What Is a Solids Control System

 

A solids control system is used in drilling operations to remove solid particles from drilling fluids  and to protect and recycle the mud.During drilling, drilling fluid carries drillilg cuttings and other harmful solids back to the surface. The core objective of a solids control system is to separate these solid particles using physical methods, ensuring stable mud properties, reducing operating costs, and protecting downstream equipment.

Definition of Solids Control

Solids control refers to the process of controlling and removing solid particles from drilling fluids during drilling operations.By efficiently removing drillilling cuttings and unwanted solids, the system ensures that drilling fluids can be reused while maintaining proper density, viscosity, and rheological properties.

Four-Stage Solids Control Equipment: Classification and Functions

1. Four-Stage Solids Control Process

Stage 1 – Shale Shaker

Removes solids particles  of   74 microns and bigger

Stage 2 – Desander

Removes solid particles in the range of 45–74 microns.

Stage 3 – Desilter

Removes solids sized 15–44 microns.

Stage 4 – Mud Decanter Centrifuge

Available in medium-speed and high-speed configurations.

Removes ultra-fine particles of 2–7 microns, close to colloidal size, often referred to as colloids or “gum”.

2. Five-Stage Processing (Gas Handling – Not Solids Purification)

This stage focuses on gas removal rather than solids separation.

Stage 1 – Mud Gas Separator

Installed before the shale shaker.

Handles large volumes of invaded gas and large gas bubbles (e.g. methane and hydrogen sulfide).

Gas separation is achieved through gravity and pressure differential.

Stage 2 – Vacuum Degasser or Centrifugal Degasser

Installed after the shale shaker.

Removes residual micro-bubbles to stabilize mud density and rheological properties.

3. Difference Between Mud Gas Separator and Vacuum Degasser

Mud Gas Separator:

Handles large gas bubbles and high gas volumes.

Prevents corrosion and safety risks caused by harmful gases.

Typically used together with a flare ignition device located 60–100 meters away.

Installed before the shale shaker.

Vacuum Degasser:

Secondary gas removal equipment.

Handles small gas bubbles.

Can also function as a mud agitator.

Installed after the shale shaker.

Mud Feeding Pumps for Desanders and Centrifuges

Mud is delivered to desanders and centrifuges using submersible slurry pumps or screw pumps.

Due to low centrifuge throughput and high wear conditions:

Submersible slurry pumps are preferred because of:

High wear resistance

Compact vertical installation

Space-saving design

Minimal maintenance with no wearing parts below liquid level

Screw pumps:

Provide stable, constant flow

Have higher cost and more wearing parts

Used only for specific operating conditions

Sand or centrifugal pumps are NOT recommended for feeding centrifuges.

 Key Mud Transfer Pump Types

1.Sand Pump (Centrifugal Pump)

General-purpose mud transfer pump

Used for desanders, desilters, and system circulation

Not suitable for centrifuge feeding

2.Submersible Slurry Pump

Mainstream centrifuge feeding pump

High wear resistance

Vertical installation saves space

Low maintenance

3.Screw Pump

Self-priming

Stable flow rate

Higher cost

Used for special conditions

4.Shearing Pump

Provides pumping and shearing functions

Used for dispersing dry materials such as bentonite

Improves mixing efficiency

Functions of Core Auxiliary Equipment

1.Agitator

Prevents mud sedimentation in tanks

Ensures uniform suction conditions

2.Mud Gun

High-pressure jet agitation

Enhances mixing in dead zones

Used for tank cleaning

3.Mixing Hopper and Shear Pump

Efficient mixing of dry materials (e.g. barite, SPC agents) with liquids

4.Mud Tank

Skid-mounted, corrugated plate design

Tank capacity customized based on rig horsepower and flow rate

Includes:

Trip tanks

Suction tanks

Mixing tanks

Supply tanks

System Accessories and Safety Configuration

Includes walkways, guardrails, stairs, cable trays, piping components, valves, sand discharge doors, inspection ports, lighting systems, insulation shelters, accommodation cabins, and MCC electrical control rooms.All components strictly comply with HSE standards.

System Flexibility and Customization

System configuration is customized based on:

Rig power

Mud flow rate

Site space limitations

Operator requirements

This ensures an efficient, reliable, and project-optimized solids control solution.


 Emial: Ivy@aipusolidcontrol.com

Website: www.aipusolidcontrol.com

 

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