10 HydrocycloneBasics 6180305 01

Training & Development

© 2013 Schlumberger. All rights reserved.

Hydrocyclone

Slide 2 © 2013 Schlumberger. All rights reserved.

Objectives 

Explain hydrocyclone theory of operations



Identify the applications of hydrocyclones



Identify the proper operation of hydrocyclones



Demonstrate proper hydrocyclone installation practices



Remedy improper operation issues and perform troubleshooting


1

5

Hydrocyclones




Unlike shakers, which use particle size, hydrocyclones separate by centrifugal acceleration.



Simple, low cost separation device developed for mining applications and adapted to the drilling industry.



Hydrocyclones are available in various sizes based on cone diameter(inches).

5

Hydrocyclones, Continued




Separation is progressively finer as cone diameter decreases (increased G-Force) and/or feed pressure increases (due to increase in G-Force)



Currently not as predominant due to advances in shakers and screens.



M-I SWACO solids control engineers should know how to operate hydrocyclones.

Hydrocyclone Separation vs. API Screen Separation

6

Fluid rheology, cone size, and feed pressure all affect particle removal size.

4” De-Silter Cone 200 Mesh Screen

6 © 2013 Schlumberger. All rights reserved.

6

Operating Ranges and Efficiency Predictions

Modern shaker/screen technology provides solids removal to 40um, eliminating the need for additional equipment

µ

30 - 70

Shakers & Screens 2003 - Today

5 - 10

De-sanders

10 - 15

Mud Cleaners

150


125

De-silters

10 - 15

Decanting Centrifuges

5 - 10

100

75

50

25

0

% Solids Removed

API RP 13c (D100) Cut Point Analysis


7

Hydrocyclone Video


Operating Principles

8

Overflow Opening (Fluid Discharge) Feed Inlet







Mud enters the feed chamber at a high velocity (provided by pump pressure).

As the mud spirals downward through the cone section, centrifugal force and inertia cause the solids to gravitate to the wall. The largest solids will discharge out the underflow opening of the hydro cyclone.

Vortex Finder Cylinder (Feed Chamber)

Cone

Underflow Opening (Solids Discharge) Air Entry


Operating Principles

8

Overflow Opening (Fluid Discharge) Feed Inlet





As the cone narrows, the inner most layers of fluid turn back toward the overflow, creating a low pressure vortex in the center of the cone. The air and cleaned fluid will rise and exit the cone through the vortex finder and out the overflow opening of the cone.

Vortex Finder Cylinder (Feed Chamber)

Cone

Underflow Opening (Solids Discharge) Slide 11 © 2013 Schlumberger. All rights reserved.

Air Entry

Operating Principles Video


9

Hydrocyclone Specifications Designation

Cone Diameter

Est. Cut Point

Est. Volume / Cone

M-I SWACO Offering

D-Sander

10” – 12”

>44µ

500 GPM

1-12 / 2-12 / 312

D-Silter

4”

>25µ

50, 60, 75 GPM 4T4, 6T4, 8T4, 10T4 (Twin Clones)

Microclone

2”

>8µ

~25 GPM


2-20

10

D-Sander 

Usually 10 - 12 inch diameter



M-I SWACO – 12”



Derrick Equipment – 10”



Downstream of rig shaker (s)



Cut point of 44 μ and higher



Name based on # of cones



500 GPM @ 75 feet of head



Adjustable APEX size



Robust design for heavy abrasive solids loading


12” Cone Replacement Component Breakdown

Insufficient Feed Pressure



Insufficient feed pressure is the primary cause of poor performance



Centrifugal sizing – speed / impeller / piping



Can ‘blank’ off cones to increase pressure / decrease flow requirements


10

M-I SWACO D-Silter 

150 GPM / twin clone



6T4 – 900 GPM



8T4 – 1200 GPM



10T4 – 1500 GPM



Cut point = > 20-25µ



4” Diameter



Replaceable components



Discard weight 1.5 to 2.5 ppg heavier than the feed weight.


11

M-I SWACO Microclone    

 

Operates at 120 feet of head 2” cones at 25 GPM 202 Microclone – (20) 2” cones for 500 GPM capacity Cut point of 8-15 > microns High volume of liquid discard Polish with HS centrifuge to increase efficiency and reduce waste volumes


12

Discussion Question What is the benefit of using a 202 Microclone in conjunction with a 414 Centrifuge?


12

Exercise: D-Sanders and D-Silters Review Answer the questions in your manual. Be prepared to discuss your answers aloud.


13

Installation Tips

14



Always use trained personnel for lifting and loading operations.



Only utilize certified lifting equipment that is designed for the load.



Mount the pump below the normal operating mud level in the pit (flooded). Keep the suction lift as short as possible with minimized turns, valves, etc. (friction / cavitation).



Utilize mechanical agitators / mixer rather than gun lines (to avoid purging solids through the system before being processed by the cones).



Install a pressure gauge on the inlet manifold to ensure proper operation of the unit.


14

Installation Tips Overflow header

6”

Breaker

45°

Feed header not shown

Air Long siphon leg

Solids free to discharge Air Slide 21 © 2013 Schlumberger. All rights reserved.

Note: Never extend overflow header below mud level

Installation Tips

12



An equalizer line or overflow must be provided to return the extra mud to the pump suction to avoid running tanks dry when processing more than the rig circulating volume (must process 150% of circulating rate to avoid roping)



Utilize mechanical agitators / mixer rather than gun lines (to avoid purging solids through the system before being processed by the cones)



Install a pressure gauge on the inlet manifold to ensure proper operation of the unit.


Step Wise Removal Process

Step wise removal is critical for successful and efficient solids control.


15

Discussion Questions What would happen if the solids control pit had high-wear overflows? What are the two reasons that we need to use equalizers?


15

Repair and Maintenance: Lock Out/ Tag Out 

     

16

Shut down unit before performing maintenance or repairs Initiate a controlled shutdown before starting repairs/maintenance LO/TO both the shaker and centrifugal feed pump Clean all parts and work area Block and secure heavy parts before working beneath unit or parts Seek assistance when heavy lifting is involved Ensure all tools, old parts, nuts, bolts washers, etc. are removed before restarting unit after maintenance


Repair and Maintenance: PPE 

Approved hard hat, safety glasses/shield; gloves and outer garments as determined by local and corporate QHSE Policies


16

D-Sander Critical Spares Item Numbe r 1

5015031

2

Part Number

D-Sander Critical Spares Description

17 3-12 Qty

2-12 Qty

Coupling Grooved End Bolt T-Gasket 10” 800 psi

1

1

5015032

Coupling Grooved End Bolt T-Basket 12” 800 psi

1

0

3

2422177

Gauge 0-60 psi/0-400 KPA 2-1/2” ¼ NPT LM

1

1

4

9621281

Feed 12” Urethane Clone Vitaulic Type

3

2

5

9621176

Clamp Small 12” Clone Urethane

6

4

6

9621177

Clamp Large 12” Clone Urethane

3

2

7

5015026


3

2

8

5015029

Coupling, Grooved 6”

6

4

9

9621173

Body Main 12” Clone Urethane

3

2

10

9621175

Body, Middle 12” Clone Urethane

3

2

11

9621174

Valve Apex 1-1/2” Clone Urethane

3

2


D-Silter Critical Spares Item Numbe r 1

9622582

2

D-Silter Critical Spares Description

Part Number

18 6T4 Qty

8T4 Qty

10T4 Qty

Elbow Grooved End 90* Polyurethane

12

16

0

9622221

Liner, Feed Urethane Twin Cone 4”

6

8

10

3

9622312

Cone Twin 4” Urethane ½” Apex

12

16

20

4

2422177

Gauge 0-60 psi/0-400 KPA 2-1/2” ¼ NPT LM

1

1

1

5

5015052

Coupling Grooved End Snap T-Gasket 2” 300 psi

24

32

40

6

5015053

Coupling Grooved End Snap T-Gasket 2-1/2” 300 psi

6

8

10

7

5015030


1

1

2

8

9622595

Elbow D-Silter 10T4, D-Silter Polyurethane 2” Grooved End

0

0

20

9

5015031


0

0

1


Hydrocyclones- Operating Variables 

Cone diameter (inches)



APEX diameter (inches)



Feed pressure (inlet manifold)



Solids size distribution (fluid entering)



Plastic viscosity (mechanical friction of solids)


19

Cone Diameter

19



Cone diameter determines processing capacity (gpm) and cut point (microns)



Larger diameter cones process greater volume and remove larger size solids



Smaller cones process less volume and remove smaller size solids



APEX diameter (replaceable) can also impact solids loading, cut point, and separation efficiencies


Feed Pressure- Feet of Head Cones are designed to process a fixed volume of mud at a specified head pressure  Feet of head is related to the pressure and fluid density  Centrifugal pump vertical height pushed a fluid column into a standpipe before consuming all of it’s energy

20




𝑃𝑆𝐼 𝐻𝐸𝐴𝐷 = 0.052 (𝐹𝑙𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦)

Feed Pressure- Feet of Head 

Most hydrocyclones require between 75 and 90 ft. of head at the equipment (not at the pump discharge flange)



Best practice: Use a dedicated pump for each hydrocyclone bank


20

𝑃𝑆𝐼 𝐻𝐸𝐴𝐷 = 0.052 (𝐹𝑙𝑢𝑖𝑑 𝐷𝑒𝑛𝑠𝑖𝑡𝑦)

Exercise: Spray vs. Roping Discharge Answer each of the questions in your manual. Be prepared to discuss your answers aloud.


21

22

Hydrocyclone Discharges What does a spray discharge indicate Overflow Opening (Fluid Discharge)

What does a roping discharge indicate Overflow Opening (Fluid Discharge) Feed Inlet

Feed Inlet Vortex Finder

Vortex Finder

Cylinder (Feed Chamber)

Cylinder (Feed Chamber)

Cone

Cone

Underflow Opening (Solids Discharge)

Underflow Opening (Solids Discharge)

Air Entry © 2013 Schlumberger. All rights reserved.

Air Entry

22

Rope Discharge Overflow Opening (Fluid Discharge) Feed Inlet Vortex Finder Cylinder (Feed Chamber)

Cone



Causes  High solids concentration causes solids to block underflow discharge  Cone wear increases and solids are expelled through the overflow opening  Solids removal efficiency is reduced  Increased sand content, piping and downhole tool wear will happen

Rope Discharge Overflow Opening (Fluid Discharge) Feed Inlet Vortex Finder Cylinder (Feed Chamber)

Cone



22 Solutions  Increase the processing rate by adding cones (1.5 times circulating rate)  Check up-stream equipment for proper operation. There may be holes in primary shaker screens.  Increase API RP 13C screens on flow line shakers (finer mesh size – screen up)  Increase APEX Size

23

Performance Monitoring Discard 1.5 – 2.5 PPG heavier than feed weight. Insufficient feed pressure is the number one cause of poor performance  Centrifugal pump (speed, impeller, piping)  ‘Blank’ off cones to increase pressure or decrease flow requirements. 


This indicates solids overloading, poor removal and excessive rig pump wear.

This indicates a condition where the cone is not overloaded with solids resulting in excellent removal efficiency.

Example of Roping


23

24

Mud Cleaners 

Hydrocyclone (s) mounted over a shaker to recover valuable fluid phase – discarding solids phase



Originally designed to recover barite allowing hydrocyclone operation with weighted fluids

2-12 / 8T4 Combo © 2013 Schlumberger. All rights reserved.

6T4 / LoPro Mongoose

24

Mud Cleaners, Continued

Useful in closed loop systems to ‘dry’ hydrocyclone discharges – valuable liquid recovery  Not applicable with microclones (cut point too fine for current shaker/screen technology)  May not be required in today’s industry with shaker and screen increased performances since 2003 

Slide 41

2-12 / 8T4 Combo


6T4 / LoPro Mongoose

Un-Weighted vs. Weighted Systems Un-Weighted  Hydrocyclones on the mud cleaner should be run as wet as possible to improve solids removal efficiency  Use the finest screens possible  In closed-loop systems, route the D-Sander and/or D-Silter underflow onto the mud cleaner screens to help dry the discharge  D-Silter suction should be from the D-Sander discharge compartment and the overflow discharged to a downstream compartment © 2013 Schlumberger. All rights reserved.

25

Un-Weighted vs. Weighted Systems Weighted Typically used when API 140 (98 – 116 micron) screens cannot be run on the shale shakers  If the screen overloads, remove (blank off / cap) enough cones to minimize fluid discard from the shaker screens  Monitor the composition and rate of losses over the screens to minimize barite and oil on cuttings in the discard  For water-based muds, dilution water added at the mud cleaner screen may reduce barite losses by reducing the hydrocyclone viscosity 


25

24

Start Up & Shut Down 1. Start shaker and pre-rinse screens with base oil

2. Notify drilling crew prior to starting (pit volume will fluctuate – may cause alarms) 3. Ensure all suction and discharge piping is properly secured and connected to the equipment 4. Start centrifugal feed pump – monitor pump, piping, cones, and shaker for leaks

© 2013 Schlumberger. All rights reserved. Start

Wash

Monitor

Verify

Document

24

Start Up & Shut Down

5. Check performance (feed, effluent, underflow PPG) for proper performance (1.5 – 2.5 PPG Heavier underflow)

6. Daily Operations Report (documentation) 

Record all mud cleaner screen sizes



Document maintenance and replacement parts used



Densities: Feed / effluent / underflow weight (PPG)

© 2013 Schlumberger. All rights reserved. Start

Wash

Monitor

Verify

Document

Shaker Decommissioning and Storage

27

Follow the procedures below when removing mud cleaner from work area or if storing unit: 

Isolate (LO/TO) and disconnect electrical power (shaker/pumps)



Wash clean of any mud/solids from shaker basket, feeder, piping, skid, and cones.



Remove screens from basket


STEM Documentation

Shaker Decommissioning and Storage, Continued

27

Follow the procedures below when removing mud cleaner from work area or if storing unit: 

Disconnect flow line from shaker and hydrocyclone unit (s)



Attach shipping brackets to baskets and skid (4 Ea.)



Move or transport shaker via lifting points indicated on skid



Cover unit while stored in M-I SWACO yard (UV Protection)


STEM Documentation

D-Silter/D-Sander Decommissioning and Storage 

Verify there are no gaskets and/or cone leaks prior to shutdown



Wash down the hydrocyclone assembly while pump is shut off and isolated



Disassemble and inspect each cone assembly for signs of wear or pack off with solids / trash.



Reassemble as per the O&M / QRG.


27

STEM Documentation

28

Trouble Shooting Tips Symptom Pressure at feed manifold is too low

Probable Cause Incorrect pump impeller size; feed pump being used for another application

  

No underflow or too little underflow

Incorrect feed pressure; no solids to be removed

   

Corrective Action Verify location of feed manifold is above the mud level Verify accurate speed is provided to the pump Verify the appropriate size and number of cyclones are used

Verify correct head pressure Verify apex valve is the correct size Verify apex valve is not plugged or even partially plugged If there is no sand, or very little, in the feed mud, install a vacuum breaker in the overflow line

    

Apex valve is too small Feed pressure is too low Processing rate too low Apex valve is too large Not enough solids in the removal range

Underflow is too heavy



Too much volume is lost through the underflow



Underflow is heavier than feed Change to a larger apex valve as mud discharge is roping Underflow is not functioning as  Verify there is enough sand in the a spray pattern mud to justify running the D-Sander

Underflow discharges as a rope Underflow is too light


Increasing processing rate to 1.5 times rig circulation  

Verify there is enough sand in the mud to justify running the D-Sander Use clamp ring to reduce size

Useful Internet Resources Shakers e-Collaboration Site • Provides technical, sales, and marketing information on all shaker models • Lists contact information for shaker experts • Accessible to all M-I SWACO employees Screens e-Collaboration Site • Provides technical, sales, and marketing information on all shaker screens • Lists contact information for screen experts • Accessible to all M-I SWACO employees Hydrocyclones e-Collaboration Site • Sub-site of Shakers • Provides information on Hydrocyclone options • Quick Reference Guide (QRG) / O&M Manuals © 2013 Schlumberger. All rights reserved.

29

Hydrocyclone Basics Thank you for participating.


10 HydrocycloneBasics 6180305 01

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