What Are the Advantages of Substitute Shaker Screen？

Speaking about the most essential pieces of drilling equipment, the shale shaker is tentatively the most important. Shale shaker separates drilling liquid such as mud from solids (also known as cuttings). Shale shaker screens are the most important components of a shale shaker as they help in separating liquids from solids by utilizing drilling fluid efficiently.

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It is a mesh screen made out of woven metal which is inserted in the shale shaker. When solids or cuttings are generated from drilling equipment, they are covered in drilling liquid. These cuttings are jolted over shale shaker screens and all the solid particles are captured. Replacement shaker screens are suitable for fitting to different types of shale shakers.

Parts of Shaker Screens

Shaker screen comprises of the following parts –

Screen Frame – The main screen is supported on a frame just like a canvas. It is made up of different materials such as flat steel sheets, square steel tubing, plastic style composites, etc. The outer perimeter of the frame is divided into small separate inner panels. These smaller panels can be of square, hexagonal, rectangular, and triangular shapes. They provide maximum rigidity and support for the mesh attached to them. The idea is to minimize the area for panels to increase the screen surface available for work.

Screen Mesh – A metal wire is woven to create a very thin, yet strong metal cloth called screen mesh. To increase the conductance of the screen mesh, the metal cloth is woven with rectangular openings which facilitate in minimizing the amount of material in the way. The screen is built with multiple screen mesh to maximize screen life. These multiple layers trap even the finest number of particles and keep the screen surface available for use for a long time.

Binding Agent – Binding agent is the substance used to bind the mesh to the screen frame. It provides maximum adhesion to both mesh and the screen frame. This binding agent is highly characteristic and can handle strong vibrations, corrosive drilling fluids, abrasive cuttings, and high heat.

Types of Shaker Screens

Various types of shaker screens used in shale shakers –

Flat Screen –Flat screen is commonly used in the Derrick shaker screen. It is cost-effective and traditional. Its screen panel is made up of two or three layers of stainless-steel screen bonded to a steel support plate.

Pyramid Screen – Pyramid screen is also used in the Derrick shaker screen. It costs higher and is made up of new screening technology that can increase the handling capacity of fluids and screening performance. It also has more screen area as compared to a flat-screen.

Metal Framed Screen – These are metal framed and are widely used across the industry. These screens enable the operators to switch motion on the fly as drilling conditions change. These screens are highly efficient in separating solids from drilling equipment.

Composite Screens – Composite screen is made with composite material with steel reinforcement. They have much higher quality, performance, storage life, delamination resistance, and improved handling.

Hook Strip Screens – Hook strip screens are constructed with two or three stainless steel layers bonded to a steel support plank. Accessory rubber plugs are inserted to the rips of the screen to cut down production costs.

Advantages of Shaker Screens

The benefits of using shale shaker replacement screens are –

Increased Shaker Capability – Some shaker screens help in increasing the total amount of usable API non-blanked screen area. This helps in significantly increasing the usable screen area which results in an improved fluid handling capacity as well.

Fine Separations – Shaker screens provide enhanced permeability, gravity, and vibration which allow more fluid to pass through the top of the screen. Shaker screens have the capability of making separations as fine as 40 microns.

Replaceable – Shaker screens are replaceable and can fit almost all types of shakers for the efficient use of existing equipment. There is no need to modify or replace the existing shaker which ultimately saves a whole lot of money.

Drier Cuttings – Shaker screens minimize fluid loss by spreading thinner layers of fluid over an increased screen area which results in faster drying. This enables shakers to screen 1 to 2 API sized particles which ultimately increases efficiency and time.

Final Review

The shaker screens is one of the most important components of drilling equipment. Shale shaker separates drilling liquid such as mud from solids (also known as cuttings).

Shale shaker screens are the most important components of a shale shaker as they help in separating liquids from solids by utilizing drilling fluid efficiently.

It is a mesh screen made of metal braid inserted into the Shaker Screen. When drilling equipment produces solids or cuttings, they become covered with drilling fluid. These cuttings vibrate on the Shale Shaker Screen and all solid particles are captured. Replacement shaker screen mesh is suitable for different types of shale shaker screens.

Parts Of Shaker Screens

Shaker screens are comprised of the following components:

1. Screen Frame: The screen is supported by a frame, similar to a canvas, made of materials like flat steel sheets, square steel tubing, or plastic composites. The frame is divided into small inner panels (square, hexagonal, rectangular, or triangular) to provide rigidity and support for the attached mesh. This design minimizes the area of the frame to maximize the screen surface area available for operation.

2. Screen Mesh: Screen mesh is a thin, strong metal cloth created by weaving metal wires. To enhance conductance, the mesh is woven with rectangular openings that minimize material interference. Multiple layers of screen mesh are used to extend screen life and trap even the finest particles, ensuring a longer usable screen surface.

3. Binding Agent: A binding agent is used to attach the mesh to the screen frame, providing strong adhesion. This agent is designed to withstand strong vibrations, corrosive drilling fluids, abrasive cuttings, and high temperatures.

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Types Of Shaker Screens

Various types of shaker screens used in shale shakers:

Flat Screen - Flat screens are commonly used in Derrick shakers. They are cost-effective and traditional. The screen is composed of two or three layers of stainless steel screen bonded to a steel support plate.

Pyramid Screen - Pyramid screens are also used in Derrick shakers. They are more expensive and consist of new screening technology, which can enhance fluid handling capacity and screening performance. They also have a larger screen area compared to flat screens.

Metal Frame Screen - These screens are made of a metal frame and are widely used in the industry. These screens allow operators to switch motions instantly as drilling conditions change. They efficiently separate solids from drilling fluids.

Composite Screen - Composite screens are made of composite materials and steel reinforcements. They have higher quality, performance, storage life, anti-stratification properties, and improved handling capacity.

Hook Strip Screen - Hook strip screens are composed of two or three layers of stainless steel bonded to a steel support plate. Rubber plugs are inserted into the screen's cracks to reduce production costs.

Advantages Of Shaker Screens

1. Replaceable: Shaker screens are replaceable components, allowing for easy maintenance and cost-effective screen replacement when worn or damaged.

2. Increased Shaker Capability: Shaker screens enhance the capability of shale shakers by efficiently separating solids from drilling fluids, leading to improved drilling performance and reduced operational downtime.

3. Fine Separations: Shaker screens are designed to provide fine separations, effectively separating solids of different sizes from drilling fluids, which is crucial for maintaining drilling fluid properties and minimizing environmental impact.

4. Drier Cuttings: Shaker screens help produce drier cuttings by efficiently removing excess drilling fluids, which can improve waste management and disposal practices.

Why Timely Replacement of Shaker Screens is Important

1. Maintaining Filtration Integrity: When a shaker screen is damaged, whether due to holes or missing separation layers, drilling fluids containing harmful cuttings can pass through the damaged area. This compromises the screen's filtration function, leading to ineffective separation of solids.

2. Reducing Equipment Strain: Ineffective screens result in increased load on subsequent equipment. This can lead to premature wear and breakage of downstream equipment.

3. Preventing Mud Loss and Cost Increase: Timely replacement of shaker screens helps prevent further mud loss and reduces the overall cost of drilling operations. In some cases, damaged screens can be repaired and reused, further reducing costs associated with screen replacement.

4. Enhancing Efficiency: By replacing screens in a timely manner, drilling operations can maintain efficiency and reduce downtime associated with equipment failures.

It is essential to monitor the condition of shaker screens regularly and replace them as needed to ensure optimal performance and cost-effectiveness in drilling operations.

Through the above content, we understand the advantages of replacing the shaker screen and the importance of replacing the shaker screen. Next, let us learn how to maintain & replace the shaker screen.

How to Maintain Shaker Screens

Shaker screens are the critical interface between drilling cuttings and the drilling fluid. During operation, the drilling fluid, laden with cuttings or other harmful solids, passes through the screen panel. Under the influence of vibration, the screen filters out particles, ensuring a clean drilling fluid return.

It's crucial to maintain shaker screens properly to ensure optimal shaker performance. The filtration accuracy directly impacts the control of solids size and content. Therefore, it's essential to select the right mesh size and regularly inspect the screen surface. Additionally, checking the overall condition of the shaker, including the tensioning system and sealing strips, is important. Quality assistant parts can also enhance screen maintenance.

After each shutdown, remove the screen panels and clean them with water. This practice helps eliminate abrasions on the screen cloth and ensures better performance during subsequent use. Store clean screens in a dry, safe place, with a recommended shelf life of 12 months. Screens with hook straps, composite frames, or rubber strips may be affected by time and ambient conditions, so a shorter storage time can help maintain their performance.

Maintaining shaker screens well is essential for efficient drilling operations. Regular maintenance not only extends the life of the screens but also improves drilling efficiency and reduces downtime.

How to Replace The Shaker Screen?

1. Stop the Shale Shaker: Before replacing the shaker screen, ensure the shale shaker is stopped. If possible, redirect the drilling mud to other shakers for processing or cleaning.

2. Remove the Old Screen: Depending on the installation method, remove the old screen. For screens installed with wedge blocks, knock the blocks out in the opposite direction of the lower position. Once loose, remove the blocks and lift out the screen panel.

3. Install the New Screen: Replace the old panel with a new one. For screens installed with tensioning bars and bolts, loosen the bolts and remove the bars or panels. The installation method may vary, with traditional methods using tensioning bars and newer versions using air compression or pressing pins. Regardless of the method, always loosen the tensioning tool first.

4. Consider Actual Demand: The frequency of shaker screen changes should be based on actual drilling conditions, such as drilling depth, fluid flow rate, and mud properties.

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