Operating a solids control system efficiently is paramount for any successful drilling operation, directly impacting cost control and environmental compliance. However, even seasoned professionals can fall into common traps that compromise system performance, leading to increased waste volumes, equipment wear, and unnecessary downtime. Recognizing and avoiding these frequent errors is the first step toward optimizing your entire drilling fluid management process and achieving significant operational savings.

Neglecting Proper Equipment Sequencing

One of the most fundamental mistakes is running solids control equipment in the wrong order. The standard sequence should be a gumbo removal, followed by shale shakers, degassers, desanders, desilters, and finally centrifuges. Bypassing or rearranging this flow severely reduces the efficiency of downstream units, allowing larger particles to reach and clog finer separation equipment.

Ignoring Screen Panel Selection and Inspection

Using the wrong screen mesh or running damaged screens is a costly error. A mesh that is too coarse allows detrimental solids to pass through, while one that is too fine can lead to premature blinding and fluid loss. Regular visual inspections for tears or deformities are non-negotiable for maintaining optimal flow rates and separation efficiency.

Incorrect Centrifuge Settings

Centrifuges are highly sensitive to operational parameters. Running a centrifuge with the wrong bowl speed, incorrect feed rate, or improper pond depth is a common oversight. This either fails to remove the target fine particles or results in excessive loss of valuable liquid phase and expensive barite from the drilling fluid.

Poor Dilution Practices

Using dilution as the primary method for solids control is an expensive and inefficient habit. While sometimes necessary, over-reliance on fresh fluid or water addition simply increases the total fluid volume without effectively removing solids, leading to higher chemical costs and a larger waste footprint.

Overlooking the Drying Shaker

The drying shaker is the final step in recovering drilling fluid from drilled cuttings. Failing to utilize it properly, or bypassing it altogether, means a significant amount of expensive fluid is sent to the waste pit instead of being returned to the active system. This is a direct and avoidable financial loss.

Inadequate Training for Personnel

Assuming that rig crew members inherently understand the nuances of solids control is a major risk. Without proper, ongoing training on the principles of solid separation and the specific equipment on site, operators cannot be expected to identify issues or make correct adjustments, leading to subpar performance.

Failing to Perform Regular Maintenance

Solids control equipment operates in a harsh, abrasive environment. Neglecting routine maintenance schedules for screen tensioning, checking rubber wear parts, motor vibrations, and lubrication leads to unexpected breakdowns. Proactive maintenance is far cheaper than reactive repairs and associated downtime.

Not Monitoring and Testing Fluid Properties

Effective solids control cannot be managed blindly. Operators must regularly test the mud properties, including solids content, particle size distribution, and rheology. Without this data, it is impossible to know if the equipment is functioning correctly or if adjustments are needed.

Misunderstanding the Role of the Degasser

A degasser is specifically designed to remove hazardous entrained gases, not solids. Using it when no gas is present, or confusing its function with a desander or desilter, wastes energy and can inadvertently aerate the drilling fluid, which negatively affects downstream hydrocyclone performance.

Underestimating the Impact of a Poor Surface System Layout

Even with the best equipment, a poorly designed surface fluid system with insufficient pit volume, incorrect piping angles, or chaotic tank arrangements can create bottlenecks and shortcuts that render the entire solids control system ineffective. Proper planning of the surface layout is critical.

For operations seeking to eliminate these common mistakes, partnering with a reliable equipment manufacturer is key. Aipu offers a comprehensive range of robust and efficient solids control systems, backed by expert technical support to ensure your equipment is correctly selected, operated, and maintained for peak performance.