What is the function of the shale shaker screen?

The Ultimate Guide to Choosing the Best Shaker Screen for Your Oil and Gas Industry

Welcome to the ultimate guide for choosing the best shaker screen for the oil and gas industry. Whether you are drilling for oil or natural gas, having the right shaker screen can make all the difference in ensuring efficient and effective solids control. In this comprehensive guide, we will walk you through everything you need to know to make the best decision for your specific needs.

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With a vast array of options available in the market, it can be overwhelming to choose the right shaker screen. That&#;s why we&#;re here to help. We will delve into the different types of screens, their mesh sizes, and the materials they are made of, along with their pros and cons. We will also discuss important factors to consider, such as flow capacity, screen longevity, and ease of maintenance.

Our guide is designed to provide you with the knowledge and insights you need to make an informed decision. By the end, you will have a clear understanding of which shaker screen is best suited for your drilling operations, ensuring optimal performance and cost-effectiveness.

So, let&#;s get started on your journey to finding the ultimate shaker screen for your oil and gas industry needs!

Importance of choosing the right shaker screen

Choosing the right shaker screen is crucial for the success of your drilling operations. A shaker screen is an essential component of the shale shaker, which is responsible for separating solids from drilling fluid. Solids control is vital in the oil and gas industry as it helps maintain drilling fluid properties, prevents equipment damage, and ensures the safety of personnel.

The right shaker screen can improve solids control efficiency, reduce waste disposal costs, and minimize downtime. It can also enhance the overall drilling process by improving drilling fluid quality, reducing wear and tear on other equipment, and increasing drilling productivity. Therefore, investing time and effort into selecting the best shaker screen is a wise decision.

Factors to consider when choosing a shaker screen

When choosing a shaker screen, several factors should be taken into consideration to ensure optimal performance. One crucial factor is the screen&#;s mesh size, which refers to the number of openings per linear inch. Mesh sizes typically range from 20 to 325, with lower numbers representing coarser screens and higher numbers indicating finer screens.

Another important consideration is the material used to construct the screen. Common materials include stainless steel, composite, and polyurethane. Stainless steel screens are durable and resistant to corrosion, making them suitable for harsh drilling conditions. Composite screens offer a balance between durability and cost-effectiveness, while polyurethane screens are known for their flexibility and longer lifespan.

Flow capacity is another critical factor to consider. The screen&#;s flow capacity determines how efficiently it can process drilling fluid and separate solids. It is essential to choose a shaker screen with adequate flow capacity to prevent bottlenecks and maintain optimal drilling operations.

Different types of shaker screens and their pros and cons

There are different types of shaker screens available in the market, each with its own advantages and disadvantages. The most common types include flat screens, pyramid screens, and hook strip screens.

Flat screens, also known as conventional screens, are the most basic type of shaker screen. They have a simple flat surface and are suitable for general-purpose applications. Flat screens are easy to install and maintain, but they may have limited solids control efficiency compared to other types.

Pyramid screens, on the other hand, have a pyramid-shaped surface with larger openings at the top and smaller openings at the bottom. This design allows for improved solids control efficiency and increased flow capacity. However, pyramid screens can be more expensive than flat screens and may require more frequent replacement.

Hook strip screens are another popular option, characterized by a hook-shaped strip that holds the screen in place. These screens are known for their easy installation and removal, making maintenance and replacement quick and hassle-free. However, hook strip screens may have lower flow capacity compared to other types and may not be suitable for high-volume drilling operations.

Mesh sizes and their impact on screen performance

Mesh size plays a crucial role in determining the performance of a shaker screen. The choice of mesh size depends on the desired cut point, which refers to the size of the particles that the screen can effectively separate.

Finer mesh sizes, such as 200 or 325, are suitable for removing smaller particles, while coarser mesh sizes, such as 20 or 40, are better at removing larger particles. It is important to select the appropriate mesh size based on the expected particle size distribution in the drilling fluid.

Using the wrong mesh size can result in poor solids control efficiency, increased screen wear, and reduced flow capacity. It is recommended to perform regular particle size analysis to determine the optimal mesh size for your specific drilling conditions.

Testing and evaluating shaker screens

Before selecting a shaker screen, it is advisable to test and evaluate different options to determine their suitability for your drilling operations. Testing can be done in a laboratory or on-site using a test rig. The test rig simulates the actual drilling conditions and allows for accurate assessment of the screen&#;s performance.

During testing, parameters such as screen conductance, cut point, and solids removal efficiency are measured and analyzed. Conductance refers to the ability of the screen to allow drilling fluid to flow through it, while cut point indicates the particle size at which the screen can effectively separate solids. Solids removal efficiency measures the screen&#;s ability to remove solids from the drilling fluid.

By conducting thorough testing and evaluation, you can make an informed decision and select the shaker screen that best meets your specific requirements.

Maintenance and cleaning tips for shaker screens

Proper maintenance and cleaning are essential for extending the lifespan of your shaker screens and ensuring consistent performance. Regular inspection of the screens is necessary to identify any signs of wear or damage. If a screen is found to be damaged or worn out, it should be replaced promptly to prevent further deterioration.

Cleaning the screens after each use is also crucial to remove any solids or debris that may have accumulated. This can be done using a pressure washer or by soaking the screens in a cleaning solution. It is important to follow the manufacturer&#;s guidelines for cleaning and avoid using harsh chemicals that can damage the screen.

Additionally, proper storage of the screens when not in use is important to prevent deformation or damage. Screens should be stored in a clean and dry environment, away from direct sunlight and extreme temperatures.

Cost considerations when selecting a shaker screen

Cost is an important factor to consider when selecting a shaker screen. The initial purchase cost, as well as the maintenance and replacement costs, should be taken into account. While it may be tempting to opt for the cheapest option, it is important to balance cost with performance and durability.

Cheaper screens may have a shorter lifespan and require more frequent replacement, resulting in higher long-term costs. On the other hand, investing in higher-quality screens may initially be more expensive but can save money in the long run by reducing downtime and replacement frequency.

It is advisable to consult with suppliers and manufacturers to obtain cost estimates and compare the total cost of ownership for different screen options. Taking into consideration factors such as screen lifespan, maintenance requirements, and solids control efficiency will help you make an informed decision based on both performance and cost-effectiveness.

Conclusion

In conclusion, choosing the best shaker screen for your oil and gas industry needs is a critical decision that can significantly impact your drilling operations. By considering factors such as mesh size, material, flow capacity, and testing results, you can make an informed decision that ensures optimal solids control efficiency and cost-effectiveness.

Regular maintenance and cleaning of the screens are essential to prolong their lifespan and maintain consistent performance. By following manufacturer guidelines and properly storing the screens, you can minimize wear and damage and maximize their durability.

Lastly, it is important to consider cost when selecting a shaker screen. Balancing initial purchase cost with long-term maintenance and replacement costs will help you make a cost-effective decision that meets your performance requirements.

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Are you interested in learning more about cost-effective Vortex Screen? Contact us today to secure an expert consultation!

With the knowledge and insights gained from this ultimate guide, you are now equipped to choose the best shaker screen for your specific oil and gas industry needs. Happy drilling!

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").

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:

• 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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