Appendix A

SOLIDS CONTROL HANDBOOK

January 1998
Schlumberger
Solids Control Programs
Dowell Page 1 of 10

Solids Control Programs

1 “SHAKCAP” Spreadsheet Program ...................................................................................1
1.1 Input ..............................................................................................................................2
1.1.1 Screen Data .........................................................................................................2
1.1.2 Mud Data .............................................................................................................3
1.1.3 Drilling Data .........................................................................................................3
1.2 Output............................................................................................................................3
1.3 Using Shakcap ..............................................................................................................4

2 “DEWATER” Spreadsheet Program...................................................................................5

2.1 Dewatering and Disposal Cost Section ..........................................................................5
2.1.1 Dewatering Equipment Used................................................................................6
2.1.2 Manpower Costs ..................................................................................................6
2.1.3 Per Barrel Costs...................................................................................................6
2.2 Interval Data and Analysis Section ................................................................................7
2.2.1 Input Data ............................................................................................................7
2.2.2 Output Data..........................................................................................................8

3 Summary Section..............................................................................................................10
FIGURES
Fig. 1. SHAKCAP spreadsheet. ..............................................................................................2
Fig. 2. Input section of the DEWATER spreadsheet................................................................5
Fig. 3. Interval data and analysis section of the DEWATER spreadsheet. ..............................7
Fig. 4. Summary section of the DEWATER spreadsheet. ..................................................... 10

1 “SHAKCAP” Spreadsheet Program

The spreadsheet file SHAKCAP can be used to calculate the flow capacity of
shale shakers for a specified screen. This spreadsheet replaces the flow
curves and hand calculations published in the previous solids control
handbook. The flow capacity equations contained in SHAKCAP are based on
empirical relationships developed from full-scale testing of numerous linear
motion shakers. This model is also available in the solids control economics
program SECOP. Fig. 1 is an example of the spreadsheet.

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 Appendix A
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Solids Control Programs
Page 2 of 10 Dowell

There are three versions of SHAKCAP. They are:

SHAKCAP.WQ1 - for Quattro Pro 3.0 or higher
SHAKCAP.WK1 - for Lotus 123 2.1 or higher
SHAKCAP.WB1 - for Quattro Pro for Windows

Fig. 1. SHAKCAP spreadsheet.

1.1 Input

1.1.1 Screen Data

The new shaker screen designations are required for input to describe the
screen panel. A complete listing of screen designations for the most
common shale shakers is included below the INPUT/OUTPUT window in the
spreadsheet.
1. Screen Name (Optional)
- typically the manufacturer's designation
- use this field to identify screen
2. Conductance (kd/mm)
- conductance value listed in the screen designation
3. Area (sq ft)

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 Appendix A
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Solids Control Programs
Dowell Page 3 of 10

- the usable area of the panel, listed in the designation

4. Number of Panels
- the number of panels required by the shaker
5. Deck Angle
- use 3 degrees as the default angle, lower for sticky cuttings, higher
only when necessary (refer to Deck Angle discussion, Chapter 3).

1.1.2 Mud Data

6. Mud Wt (ppg)
7. Mud PV (cp)
8. Mud Type (Polymer or Non-polymer)
- enter 0.6 for polymer muds (e.g., PHPA).
- enter 1.0 for all other muds.

1.1.3 Drilling Data

9. ROP (ft/hr)
- estimated average ROP for the interval
10. Hole Diam (in)
- bit diameter is normally sufficient
11. Flow Rate (gpm)
- total circulating rate

1.2 Output
2
1. Usable Screen Area, (ft )

- 2/3 of the total available screening area

2. Drl. Solids Generated, (gpm)
- rate at which solids will be returned
3. Solids Loading Factor, (%)
- the percent drilled solids in the mud

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SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Solids Control Programs
Page 4 of 10 Dowell

4. Flow Capacity-Fluid Only, (gpm)

- the estimated flow capacity of one shaker without solids
5. Flow Capacity-With Solids, (gpm)
- the estimated flow capacity of one shaker with the effect of solids
loading taken into account
6. No. of Shakers Required
- the total number of shakers required to process the entire flow rate
using the specified screens

1.3 Using Shakcap

1. The flow capacities are calculated for single deck shakers. Adjustment
for tandem deck shakers or cascading systems can be made by
reducing ROP by 25-50% to account for the solids removed by the
scalping deck.
2. Acceleration is assumed to be constant for all shaker types. This model
assumes 3.0 g's normal to the screen. This may cause some
discrepancies between actual and predicted flow capacities for shakers
with significantly different accelerations.
3. To estimate the screen size required for a given number of shakers, the
following procedure is recommended:
A. Enter all input data except screen name. Choose a screen series
from the supplied designation tables and use an area value
common to that series. For example, all screens in Derrick's PWP
2
HP series have an area of 5.3 ft .
B. Enter some starting value for conductance as a “first guess”.
C. Adjust the conductance value in the input column until the number
of shakers required matches the actual number available.
D. Decrease the conductance in 0.2 or smaller increments until the
“Flow Capacity-With Solids” output closely matches the anticipated
circulation rate per shaker.
E. Find the screen in the series with a conductance that most closely
matches the required conductance. Enter that screen's name and
conductance into the input table. Check that the number of
shakers is correct.
4. The flow capacity for polymer muds, such as PHPA, is impossible to
predict with any certainty. The spreadsheet uses 0.6 as an “average”
flow capacity reduction factor. Actual throughput will depend heavily
upon the concentration of the polymer and the amount of shear
imparted.

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 Appendix A
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Solids Control Programs
Dowell Page 5 of 10

2 “DEWATER” Spreadsheet Program

This spreadsheet was developed to help assess the economics of using a
chemically-enhanced dewatering unit to reduce liquid discharge volumes.
Dilution volumes, liquid and sludge discharge volumes are predicted for up to
4 drilling intervals with and without the dewatering option. The total costs of
each case are compared to determine the most economical option. The
output also can be used to estimate reserve pit or cuttings haul-off
requirements. Computations are based on the mass balance equations
presented in the economics chapter of the Solids Control Handbook and will
not be repeated here.
The spreadsheet is provided in two formats: Lotus .wk1 and Quattro Pro
.wq1. The spreadsheet is divided into 3 sections: Dewatering and disposal
cost input (Fig. 2), interval data (Fig. 3), and cost analysis summary (Fig. 4).
Required input cells are highlighted or shaded, depending on the
spreadsheet software. Scroll down through the spreadsheet to view the
sections.

2.1 Dewatering and Disposal Cost Section

Fig. 2. Input section of the DEWATER spreadsheet.

Cells A1.G22 contain the input data required for the dewatering economics
calculations.

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SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Solids Control Programs
Page 6 of 10 Dowell

2.1.1 Dewatering Equipment Used

Input the number and unit cost for the listed equipment. These costs can be
obtained from a service company in your area. The spreadsheet uses only
the total equipment cost in the calculations; individual entries do not have to
be precise, provided the total equipment cost is correct.

2.1.2 Manpower Costs

ENGINEER, TECH
Enter the estimated daily cost for each service engineer or technician. The
number of personnel required will be made as a separate entry for each
interval, since the number of service personnel will often depend on the
average daily processing rate.

2.1.3 Per Barrel Costs

VALUE OF RECOVERED LIQUID
This is applicable when the liquid phase recovered from the dewatering unit
can be used to defray the cost of the dilution mud. For example, if the base
fluid is a brine costing $2/bbl, the cost of dilution will be reduced by $2 for
each barrel of liquid recovered by the dewatering unit. If the liquid is to be
treated and discharged, or if the recovered liquid has little value, enter a “0”
in this cell.
LIQUID, SOLID DISPOSAL COSTS
Input the estimated cost per bbl for disposal of liquids and solids. The
disposal costs should include any applicable charges for pit construction,
liquid or cuttings haul-off, spreading, and remedial treatment to reclaim the
site. Offshore site charges include cuttings box rental, transportation and
material disposal.
DEWATERING COST
Chemical dewatering cost will depend primarily on the mud and solids type
presented to the dewatering unit. Low solids non-dispersed muds may cost
as little as $1/bbl to treat. Heavily dispersed mud systems and fine, reactive
solids can push chemical treatment costs to near $10/bbl. Refer to the
Dewatering chapter for more information regarding dewatering chemical
costs. When possible, have the service company pilot test a sample of the
mud to provide an estimate of chemical treatment cost to flocculate. Further
chemical treatment, such as pH adjustment, may be necessary to reuse the
recovered liquid in the mud system. This cost should also be included in the
chemical treatment cost.

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 Appendix A
SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Solids Control Programs
Dowell Page 7 of 10

2.2 Interval Data and Analysis Section

Four intervals are provided in the spreadsheet. Each interval will require an
estimate of drilling time, section length and hole size, existing solids control
efficiency, low gravity solids content and initial circulating volume. The
spreadsheet will calculate the predicted dilution and disposal volumes for the
interval, and provide an analysis of dewatering costs per barrel and interval
dewatering cost.

Fig. 3. Interval data and analysis section of the DEWATER spreadsheet.

(1 of 4 intervals)

2.2.1 Input Data

DRILLING DAYS
Input the number of rotating days anticipated for this interval.
START/STOP DEPTH, ft
Enter the beginning and ending depth of the interval.
BIT SIZE, in.
Enter the bit size for the interval.

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January 1998
Schlumberger
Solids Control Programs
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WASHOUT,%
This is the estimated average volume % washout. This less than 10% for
hard, consolidated formations. Highly dispersive or unconsolidated formation
may wash out as much as 50%.
INITIAL CIRCULATING VOLUME, bbls
Enter the estimated volume in the surface pits and downhole at the
beginning of the interval.
INITIAL/ENDING LGS, %
For the purposes of this spreadsheet, LGS pertains to the drilled solids
content. If the mud is new, enter 0 as the initial drill solids content. The
ending LGS should be the maximum percent drilled solids to be tolerated in
the mud.
EQUIPMENT EFFICIENCY, %
Enter the estimated efficiency of the active system solids control system.
This value can be determined by running the solids control equipment
performance and economics program, SECOP. Usually, this figure will range
from 30% for poor solids control systems and fine drilled solids to 75% for
excellent solids control and coarse drilled solids.

2.2.2 Output Data

SOLIDS GENERATED, bbls
This is the total volume of drilled solids generated in the specified interval.
SOLIDS REMAINING, bbls
The solids left in the mud after processing by the solids removal equipment.
DILUTION REQUIRED, bbls
This is the dilution volume required to reduce the mud system to the
maximum specified LGS content at the efficiency specified for the solids
removal equipment.
MUD VOLUME TO TREAT, bbls
This is the volume of whole mud which must be dumped to accommodate
the required dilution volume.
EQUIPMENT SLUDGE, bbls
The volume of wet solids discharged by the solids removal equipment,
assuming a 1:1 ratio of liquid to solids. This program does not account for
weight material which may be discharged by the equipment. In weighted mud
applications, the actual equipment sludge volume may be higher.

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January 1998
Schlumberger
Solids Control Programs
Dowell Page 9 of 10

DEWATERING SLUDGE, bbls

The volume of wet solids discharged by the dewatering equipment,
assuming a 1:1 volume ratio of liquid to solids.
TOTAL SLUDGE, bbls
The total sludge volume is the sum of the equipment sludge and the
dewatering sludge volumes.
LIQUID SAVED, bbls
This the estimated total volume of liquid recovered by the dewatering unit.
DEWATERING RATE, bbl/day
This is the average volume which must be treated daily to accommodate the
required dilution volume.
DEWATERING COST, $/bbl
This is the average cost per barrel to treat the expected volume of whole
mud discharged, based on the dewatering chemical cost and the daily
equipment and manpower costs.
INTERVAL COST w/ DEWATERING, $
This is the total waste disposal and dewatering cost less the value of the
recovered fluid.
SAVINGS (LOSSES), $
The interval cost with dewatering is subtracted from the total disposal cost
without dewatering. Positive values indicate savings, or the reduction in cost
attributable to dewatering, for this interval.

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SOLIDS CONTROL HANDBOOK
January 1998
Schlumberger
Solids Control Programs
Page 10 of 10 Dowell

3 Summary Section
The summary section begins at line 100. This section of the spreadsheet
provides cumulative cost data on interval savings or losses and total liquid
and sludge discharge volumes. At the bottom of this section, a
recommendation is displayed regarding the deployment of a dewatering unit
based on the economics of each interval. Savings of less than $1000 for an
interval are considered uneconomic.

Fig. 4. Summary section of the DEWATER spreadsheet.

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