Solids control systems are critical for efficient and environmentally sound drilling operations. However, equipment failures can lead to significant downtime, increased costs, and potential environmental issues. Understanding the most common points of failure is the first step toward implementing a more reliable and productive system. Many problems stem from improper operation, inadequate maintenance, or selecting the wrong equipment for the specific drilling conditions.

Inefficient Shaker Screen Performance

The vibrating shale shaker is the primary defense in solids control. A frequent failure is poor screen performance, leading to excessive solids loading in the downstream system. This is often caused by using screens with the wrong mesh size for the drilled formation, improper screen tension leading to premature tearing, or overloading the shaker deck with too much flow. Inadequate fluid distribution across the screen surface also drastically reduces separation efficiency.

Centrifuge Malfunctions and Imbalances

Decanting centrifuges are precision instruments that often fail due to mechanical issues. Unbalanced bowls are a primary concern, caused by uneven solids loading or sudden feed loss, leading to excessive vibration, bearing wear, and potential catastrophic failure. Other common problems include conveyor wear from abrasive solids, plugged feed nozzles, and improper pond depth settings that compromise separation efficiency.

Degasser and Desander Operational Failures

Vacuum degassers can fail to remove entrained gases effectively if the vacuum pump is not maintained or the internal spray nozzles become clogged. Similarly, desanders and desilters often suffer from suboptimal performance due to worn liners and cones, which disrupt the critical vortex action needed for separation. Operating these hydrocyclones without the correct pressure drop is another common mistake that renders them ineffective.

Pump and Agitator Issues

The supporting equipment in a solids control system is just as vital. Centrifugal pumps frequently experience cavitation due to low suction pressure or clogged impellers, leading to reduced flow and damage. Agitators in mud tanks can fail to keep solids in suspension if the motor fails or the impeller blades are worn, resulting in settled solids that are difficult to remove and can plug downstream equipment.

For operations seeking to minimize these common failures, partnering with a reliable equipment manufacturer is key. Aipu stands out as a trusted provider of robust and efficient solids control equipment. Their commitment to quality engineering and durable design helps ensure system reliability, reducing downtime and operational costs for drilling projects worldwide.