BSS Mud School
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Transcript of BSS Mud School
Surface Solutions™
2 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
“Engineered Waste
Management Solutions
Customized to Maximize
Drilling Effectiveness
Baroid Surface Solutions ™ Value Proposition
3 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Definition:
Methods of treating drilling waste streams, thereby enabling
operators to:
• Recover and recycle fluids
• Dispose of solids safely
• Comply with environmental regulations
Elements of a solution typically involve:
• Handling technologies - moving and storing waste streams
• Separation technologies - separating solids from liquids
• Treatment technologies - processing waste streams to meet safe
disposal requirements
3
Surface Solutions
4 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
BSS Support: Surface Solutions (continued)
High-volume centrifuges remove fine particles from drilling muds.
High-flow filtration units help reclaim completion fluids.
Honey Comb Bottom™ tanks are a cost-effective alternative to the skip-and-ship operations used on most rigs.
TCC (thermo mechanical cuttings cleaner) technology uses far less energy than the aging industry standard, TDU (thermal desorption unit).
Dissolved Air Flotation (DAF) units lift small particulates and oil to the surface of a tank where they can be skimmed from the surface.
The Full-Circle Cuttings Injection Process reduces drilled cuttings to an engineered slurry, then injects them back into a disposal domain for geological periods of time.
Cuttings Dryers allows us to reduce the total waste stream volumes, lowering disposal and transportation costs.
4
5 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Waste Minimization & Reuse Waste Handling & Transfer Waste Treatment & Disposal
Conventional SCE Equipment • Shale Shakers
• Centrifuges
Standard Transfer Systems • Screw Conveyors
• Gravity Transfer
Thermal Treatment • Thermal Desorption
• Incineration
Rig Audits Vacuum Transfer Systems • SupaVAC
Injection • Full Circle Cuttings Re-Injection Process
Cuttings Drying Equipment • Vertical & Horizontal Dryers (V-71 & V-133)
• Vacuum Dryers (RVD)
• Drying Shakers
Skip & Ship • Cuttings Skips
• Cuttings Trucks
Fixation • Stabilization and Disposal
• Use for Construction Purposes
Liquid Mud Plant • Swift Plants
Bulk Transfer • HCB tanks
• Cuttings Containers
Bioremediation • Composting
• Landfarming
• Bioreactors
Full suite Derrick Equipment
and screens
Dedicated Liquid Trucks Landfill disposal
Filtration. Dedicated Cuttings Trucks
and CTT
Mud and Liquid Treatment • Enviro-Floc System
• Slop Water Treatment
Drilling Waste Management
6 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
What is Drilling Waste Management?
“A strategy of minimizing environmental
liability for the customer using the best, available technology in the most efficient and
cost-effective manner.”
7 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Drilling Waste Types
OBM Cuttings WBM Cuttings Waste Brines Waste WBM Waste OBM Produced & Oily Water
• High Oil Content
• Emulsified
• Solid Laden (LGS)
• Internal phase
• Organic additives
• Biodegradability
Issues
•Hydrocarbons Mobility
• Oil Content >10%
• Solids Degradation
over time
• Solids nature (Salt,
Rock)
•Organic additives
• Biodegradability
Issues
•Hydrocarbons mobility
•Solid Laden (LGS)
• High water content
• Internal phase
• Organic additives
• Volumes
• Solids Degradation
over time
• Solids Nature (Salt ,
Rock)
• High water content
• Internal phase
• Organic additives
• Volumes
• Solids contamination
• Oil Content
• Internal phase
• Polymer contamination
• Scaling Issue
• Gas contamination
• Solid contamination
• Oil Content
• Internal phase
• Scaling issue
• Inconsistent
• Volumes
• Gas contamination
8 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Waste Management Hierarchy
1. Reduction at source Example-riser-less and slim-hole drilling
2. Recycling- Example-cuttings dryers recover fluids
3.Treatment- Example-Thermal Desorption
4. Disposal- Example-cuttings re-injection
9 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Role of Solids Control & Waste Management
Increased penetration
rates (ROPs)
Reduced mud costs
Less dilution
Lower probability and
severity of differential
sticking
Lower ECD
Reduced torque and
drag
Lower pump maintenance
costs
Better cementing jobs
Less pressure loss in system
Better control over fluid
properties
Reduced formation damage
Reduced disposal costs
Importance of Solids Control
10 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
11 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
A 20 micron drilled
solid surface area =
2400 sq. microns
The same solid cut
in half on each face
4800 sq. microns
Another 1/4 cut on
each face.
The original 20 micron
solid reduced and
sized 2 micron
particles. Surface area
24,000 sq. microns.
DRILLED SOLIDS DEGRADATION
An idealistic
representation of
the gradual
reduction in size
of a re-cycled
drilled solid by
mechanical
forces.
If we can remove
this . . . . . . .>
We can avoid this . . . .
12 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
“Confidential –Internal Halliburton Use Only. © 2004 Halliburton. All Rights Reserved.”
Basic Economics - 80% SRE (Solids Removal Efficiency)
1000’ of 12¼” hole - 145 bbls drill solids
If the solids removal efficiency is 80% - 29 bbls of
solids remain in the system. (0.2 x 145 = 29)
To maintain 5% drilled solids requires 580 bbls of
dilution. (29 / 0.5 = 580)
Less 145 bbls mud to fill the hole you just created =
435 bbls additional new volume (dilution) required.
13 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
“Confidential –Internal Halliburton Use Only. © 2004 Halliburton. All Rights Reserved.”
Basic Economics - 90% SRE (Solids Removal Efficiency)
1000’ of 12¼” hole = 145 bbls drill solids
145 bbls x (1-.90) = 14.5 bbls solids remaining
14.5/.05 = 290 bbls new mud
290 less 145 bbls to maintain volume = 145 bbls
additional dilution volume
145/435 = 1/3 the additional dilution volume required to
maintain LGS 5% with a 10% improvement in separation
efficiency.
In other words: A small improvement in solids removal efficiency
(SRE) has a large impact upon dilution rates & mud costs.
15 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Gumbo Removal - Scalping
A Sticky Situation . . .
16 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Flo-Line
Primer
Gumbo Chain
Gumbo bars,
boxes,
Divert
overboard
Flo – Line Primer
17 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
1
7
19 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
20 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Screen Frame
Screens
Screen Tensioners Shock Mounts
Vibrator Motors
Header Box/ Back Tank or Possum Belly
Catch Pan
Inclination Control
21 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Flo-Divider
22 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
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2
23 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
“Confidential –Internal Halliburton Use Only. © 2004 Halliburton. All Rights Reserved.”
Screen Selection
Screen Selection is a
compromise between:
Solids Removal
Circulating Rate
Dryness of Discharge
24 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Types of Screens
Pyramid Screen Conventional (Flat) Screen
Solids Form Continuous Bed
Impeding Fluid Throughput Vibration Forces Solids
Into Troughs
25 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
3 Dimensional Screens
Increases Screening
Capacity
Screen Finer Faster
Provides Drier Cuttings
Reduced Mud & Disposal
Costs
Pyramid Screen™
Pyramid Plus™ Screen
26 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
27 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Screens are a ‘filter’
Back Plate
Coarse Backing Mesh
Fine Intermediate Mesh
Fine Top Mesh
Modern screens are considered
to be “sandwich” screens. They
have many layers as per this
example.
28 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Operating Guidelines
Do:
• Run finest mesh possible while covering 75% of screen area.
• Run screen frame as level as possible to reduce screen wear
• Ensure screens are properly mounted on a clean screen frame.
Do Not:
• Mix screen mesh on the same shaker
• Bypass the shaker to change screens
• Use spray bars to wash solids through the screen
29 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
30 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Degassers
Nobody wants gas . . .
31 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Do not provide a vacuum
Limited surface area for
mud dispersion
Ineffective on high
density/viscosity fluids
Provide very thin film
Low power requirements
Low Cost
Atmospheric
32 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Effective on all muds
Large surface area for
dispersion
Vacuum provided by
external pump (eductor).
Requires more space than
atmospheric.
Requires more power than
atmospheric
Vacuum
33 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Principles of Degassing
Bring gas bubble to
the surface
Increase the size of
the bubble via
vacuum
Spread mud as a
thin film (expose
bubble to air)
Vent gas to safe
area
34 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
35 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Centrifugal pumps
stop working
Reduces mud weight
Reduces hydrostatic
head in well bore
Solids control
equipment operates
less efficiently
Hazardous in high
concentrations
Problems…
36 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Doing more with less. . .
Hydrocyclones
Desander
Desilter
37 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
38 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Con
1. Cone Body
2. Beach Point
3. Apex valve
4. Vortex Finder
5. Apex Nut (adjustment)
3
4
5
Hydro-cyclones & Mud Cleaners
39 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
40 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
41 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Mud Cleaners
3 x 10” Cones 16 x 4” Cones
1 - 3-panel screen frame
42 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Centrifuges
44 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Centrifuges
BSS has at least a
dozen different
types and sizes of
centrifuges in our
fleet
45 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
“Confidential –Internal Halliburton Use Only. © 2004 Halliburton. All Rights Reserved.”
Operating Principles of
a Decanting Centrifuge
47 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Feed inlet
Main Drive
Motor
Back Drive
Motor
Bowl
Conveyor
Gearbox
Torque
Limiter
Components
Pumps, Valves and Piping
49 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Proper Installation & Piping
Degasser Vessel
20' max
Main Shakers
Desander
Desilter
50 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
51 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Centrifugal Pump Progressive Cavity Pump
(PCP)
Diaphragm Pump
53 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Pumps
Application Centrifugal PCP or Lobed Diaphragm
D-gasser
D-sander
D-silter
Mud Cleaner
Low Speed Centrifuge
High Speed Centrifuge
Barite Recovery
Mixing/Transfer/Charge
Slurry transfer/Skimming
54 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Active System
Reserve Pits
Suction Pit
Return Pit
Rig Pumps
Cuttings Dryers & Screw Conveyors
56 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Cuttings Drying – Two Trains of Thought
Drying Shaker
Vibrating Screen
7.3 G’s
8% - 12% Typical Oil on Cuttings
Vertical Cuttings dryer
Spinning screen basket with scroll
300 G’s
1.0 – 4.5% typical Oil on Cuttings
57 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Cuttings Dryer Installation - Horizontal
Dry Cuttings Overboard
SCREW CONVEYOR
Progressive Cavity Cuttings Pump
Clean mud to Active Centrifuge Feed Pump
FHD Centrifuge
58 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
59 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Before & After – 12.25” hole - GOM
12.9% Oil on Cuttings 3.3% Oil on Cuttings
60 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
62 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Old School – What not to do…..
65 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Auger System
NEVER operate augers without a
protective guard / cover or
Emergency Stop controls in place.
66 © 2012 HALLIBURTON. ALL RIGHTS RESERVED. 66
Do not Walk on
Equipment
Do not Sit on
Equipment
LOTO equipment
prior to performing
all Maintenance
and or removing
cover or grating.
Preform
inspections to
insure all controls
are labeled and
working properly
67 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
What Not to do…. “Stop Work”
68 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Examples of Proper Install
Inside these covers
is the grating open
over the auger??
69 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
DEWATERING What is it?
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Dewatering Applications –
When does it make sense?
1. Solids control process for colloidal - ultra-fines
removal = Lower drilling fluid costs
2. Recover and recycle liquid phase of a suspension
3. Pit-less location, no pit construction allowed
4. Clear water drilling – Lets you drill faster!
5. Zero discharge locations
71 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
What do we want to do?
Improve solid-liquid separation of a waste water-based
drilling mud through a centrifuge
72 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
ENVIRO-FLOC® Dewatering System
73 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Halliburton Standard Floc Unit
74 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Coagulation
Reduction in repulsive potential between the electrical double layer that exists between
turbidity particles. De-stabilization of suspension so the particles no longer repel each
other.
Dewatering Process
Flocculation
Physical linkage between particles brought about by a high molecular weight
polymer to create a random three-dimensional structure called a ‘floc.’
75 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Conditioning
Remove as many solids
as possible – mechanically
through screening,
centrifugation, etc.
Take mud from the
reserve pit or after the last
solids control device
76 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Coagulation
Dilute with water
– Reduce solids
concentration
– Destabilize
suspension
Acidification
– Neutralize system pH
– Pin Flocs formation
– Coagulant addition
– Pin-flocs definition
77 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Flocculation
Coagulated particles
are aggregated with a
polymer chain to form
a heavier and larger
solid.
These “Flocs” are
now large enough to
be easily centrifuged
out of the water
78 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Destination of Clarified Water
Centrifuge returns clarified water to a holding tank for:
Make-up of new mud.
Dilution of active system
Transferred to the wastewater storage and treatment system
– Recycled for washing purposes – rig washing, etc.
– Treated and disposed of in an acceptable manner.
80 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Dewatering Water-Based Drilling Fluids
Return to
environment
Recycle
Disposal
M. Hurd
81 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Mud Cleaner
Drying Shaker
Barite Recovery
Centrifuge
Dewatering Centrifuge
Dewatering Unit
Effluent
tank
Dodge
WYOMING
82 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Separation Methods
Accelerated Sedimentation
Centrifugal Force
Filtration
Coarse Filtration
Gravity Settling
Hydrocyclones over a vibrating screen
Chemically Enhanced Centrifugation
83 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Solids Removal By Mechanical Means
Equipment Name Typical Number
Gumbo Buster / Scalper 1 - optional
Shale Shaker 2-8
Sand Trap 1
Desander 2 x 10” cones
Desilter 16 x 4” cones
Mud Cleaner Usually 1
Centrifuge Usually 1 –
Sometimes 2
Floc Unit (Dewatering) Region Dependent
Separation Method
Coarse Filtration
Filtration
Gravity Settling
Accelerated Sedimentation by
centrifugal force
Hydrocyclones over
a vibrating screen
Accelerated
Sedimentation by
centrifugal force
Chemically Enhanced
Centrifugation
Accelerated Sedimentation by
centrifugal force
84 © 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Questions?