What is Shale Shaker Screen and Why Do We Use Them?

Welcome to the ultimate guide for choosing the best shaker screen for the oil and gas industry. Whether you are drilling for oil or natural gas, having the right shaker screen can make all the difference in ensuring efficient and effective solids control. In this comprehensive guide, we will walk you through everything you need to know to make the best decision for your specific needs.

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With a vast array of options available in the market, it can be overwhelming to choose the right shaker screen. That's why we're here to help. We will delve into the different types of screens, their mesh sizes, and the materials they are made of, along with their pros and cons. We will also discuss important factors to consider, such as flow capacity, screen longevity, and ease of maintenance.

Our guide is designed to provide you with the knowledge and insights you need to make an informed decision. By the end, you will have a clear understanding of which shaker screen is best suited for your drilling operations, ensuring optimal performance and cost-effectiveness.

So, let's get started on your journey to finding the ultimate shaker screen for your oil and gas industry needs!

Choosing the right shaker screen is crucial for the success of your drilling operations. A shaker screen is an essential component of the shale shaker, which is responsible for separating solids from drilling fluid. Solids control is vital in the oil and gas industry as it helps maintain drilling fluid properties, prevents equipment damage, and ensures the safety of personnel.

The right shaker screen can improve solids control efficiency, reduce waste disposal costs, and minimize downtime. It can also enhance the overall drilling process by improving drilling fluid quality, reducing wear and tear on other equipment, and increasing drilling productivity. Therefore, investing time and effort into selecting the best shaker screen is a wise decision.

When choosing a shaker screen, several factors should be taken into consideration to ensure optimal performance. One crucial factor is the screen's mesh size, which refers to the number of openings per linear inch. Mesh sizes typically range from 20 to 325, with lower numbers representing coarser screens and higher numbers indicating finer screens.

Another important consideration is the material used to construct the screen. Common materials include stainless steel, composite, and polyurethane. Stainless steel screens are durable and resistant to corrosion, making them suitable for harsh drilling conditions. Composite screens offer a balance between durability and cost-effectiveness, while polyurethane screens are known for their flexibility and longer lifespan.

Flow capacity is another critical factor to consider. The screen's flow capacity determines how efficiently it can process drilling fluid and separate solids. It is essential to choose a shaker screen with adequate flow capacity to prevent bottlenecks and maintain optimal drilling operations.

There are different types of shaker screens available in the market, each with its own advantages and disadvantages. The most common types include flat screens, pyramid screens, and hook strip screens.

Flat screens, also known as conventional screens, are the most basic type of shaker screen. They have a simple flat surface and are suitable for general-purpose applications. Flat screens are easy to install and maintain, but they may have limited solids control efficiency compared to other types.

Pyramid screens, on the other hand, have a pyramid-shaped surface with larger openings at the top and smaller openings at the bottom. This design allows for improved solids control efficiency and increased flow capacity. However, pyramid screens can be more expensive than flat screens and may require more frequent replacement.

Hook strip screens are another popular option, characterized by a hook-shaped strip that holds the screen in place. These screens are known for their easy installation and removal, making maintenance and replacement quick and hassle-free. However, hook strip screens may have lower flow capacity compared to other types and may not be suitable for high-volume drilling operations.

Mesh size plays a crucial role in determining the performance of a shaker screen. The choice of mesh size depends on the desired cut point, which refers to the size of the particles that the screen can effectively separate.

Finer mesh sizes, such as 200 or 325, are suitable for removing smaller particles, while coarser mesh sizes, such as 20 or 40, are better at removing larger particles. It is important to select the appropriate mesh size based on the expected particle size distribution in the drilling fluid.

Using the wrong mesh size can result in poor solids control efficiency, increased screen wear, and reduced flow capacity. It is recommended to perform regular particle size analysis to determine the optimal mesh size for your specific drilling conditions.

Before selecting a shaker screen, it is advisable to test and evaluate different options to determine their suitability for your drilling operations. Testing can be done in a laboratory or on-site using a test rig. The test rig simulates the actual drilling conditions and allows for accurate assessment of the screen's performance.

During testing, parameters such as screen conductance, cut point, and solids removal efficiency are measured and analyzed. Conductance refers to the ability of the screen to allow drilling fluid to flow through it, while cut point indicates the particle size at which the screen can effectively separate solids. Solids removal efficiency measures the screen's ability to remove solids from the drilling fluid.

By conducting thorough testing and evaluation, you can make an informed decision and select the shaker screen that best meets your specific requirements.

Proper maintenance and cleaning are essential for extending the lifespan of your shaker screens and ensuring consistent performance. Regular inspection of the screens is necessary to identify any signs of wear or damage. If a screen is found to be damaged or worn out, it should be replaced promptly to prevent further deterioration.

Cleaning the screens after each use is also crucial to remove any solids or debris that may have accumulated. This can be done using a pressure washer or by soaking the screens in a cleaning solution. It is important to follow the manufacturer's guidelines for cleaning and avoid using harsh chemicals that can damage the screen.

Additionally, proper storage of the screens when not in use is important to prevent deformation or damage. Screens should be stored in a clean and dry environment, away from direct sunlight and extreme temperatures.

Cost is an important factor to consider when selecting a shaker screen. The initial purchase cost, as well as the maintenance and replacement costs, should be taken into account. While it may be tempting to opt for the cheapest option, it is important to balance cost with performance and durability.

Cheaper screens may have a shorter lifespan and require more frequent replacement, resulting in higher long-term costs. On the other hand, investing in higher-quality screens may initially be more expensive but can save money in the long run by reducing downtime and replacement frequency.

It is advisable to consult with suppliers and manufacturers to obtain cost estimates and compare the total cost of ownership for different screen options. Taking into consideration factors such as screen lifespan, maintenance requirements, and solids control efficiency will help you make an informed decision based on both performance and cost-effectiveness.

Shale shakers are important pieces of machinery for drilling. They are the first step in a drill's solids control system. They are used for removing large solid masses from the fluid drilled out. These are used in the upstream market of the oil and gas business and in coal cleaning and mining. An essential part of the Derrick shale shaker is the shale shaker screen. A shale shaker screen is a type of screen that is made of metal. It can separate solids from drilling fluids like mud and take them out. Most shale shaker screens have polyurethane, composite, or stainless steel frames. Shale Shaker Screens are an integral part of the drilling equipment used in numerous industries, most notably in the coal processing, mining, and oil & gas drilling industries.

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Specifications for a shale shaker screen change depending on the mesh size, which is set to meet the various API screen number criteria. Shale shaker screens can have a variety of frames, including steel frames, hook strip flat-style screens, composite frames, and others.

Let's take a look at the different types of shale shaker screens and their features:

Hook strip screen panels

The Hook Strip Flat Shaker Screen separates harmful drilled solids from drilling fluid by using an advanced frame design and unique mesh combinations. It consists of one to three layers of screen cloth and is the most common type of shaker screen. The fabric is often stuck to a thin metal grid plate with holes or a plastic grid.

The shaker screen panel is held in place on the shaker deck by a system of hookstrips and drawbars on both sides of the shaker that are locked together. Each drawbar is pulled down and toward the side of the basket by using three or more tensioning bolts. This puts the screen in place on the shaker deck and spreads the tension evenly along the hookstrip.

Essential features:

• Helps get more energy from the shaker basket to the screen so that solids can be separated faster.
• Extends the life of the screen, saving money on replacement costs and reducing downtime.
• It eliminates the need for crown rubbers, so you don't have to pay for replacements.
• Individual seals around the edge of the screen stop leaks from happening.
• Makes sure that screens fit tightly in the shaker basket and won't move once they're in place.

Derrick FLC 500 PWP:

Derrick FLC 500 series shale shakers' replacement screens are designed for the FLC 500 flat shaker screen. It is made of two or three layers of wire mesh cloth made of stainless steel (304 or 316), which is then joined with a steel backing plate. A one-sided quick-locking tension system on the FLC 500 PWP screen speeds up panel replacement.

Essential features:

• Wire mesh made of stainless steel 304/316 for durability.
• Excellent trapping (dreg) effect, quick-lock tension system.
• Simple installation, removal, and inspection of screens.
• Boost shaker productivity and lessen mud loss.
• A realistic and scientific cost control strategy for competitive pricing.
• Higher flow rates without compromising the integrity of the cut point.
• Compliant with API RP 13C (ISO ).
• Having enough inventory available as quickly as possible to meet client demand.
• Yearlong warranty
• 400'450 hours of working time.

Derrick 500 PMD shaker screen:

For all Derrick 500 series shale shakers, replacement Derrick 500 PMD shaker screens are produced. Each screen panel has two quick-lock 1/2 turn tension bolts and two innovative tension fingers that make installation quicker, simpler, and more dependable. Low mesh count bottom layer is waved by coarse wires and then firmly connected to the backing plate. It maximizes separation efficiency and has a longer service life.

Essential features:

• Excellent trapping (dreg) effect, quick-lock tension mechanism, corrosion, high temperature, and collision resistance.
• Flat screens have 56% less screen surface area.
• Increase the capacity for removing solids.
• Boost shaker productivity and lessen mud loss.
• Compliant with API RP 13C (ISO ).
• One-year warranty period
• As many as 450 hours of working time.

Steel Frame Shaker Screen

Steel frame shale shaker screens:

Shale shaker screens with a steel frame are made of two or three layers of stainless steel wire mesh. The whole screen is made up of many small, separate meshes to stop the damage from causing it to stretch too much. Its backing and working layer were glued together, making the screen stronger. In the meantime, the rubber plugs can be fixed quickly. This saves a lot of time and money on disposal costs.

Steel frame shale shaker screen is stronger and better at resisting wear than flat shaker screen and hook strip flat screen. The screen has a strong and stable frame made of high-strength steel and grids that hold it up. So, the shaker screen can hold much more material and work much more efficiently.

Essential features:

• The frame is made of high-strength steel and is very resistant to wear.
• Structure is strong and can hold a lot of weight.
• Effective panel pressure distribution system.
• Better screening performance and more efficient work.
• Plug repair system works well, so there is less downtime.
• You can get them in different colors.
• Its overall operational cost is low; hence, it's economical.

Composite Shaker Screens

Composite shaker screens are better at controlling quality by nature. There is no chance of breaks in service or changes in quality. There is no way for a person to make a mistake when welding, powder-coating, or grinding. This makes sure that the quality of each screen is the same. Woven wire cloth can be stretched tighter with the help of composite screens. As a result, they have a better cutting point and last longer. Composite shaker screens improve solids control efficiency to cut costs and waste volumes, no matter the formations or drilling applications used.

Essential features of a Composite Screen:

• Screens with metal frames are made of pieces glued together with powder-coat paint. This bond depends on how smooth the powder coat was, how well the metal frame was cleaned, and how well the heat press was run. Composite screens aren't glued together. So, neither the perforated plate nor the wire mesh can come apart from the frame before it should.
• The surface area of a composite screen is 47% bigger than that of a standard flat-panel pre-tensioned flat-panel screen. The higher hydraulic capacity is a direct result of this extra surface area. This means that drilling fluids with higher viscosity can be used at a higher flow rate.
• Many things can go wrong with how long you can store a metal-framed screen. The screens can get bent if they are shipped or if they are handled in the wrong way. No matter how much powder coat is used, the base metal can still rust. When managing composite screens, this is not the case. Screen frames don't get dents or bend if they are handled wrong. They also don't have any metal in the open, so the frame can't rust.

Corrugated Shaker Screen

Corrugated shaker Screen: 

Corrugated Screen with a three-dimensional design has the advantage of adding a large screen area that flat screens don't have. Because of this, a screen makes it possible to handle more fluid. The effective area of the corrugated mesh is 25% to 50% bigger than that of flat mesh with the same specifications. So, a lot more drilling fluid can be processed.

Essential features:

• When using Corrugated Shaker Screens, rigs can screen two to three mesh sizes finer than they could with the conventional flat panel screens without losing capacity. This makes it easier to get rid of solids.
• Corrugated Shaker Screens can separate particles as small as 43 microns.
• There is no need to change or replace the equipment you already have. Corrugated Shaker Screens are suitable for all shakers, so you can get the most out of the equipment you already have.
• Corrugated shaker screens reduce the amount of fluid that leaks out by spreading thinner layers of fluid over a larger screen surface. This makes the drying process work better.
• Gravity and vibration push the solids into the troughs of the corrugated screen, which lets more liquid flow through the top of the screen.

What factors to consider while selecting a screen shaker screen?

The main things that help you choose the right screen are the solids' size, the mud's weight, viscosity, density, etc. If you choose the wrong screen, you could lose expensive drilling fluids, have pumps break down early, overload other solids removal equipment like a decanting centrifuge, shorten the equipment's life, slow the penetration rate, or cause other severe problems in the well bore.

Some other factors include:

• Flow rate of the liquid
• Motor vibration
• Cut pint of the screen
• Metal's grade
• Accuracy of mesh micron

Final Thoughts:

A shale shaker is an essential component, especially for drilling purposes. The shaker screen plays a vital role in filtering the solid masses from the drilling fluid. As a result, proper research is necessary to buy the best screens to get the optimum results. Moreover, the maintenance part shouldn't be neglected either, because even the best of the screens may wear if not maintained properly.