Derrick Corporation

These systems are engineered to optimize the performance of shale shakers. They ensure that drilling fluid is evenly distributed across the entire screen surface of a shaker. By promoting a consistent, uniform flow, flow distributors prevent screen overloading in certain areas and underutilization in others, which significantly increases the processing efficiency and overall capacity of the solids control system. This uniform distribution is crucial for maximizing solids removal.

Hydrocyclones are key components in the secondary stage of solids control. They use centrifugal force to separate solids from drilling fluids. The fluid is pumped at a high velocity into a conical chamber, creating a vortex. Heavier solids are thrown to the outer wall and discharged from the bottom, while the lighter, cleaned fluid exits from the top. Desanders target solids in the sand-size range, typically larger than 74 microns, while desilters are designed to remove smaller, silt-sized particles between 12 and 74 microns, effectively cleaning the fluid for reuse.

Shale shakers are the first and most vital line of defense in a drilling rig's solids control system. They are vibrating screens that filter large cuttings and solids from the drilling fluid as it returns from the wellbore. The fluid passes through the screen, while the unwanted solids are conveyed to the discharge. High-performance shale shakers, like Derrick's, are known for their ability to achieve a high "G-force" to aggressively separate solids from the valuable drilling mud, minimizing mud loss and maintaining fluid properties.

Rather than replacing an entire piece of equipment, conversion kits provide a cost-effective solution to upgrade existing machinery. These kits are specifically engineered to improve the performance of older models, often incorporating new screen technologies or enhanced mechanical components. This allows operators to achieve better separation efficiency, higher capacity, and extended asset life, bringing older equipment up to modern performance standards without the significant capital expenditure of a full replacement.

Belt scalpers function as a pre-screening device for drilling fluids, primarily used to handle large, coarse solids and cuttings. They are often placed before the main shale shakers to remove bulky materials that could potentially damage the shaker screens or motors. By taking on the heavy initial load, they protect the more delicate and fine-mesh screens of the shale shakers and ensure they can operate at peak efficiency for fine solids removal.

Centrifugal pumps are the workhorses of the drilling fluid system. They are used to circulate drilling mud, transfer it between tanks, and feed other equipment like hydrocyclones and centrifuges. These pumps generate flow by converting rotational kinetic energy into the hydrodynamic energy of the fluid. Their robust design and high flow rates are essential for maintaining the continuous movement and processing of the drilling fluid.

Centrifuges are a highly advanced form of separation technology, used to remove very fine solids—often less than 12 microns—that are too small for shale shakers or hydrocyclones to handle. They use extremely high centrifugal forces to separate these micro-solids and recover valuable fluid, which is then returned to the active mud system. Centrifuges are crucial for achieving a higher degree of solids control, reducing waste, and minimizing the environmental impact of drilling operations.

Degassers are critical for removing unwanted gases, such as methane or hydrogen sulfide, that may become entrained in the drilling fluid as it circulates through the wellbore. These gases can reduce the fluid's density, leading to pump cavitation and, in severe cases, the potential for a dangerous well control incident or "kick." Degassers use either atmospheric or vacuum-based methods to efficiently pull these gases out of the fluid, restoring its proper weight and ensuring safe drilling operations.

Mud agitators are mounted on top of mud tanks to continuously mix the drilling fluid. Their primary purpose is to keep solids suspended in the fluid and prevent them from settling at the bottom of the tank. This constant agitation ensures that the mud remains a homogeneous mixture with consistent properties, such as density and viscosity. Proper agitation is vital for preventing solids build-up and ensuring that the drilling fluid performs its functions correctly.

Mud hoppers are venturi-type jet mixers used to add and mix new materials into the drilling fluid. They are positioned to allow the introduction of dry additives like bentonite, barite, and various chemicals. As drilling mud is pumped through the hopper, it creates a powerful suction that pulls the new additives into the fluid stream and quickly disperses them, ensuring a rapid and thorough mixing process.

As the filtering medium for shale shakers, woven wire screens are the workhorse of solids control. They are made from high-strength wire and come in various mesh sizes to target specific particle sizes. Derrick's patented Pyramid Screens (PWP™) are a notable innovation in this area. They feature a unique, multi-layered design with a larger surface area than traditional flat screens, which leads to increased fluid capacity and more efficient solids removal without blinding the screen.

Synthetic screens are a modern alternative to traditional woven wire screens. They are made from durable, high-performance synthetic materials that offer superior wear resistance and a longer operational lifespan. These screens are less prone to tearing and degradation from abrasive solids, which can lead to reduced screen costs, less downtime for screen changes, and improved overall separation efficiency.

The vibratory motors are the power behind the motion of the shale shaker. They are specially designed to generate the high-G force vibrations necessary to effectively separate solids from drilling fluids. Derrick's Super G motors are known for producing forces up to 8.0 G's, which drastically increases the processing capacity of the shaker and ensures that more fluid is recovered with fewer solids remaining. They are engineered for reliability and long service life in harsh operating conditions.