10 HydrocycloneBasics 6180305 01

Training & Development
2013 Schlumberger. All rights reserved.
Hydrocyclone
Slide 2
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
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).
Hydrocyclones, Continued
Slide 5
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
Fluid rheology, cone size, and feed pressure all affect particle removal size.
4 De-Silter Cone
200 Mesh Screen
6
Operating Ranges and Efficiency Predictions
Modern
shaker/screen
technology provides
solids removal to
40um, eliminating
the need for
additional equipment
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
% Solids
Removed
API RP 13c (D100) Cut Point Analysis
Slide 8
Hydrocyclone Video
Slide 9
Operating Principles
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
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
Air
Entry
Operating Principles Video
Hydrocyclone Specifications
Designation
Cone
Diameter
Est. Cut Point
Est.
Volume / Cone
M-I SWACO
Offering
D-Sander
10 12
>44
500 GPM
1-12 / 2-12 / 312
D-Silter
>25
50, 60, 75 GPM 4T4, 6T4, 8T4,

10T4
(Twin Clones)
Microclone
>8
~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 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
Slide 15
10
M-I SWACO D-Silter
150 GPM / twin clone
6T4 900 GPM
8T4 1200 GPM
10T4 1500 GPM
Cut point = > 20-25
4 Diameter
Replaceable components
Discard weight 1.5 to 2.5 ppg heavier than the feed weight.
Slide 16
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?
Slide 18
12
Exercise: D-Sanders and D-Silters Review

Answer the questions in your
manual.
Be prepared to discuss your
answers aloud.
Slide 19
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.
Slide 20
14
Installation Tips
Overflow
header
Breaker
45
Feed header
not shown
Air
Long siphon leg
Solids free to
discharge
Air
Slide 21
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.
Slide 22
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?
Slide 24
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
Slide 26
16
D-Sander Critical Spares

Item
Numbe
r
1
5015031
Part
Number
D-Sander Critical Spares

Description
17
3-12
Qty
2-12
Qty
Coupling Grooved End Bolt T-Gasket 10 800 psi
5015032
Coupling Grooved End Bolt T-Basket 12 800 psi
2422177
Gauge 0-60 psi/0-400 KPA 2-1/2 NPT LM
9621281
Feed 12 Urethane Clone Vitaulic Type
9621176
Clamp Small 12 Clone Urethane
9621177
Clamp Large 12 Clone Urethane
5015026
5015029
Coupling, Grooved 6
9621173
Body Main 12 Clone Urethane
10
9621175
Body, Middle 12 Clone Urethane
11
9621174
Valve Apex 1-1/2 Clone Urethane
D-Silter Critical Spares

Item
Numbe
r
1
9622582
D-Silter Critical Spares

Description
Part
Number
18
6T4
Qty
8T4
Qty
10T4
Qty
Elbow Grooved End 90* Polyurethane
12
16
9622221
Liner, Feed Urethane Twin Cone 4
10
9622312
Cone Twin 4 Urethane Apex
12
16
20
2422177
Gauge 0-60 psi/0-400 KPA 2-1/2 NPT LM
5015052
Coupling Grooved End Snap T-Gasket 2 300 psi
24
32
40
5015053
Coupling Grooved End Snap T-Gasket 2-1/2 300 psi
10
5015030
9622595
Elbow D-Silter 10T4, D-Silter Polyurethane 2 Grooved End
20
5015031
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 its energy
20
=
0.052 ( )
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
Slide 32
20
=
0.052 ( )
Exercise: Spray vs. Roping Discharge

Answer each of the questions in your
manual.
Be prepared to discuss your answers
aloud.
Slide 33
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
Air
Entry
22
Rope Discharge
Overflow Opening
(Fluid Discharge)
Feed Inlet
Vortex Finder
Cylinder
(Feed Chamber)
Cone
Underflow Opening
(Solids Discharge)
Air
Entry
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
Underflow Opening
(Solids Discharge)
Air
Entry
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
Slide 39
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

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 todays 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
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
Slide 43
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
29
Hydrocyclone Basics
Thank you for
participating.
Slide 51

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Training & Development

2013 Schlumberger. All rights reserved.

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

2013 Schlumberger. All rights reserved.

2013 Schlumberger. All rights reserved.

Unlike shakers, which use particle

Simple, low cost separation

Hydrocyclones are available in

Separation is progressively finer

Currently not as predominant due

M-I SWACO solids control

Hydrocyclone Separation vs. API Screen Separation

Operating Ranges and Efficiency Predictions

Shakers & Screens 2003 - Today

2013 Schlumberger. All rights reserved.

API RP 13c (D100) Cut Point Analysis

Mud enters the feed chamber at a

As the mud spirals downward

2013 Schlumberger. All rights reserved.

As the cone narrows, the inner most

Operating Principles Video

2013 Schlumberger. All rights reserved.

Est. Cut Point

1-12 / 2-12 / 312

50, 60, 75 GPM 4T4, 6T4, 8T4,

2013 Schlumberger. All rights reserved.

Usually 10 - 12 inch diameter

Downstream of rig shaker (s)

Cut point of 44 and higher

Name based on # of cones

500 GPM @ 75 feet of head

Adjustable APEX size

Robust design for heavy abrasive solids loading

2013 Schlumberger. All rights reserved.

Insufficient Feed Pressure

Insufficient feed pressure is the primary

Centrifugal sizing speed / impeller /

Can blank off cones to increase

M-I SWACO D-Silter

150 GPM / twin clone

6T4 900 GPM

8T4 1200 GPM

10T4 1500 GPM

Cut point = > 20-25

M-I SWACO Microclone

Operates at 120 feet of head

2013 Schlumberger. All rights reserved.

Exercise: D-Sanders and D-Silters Review

Always use trained personnel for lifting and loading operations.

Install a pressure gauge on the inlet manifold to ensure proper

Note: Never extend

An equalizer line or overflow must be provided to return the extra

Install a pressure gauge on the inlet manifold to ensure proper

Step Wise Removal Process

Step wise removal is critical for

2013 Schlumberger. All rights reserved.

Repair and Maintenance: Lock Out/ Tag Out

Shut down unit before performing maintenance or repairs

2013 Schlumberger. All rights reserved.