to depth. They then look at the samples and analyze what kind of rock they have at a certain depth. This helps determines what depth that type of rock was encountered.

Structure

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Shale shakers consist of the following parts:

• Hopper - The hopper, commonly called the "base" serves as both a platform for the shaker and collection pan for the fluid processed by the shaker screens, also known as "underflow". The hopper can be ordered according to the needs of the drilling fluid, aka "mud" system. It can come in different depths to accommodate larger quantities of drilling fluid as well as have different ports for returning the underflow to the mud system.

Oil well shaker

• Feeder - The feeder is essentially a collection pan for the drilling fluid before it is processed by the shaker, it can come in many different shapes and sizes to accommodate the needs of the mud system. The most commonly used feeder is known as the weir feeder, the drilling fluid enters the feeder usually through a pipe welded to the outside wall near the bottom of the feeder tank, it fills the feeder to a predetermined point and like water flowing over a dam the mud (drilling fluid) spills over the weir and onto the screening area of the shaker. This method of feeding the shaker is most widely used due to its ability to evenly distribute the mud along the entire width of the shaker allowing for maximum use of the shaker's screening deck area.

Some feeders can be equipped with a bypass valve at the bottom of the feeder which allows the drilling fluid to bypass the shaker basket and go directly into the hopper and back into the mud system without being processed by the shaker screens.

• Screen basket - Also known as the screen "bed" it is the most important part of the machine, it is responsible for transferring the shaking intensity of the machine, measured in "G's", while keeping the "shaking" motion even throughout the entire basket. It must do all that while holding the screens securely in place, eliminating drilled solids bypass to the hopper and allowing for easy operation and maintenance of the machine. Different brands of shakers have different methods of fulfilling these demands by using specialized screen tensioning apparatus, rubber seals around the screens, basket reinforcement to limit flex, rubber float mounts rather than springs, rubber deck seals and selective vibrator placement.

New Shale Shakers

• Basket angling mechanism - The shaker basket must be capable of changing its angle to accommodate various flow rates of drilling fluids and to maximize the use of the shaker bed, this is where the angling mechanism plays an important part. The drilling fluid flowing over the shaker bed is designated into two categories:
  • Pool: Which is the area of the screening deck that consists mostly of drilling fluid with drilled cuttings suspended within it.
  • Beach: Is the area where the fluid has been mostly removed from the cuttings and they begin to look like a pile of solids.

As a rule of thumb the beach and pool are maintained at a ratio of 80% pool and 20% beach, this of course can change depending on the requirements of cutting dryness and flow rates.

There are various angling mechanisms currently in use which vary from hydraulic to pneumatic and mechanical, they can be controlled from either one side of the shaker or must be adjusted individually per side. Mechanical angling mechanisms can be very dependable often requiring less maintenance but usually take more time to operate than their hydraulic or pneumatic counterparts whereas the hydraulic/pneumatic angling mechanisms are much faster to operate and require less a physical means of operation.

• Vibrator - This is the device which applies the vibratory force and motion type to the shaker bed. A vibrator is a specialized motor built for the purpose of vibrating, While containing an electric motor to provide the rotary motion it uses a set of eccentric weights to provide an omnidirectional force. To produce the proper Linear motion a second, counter rotating, vibrator is added in parallel to the first. This is what gives us the linear motion, "high G" shaking of the basket.

Mudloggers collecting samples out of the shakers

Some shakers come with an optional third motor on the shaker bed, this motor is most often used to modify the elliptical motion of the basket making it more circular therefore "soften" the motion, but comes at a cost of decreased G's and slower conveyance of the cuttings. This motion is usually used for sticky solids. NOV Brandt VSM 300 shale shaker is the world&#;s first balanced elliptical motion shaker.

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Shaker screen panels

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A shaker screen consists of the following parts:

Oil rig shaker

• Screen frame - Much like a canvas for painting a screen has to be supported on a frame in order to do its job, this frame differs between manufacturers in both material and shape. Screen frames can be made from materials such as, square steel tubing, flat steel sheets, plastic type composites or they can just be supported on the ends with strips of steel (similar idea to a scroll). These frames consist of a rectangular shaped outer perimeter which is divided into small individual inner panels. These smaller panels differ in shape from manufacturer to manufacturer and have been known to come in shapes such as square, hexagonal, rectangular and even triangular.

These differing panel shapes are used in an attempt to reduce the quantity of panels on each frame but still provide maximum rigidity and support for the mesh attached to them. The purpose of reducing these panels is to maximize usable screening area as the walls of each panel get in the way of the mesh and prevent it from being used, this is known as "blanking". The non-blanked screening area of a shaker screen is widely used as a selling feature, the more screen surface you have available to work the more efficient your shaker becomes and therefore can handle a higher quantity of fluid.

• Screen mesh - Just like thread is woven together to create cloth, metal wire can be woven to create a metal cloth. Screen mesh has evolved over many years of competitive screen manufacturing resulting in very thin yet strong cloth designed to maximize screen life and conductance as well as to provide a consistent cut point. To increase the conductance of a mesh screen you have to minimize the amount of material in the way, this is done by either reducing the wire diameter or weaving the cloth to produce rectangular openings. Rectangular openings increase the screens conductance while minimizing the effect on its cut point where as square openings provide a more consistent cut point but offer a lower conductance.

To maximize screen life most manufacturers build their screens with multiple layers of mesh over a very sturdy backing cloth to further protect the cloth against solids loading and wear. The multiple layers of mesh act as a de-blinding mechanism pushing near sized particles, which may get stuck in the openings, out of the mesh reducing blinding issues and keeping the screen surface available for use.

• Binding agent - The binding agent is the material used to bind the mesh to the screen frame, it is designed to maximize adhesion to both materials while being able to handle high heat, strong vibration, abrasive cuttings and corrosive drilling fluids.

Plastic composite screens tend not to use adhesives but rather heat the mesh and melt it into the screen frame to form a bond.

• Modular screen technology - One of the more recent advances in oilfield screen technology has brought us the "modular panel screen". This technology is an innovative design whereby the screen surface is partitioned into grid sections of modular panels, so damaged sections can be individually repaired to prolong the screen life. Traditionally, a screen is disposed entirely when only 15% screen area is damaged, this approach wasted over 85% of non-damaged screen area as well as the frame. For oilfield activity in remote environment, the reduction to waste and logistics proved to be a significant benefit.
• Pyramid Screen technology - this technology is a method for increasing the screening area of a shale shaker without the need to build larger machines. When seen from the side these screens look like corrugated cardboard, having a flat bottom and wave like shapes on top. These waves are designed to increase the surface area of the screen panel by building up instead of out, thereby maximizing the surface area of the screen without the need to build larger shaker screens and in turn larger, heavier and more expensive shakers.

There are many proven studies by Derrick solutions in regards to the reason for the improved performance of these 3D screens such as:

• Increasing the screening area of each panel transfers the load across more surface area and therefore the wear tends to be decreased in comparison to other screens.
• The corrugated shape of the screens encourages solids to settle in the valleys of the screen, keeping the peaks of the screen available to process drilling fluid.
• The tapered valleys, while moving under high G's, apply a compression force on the solids similar to wringing out a cloth to draw out liquid.
• Increasing the surface area of the shaker allows the use of finer screens earlier in the drilling process while maintaining acceptable flow rates and penetration rate. Effectively removing harmful drilled solids before they can begin to wear out the solids control equipment.

There are many theories on screening performance that yields inconsistent results. The only way to truly gauge the performance of any screen is to try it out and collect comparative data of your own.

Causes of screen failure

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The causes of premature screen failure are:

• Mishandling of screen panels during storage
• Improper handling during installation
• Improper installation of shaker screen to shaker basket
• Over/under tensioning
• Dirty, worn, or improperly installed deck rubbers
• Improper cleaning of the screens while in storage
• Extremely high mud weight
• Heavy solids loading
• Improperly manufactured screens
• Use of high pressure wash guns to clean or un-blind screens

API standards

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API Standard Screen Identification

The American Petroleum Institute (API) Screen Designation is the customary identification for screen panels. This includes:

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• API Number: the sieve equivalent as per API RP 13C
• Conductance: the ease with which a liquid can flow through the screen, with larger values representing higher volume handling
• Microns: a unit of length equal to one-thousandth of a millimeter
• Non-blanked area: an evaluation of the surface area available for liquid transmission through the screen

References

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A Shale shaker screen refers to the type of mechanical screen. It can separate solids and take them out from drilling fluid such as mud. Most shale shaker screens have stainless steel, composite, or polyurethane frame. The shale shaker has a moving or vibrating screen that removes cuttings from the mud for easy disposal. The vibrating sieve or screen can strain the cutting out of the mud. So, it plays a vital role before pumping the mud back into the borehole.

Shale shakers have become the easiest and most commonly used solids removal equipment. It can reduce costs during drilling applications. It comes in handy when you use a liquid as a drilling fluid. Circulate rate, drilling fluid properties, and shaker design control the screen selection. Unfortunately, when you use shale shakers incorrectly, the performance of the solid removal equipment falls down. Hence, you should choose the best shale shakers and use them properly. Read ahead to know more.

Benefits Of Shale Shaker Screen

While shale shaker has high significance, most people often overlook this piece of equipment. It has high importance on a drilling rig. The shale shaker screen acts as the first line of defense against major solids control equipment and drill cuttings. A Shale shaker can ensure solids control. Therefore, it can ensure the following benefits:

• Increased drilling
• Lower disposal costs
• Reduced mud costs
• Enhanced bit life

Choosing The Best Shale Shaker Screens

To control the mud and chip, you have to choose the best shale shaker screen. It is a prominent factor in the enhanced efficiency of the equipment. The equipment you choose must suit the specific needs of your project. It includes selecting the accurate vibrating screen needed according to the drill cutting&#;s type and the characteristics of the mud. Here are some of the factors you should check:

Type Of Shale Shaker Screen

Depending on the type of project, you need to choose the shale shaker screen. Below given are the types of shale shaker screens:

Linear Motion Shale Shakers

It is the equipment incorporating the latest shaker technology. It is the shaker used commonly for solid control in the gas and oil drilling industries. The linear motion using a pair of shafts may provide enhanced cutting conveyance. The shafts rotating in the opposite directions can also ensure improved liquid retention due to uphill slope operation.

Balanced Elliptical Motion Shale Shakers

The shale shakers with balanced elliptical motion may prove effective where you expect a high and heavy presence of solids while drilling top-hole sections. This type of shale shaker produces an unbalanced force due to a difference in power between the two vibrating motors. This type of shale shaker can remove solids effectively. It can also aid in eliminating larger particles present in the drilling fluids. It reduces screen consumption due to the relatively moderate vibration strength of this type of shale shaker.

Circular Motion Shale Shakers

This type of shale shaker has a single vibrator shaft. You can locate it at the shaker tray&#;s center of mass. The motors have concentric shaft has counterweights fitted to them that provides a circular motion. The circular motion can help transport solids that can lower the drilling fluid loss. This type of shale shaker can operate as stacked units.

Proper Using Of Shale Shaker Screens

Like finding the perfect shale shaker screen, you should also ensure proper use of it. Maintaining the shale shaker screen has high significance as selecting the screen itself. While using it for normal drilling, you have to ensure the fluid flows properly through the screen tube. It needs to flow at a distance of 25% to 50% from the furthest outgoing line.

It is vital to make the shaker horizontal for a more consistent position. This position across the screen ensures the selection of the correct size grid. Raising or jacking up the shaker plate can lead to the solid spending increased amount of time close to the shaker screen&#;s flow line. It can reduce the vibrating screen&#;s life.

While using the shaker, never puncture the mesh that can happen when cleaning the screen. Puncturing the mesh can reduce the screen&#;s effectiveness. Using shaker screens without a top grid also reduces the effectiveness. Hence, you have to replace it with a vibrating screen having holes in it. Maintaining the shale shaker can improve the efficiency and efficiency of the shale shaker screens.

Replacing Shale Shaker Screens

While using shale shaker screens, you need to ensure their efficiency. Hence, it requires replacing. Replacing the shale shaker screen can involve less cost compared to replacing the mud system or rebuilding the directional tool and mud pump. It is vital to ensure the other components such as the rubber shaker bypass and shaker work well. It is because the opening of the bypass during the drilling can result in the shale entering the mud tank present below. It results in zero efficiencies. While drilling, shale can end up in the feed pump&#;s screen box. It leads to the reduction of the volume centrifuge volume. Checking the screen box can help you understand the need for the shale shaker screen replacement. The higher efficiency of the shale shaker screen can result in high success rates of the centrifuge.

Applications Of Shale Shakers

Do you know that a foot of good drilling can generate around 1.2 barrels of mud? This waste drilling mud can impact the overall cost and effectiveness of the drilling activities. Many drilling companies can feel the negative impact of the waste mud. The companies need to focus on waste control and the environmental hazards linked to it while drilling. Hence, such companies look for solids control equipment to lower the cost while increasing effectiveness. Using the best shale shakers can come to the rescue in such cases. Many modern drill rigs have included shale shakers in the processing of drilling fluid to increase efficiency and throughput.

While shale shakers have overwhelming use in the production and exploration of petroleum products, they can also prove significant in other industries. So, shale shakers can prove important in any industry that requires the removal of solids. The mining industry uses screening devices such as shale shakers. The features such as fine screening and linear vibration capabilities can make shale shakers desirable to the precious metal and coal mining companies. The process industry can also make use of the shake shaker equipment for a variety of applications requiring screening and shakers. Clients also use it in the process flow of paper, chemicals, powder, sand, plastic, and other significant plants.

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Seek Assistance From The Professional Team

If you require access to the best shale shakers, you need to consult the experts. Solid Control World has become a popular name in helping businesses decide on the best drilling equipment required for the project. The expert team can also aid in providing suggestions to make critical business decisions. The choice of best options like shale shakers can help your business make risk-free choices with confidence. It can ensure the success of your project within the suggested deadline and on budget. The team offers services in three main methods:

Pre-Sales Services

The expert team will consult with you to decide on the best drilling equipment needed for the project. It is the most crucial decision your business can make for the best results. The experts can provide the confidence to help you make risk-free choices for project success. The consultation offered before the start of the project can help you decide on the following:

• The best equipment suited for your specific project
• The cost-effective choice of equipment ensures the success of the process

Apart from these, the team can also provide high-quality price proposals. The client-specific competitive price proposal will help in the guaranteed success of the process.

Current Project Services

The expert team at Solid Control World can offer free other services after deciding on the best equipment needed for the project. The range of services offered will aid in the installation, usage, and maintenance of the equipment selected. The current project services include:

• Detailed user assistance documentation by the expert team for understanding every equipment piece. It will help the clients use them correctly for enhanced safety and efficiency.
• Professionals compile customer-specific procedures to make it easier for clients to install and run the equipment provided as required.
• Assign personal customer liaison contact for every client to help them receive, install, and use the equipment provided by the team.

After Sales Services

Solid Control World can also provide after-sales services to clients. It will help the clients maintain the equipment accessed to enhance efficiency. This step will help you complete the project. The equipment accessed from the team will receive the following:

• One-year guarantee and free service while commissioning and training for the first time.
• 24×7 free technical support service provided over the . Online support using the website or .
• Ten-year validity for spare parts and maintenance for the listed equipment.

Solid Control World always provides clients with the best services to ensure you never face any problems. The technical support provided can overcome any issue with ease. You get prompt solutions based on the defect report or technical support request.