The Centrifuge and Mud Technology~

RAY WILLIAMS*AND JOHNMESAROS~

ABSTRACT
The decanter-type centrifuge has now operated con-
tinuously on weighted Gulf Coast muds since 1953. I t h a s
become a valuable and versatile tool i11 the hands of the
competent field-mud engineer. With it he can salvage
barite and reject harmful light native solids. This makes
it possible to reduce additions of water and chemicals,
to eliminate contaminants, aiid t o produce a n effective
packer mild.
Maiiagenieiit approves because well costs a r e reduced.
Drilling engineers find t h a t penetration rates a r e in-
creased aiid hole troubles reduced. Drilling crews a r e
relieved from the work and hazard of adding large
amounts of barite and massive chemical treatments t o
the mud.

INTRODUCTION I COST O F DILUTING A MUD

The centrifugal treatment of yeighted drilllng muds
i s l ~ e c o ~ n i nincreasingly
g prominent i n today's drilling
operations. I t is f a s t becoming recognized a s the key
tool which allows the mud engineer to prepare and main-
tain the low-solids muds needed t o drill n ~ o d e r n ,deep,
high-l~ressurewells wit11 some semblance of economy.
I t s efficiency a s a sollcls remover h a s been known f o r
some time. No\v, its versatility a s a mud-engineering
tool is I~eingexploited.
The greatest value of centrifuging a s a mud-engineer-
ing tool is based on the problems of maintaining
weighted muds. Even when no difficulties a r e being
exper~enced,the normal maintenance of high-density
mud 1s very costly. Watering back such a mud h a s been
a n accepted procedure because the fine formation par-
ticles which a r e not removed by the shale-shaker screen
or by settling in the tanks become a p a r t of the mud.
The presence of these fine, lightweight formation par-
ticles affects the mud adversely in t h a t they occupy
space. The volhne of the liquid phase is reduced when
these additional tsolids a r e present. The character of these
solids can be altered by chemical treatment so t h a t more
of then1 can be tolerated before a mud loses its desired
properties, but eventually their concentration i n t h e mud
must be reduced. The practice of watering back, there-
fore, h a s been necessary to inaintaln the mud in i t s
normal range of properties. I n high-density muds the
problem i s intensified by the presence of large amounts
Remembering t h a t when a certain,volume of water i s
added t o the system, room must be made f o r t h a t water,
we ,should first look a t the econon~icfactors involved in
watering back a mud. The preparation of a new mud
having a density, f o r example, of 17.0 Ib per gal, \\rill
involve t h e use of the typical amounts of materials a s
given i n Table 1.
The cost of preparing a barrel of 17-1b mud i s $15.85.
Suppose t h a t a 1,000-11111 mud ,system needs t o be \i~aterecl
back a n amount t h a t will require the jetting aivag of
100 bbl of mud.
The mud, a f t e r being diluted, must be conditioned with
weighting material and sufficient chein~calsto maintain
the desired properties. I n actual practice, the condition-
i n g takes place a t the same time a s the aclditiorl of the
water, and such additives a s bentonite may not be used.
The cost of getting the total system back to ~ t original
s
17.0 Ib per gal weight and the use of the necessary
chemical aclclitives will amount t o about the same a s
would the preparation of a new mud.
Conchtioning the mud system by the watering-back
method ~ v i l l ,therefore, be equal In cost to the value of
I Table 1
I Cost of Preparing 1 Bbl of 17-lb Mud - $ 1 5.85

of barite, which is the most expensive component of the I Amount

mucl. Required, Cost Total Cost
Pounds per per of
The amount of water which is added t o the mucl a t any Rlatenal Barrel Pound Material
given time depends upon the condition of the mud. The
addition of 10 percent t o the volume 1s common, and Bentonite .................... 6 0.02 0.12
sornetinles i t is,necessary to add 20-percent water to get Driscose ..................... 1% 0.90 1.35
a mud into proper condition. This is i n addition to the Graphite ...................... 2 0.16 0.32
Quebracho .................. 1 0.18 0.18
normal amount of water which i s always going Into the Caustic ........................ 1 0.09 0.09
mud while drilling is in progress. Weight material ..........475 0.086 12.35

*Phillips Petroleum Co.. Alvin, Texas : slnce removed to International $14.41

.
Drilllng Co Rome, Italy. , (Handling and breakage-10 percent). .......... 1.44
.
SPhllllps Petroleum Co Bartlsjville. Okla.
tPresented by Ray Wlll~arns'at the spring meetrng of the Southern
Distr~ct.D~visronof Product~on,Shreveport. L a . March 1957. I Total cost ............................................................. $15.85
186 RAY WILLIAMSAND JOHN
MESAROS
100 bbl of mud worth $1,585 which w a s jetted away plus
the cost of making 100 bbl of new 17-lb mud-another
$1,585. The cost of this procedure w ~ l lbe $3,170.
COST O F CENTRIFUGING A MUD
The centrifuge process eliminates the need for water-
i n g back a mud because the drilled solids a r e removed
mechanically. The barites a r e removed and returned t o
the mud system i n the form of a heavy sludge. The sludge
must be thoroughly mised back into the rest of the mud
i n the tanks. The light solids and water and chemicals
a r e discharged into the reserve pit a s effluent.
I f 100 bbl of mud a r e processed through the centrifuge,
all of t h e chemicals ~ 1 1 be1 lost and a small amount of
barite will be rejected along with the clays, depending
upon the efficiency a t which the n ~ a c h i n eis being made
t o operate. L e t u s assume t h a t the machine i s t h r o w ~ n g
away 15 percent of the barite w111ch it processes. Because
there i s $1,235 worth of barite in 100 hbl of the mud, the
centrifuge will recover 85 percent o r $1,050 worth of
b a r ~ t e(see Table 2).
The chen~icalsi n 100 bhl of this 17-lb mud a r e also
lost In the process. The difference in the cost of the mud
ancl t h e value of the barite recorerecl represellts the cost
of centrifuging the mud. This cost illust 1)e in addition
t o t h e $1,585 \vhicll was originally spent to prepare tile
mud.
One thousand and fifty dollars can be saved by using
t h e celltrifuge one tillle to keep mud properly con-
ditioned. The watering-hack metllocl is still i n comnlon
practice, and in sollle areas i t is necessary to condition
tile mud i n this manner a s often a s three o r four times
a week. Where tile centrifuge 1s made to perform prop-
erly, i t is effectively renloving solids in s u c l ~quantity and
over such a range of sizes t h a t these larger water dilu-
tio11s a r e not necessary; n o r a r e the larger and often
complicated chemical treatments of the past needed.
CENTRIFUGE CONSTRUCTION AND OPERATION
The reason t h a t weighted ~ n u d scan be processed prof-
itably through a centrifuge is the difference i n specific
g r a r ~ t ybetween barite and formation clays or solicls.
The specific gravity of barite is 4.2 \vhile t h a t of foinla-
Table 2
Cost of Centrifuging 100 Bbl of 17-lb M u d
Original cost to prepare 100 bbl ............................ $1,585.00
Cost of barites a n d chemicals lost in process ........ 535.00
Total cost ........................................................ $2,120.00
The total cost of centrifuging 100 bhl of 17-Ill mud i s
$2,120. This method conlpares with tlle method by which
100 bbl of nlud i s jetted away to be replaced by water and
new nlud a s follows:
Cost of jetting and watering back ........................ $3,170.00
Cost of centrifuging ................................................ 2,120.00
Difference ...................................................... $1,050.00
{ EFFLUENT PORT
i '.-J---
P, t
- INLET
EFFLUENT PORT,
SLUDG~
Fig. 1-Flow of Mud through Continuous-type
Centrifuge
tion solids averages about 2.5. Several ~ n a n u f a c t u r e r sa r e
now p r o v ~ d ~ ncentrifuges
g \vhlch a r e adaptable f o r use
on drilling muds.
The decanter-type machine performs its separation by
subjecting the fluid to centrifugal force while passing
through a rotating cone. (See Fig. 1.)
The ~ n u denters the rotating conical bowl a s a diluted
slurry containing solids from the foilnation and heavy
weighting m a t e r ~ a l . When the feed ~ n i s t u r e is first
thro\vn against the walls of the r o t a t ~ n g bowl, the
heaviest particles come out of the llquid and cling t o tlie
rotating \vall. The size of the heavy particles determines
a t what point in t h e cone the centrifugal force is g r e a t
enough t o remove them. The force is greatest a t the point
where t h e d ~ a m e t e rof the bowl 1s largest. The heavy
barite solids \vhich become stacked against the howl a r e
nloved toward the smaller end of the bowl by a slliral
conveyor inside the 11o\vl. The conveyor moves in t h e
same direction but a t a slightly slo\ver speed t h a n the
bowl. The barite is then discharged a s a high density
sludge through pelts In the bowl.
The ligllt\veight solids will not he thrown out of the
feed llquid a s easily a s will the heavies and, therefore,
will flo\tr out of the bo\rl \vith the 11qu1d effluent or orer-
flow through port's a t the large end of the hoxrl.
111 Fig. 1, t.he slleecl a t wlllch the conical 11owl is rotat-
,ing \\,ill determine tlie amount of c e ~ ~ t r i f u gforce
al which
i s cle\~eloped. Because of the shape of the horizontally
l~ositionedcone, there will always be fluid l y ~ n ga t t h e
\vide end of the bowl. When the bowl is rotating, t h e
liquid will be thro\x,n around the walls. This liquid foiqns
t h e pool and its volume is determined by t h e position
of t h e adjustable effluent discharge poi-ts. If t h e pool
volume i s large, t h e particles a r e retained f o r a longer
period of time than they \voultl be if the volume were
~ h ~the ~longer~ thef ~ ~ are ~retained
,
i,, the pool of liquid, the lollger they will be esl,osed to
t h e forces of rotation.
The two factors which most affect the centrifuge
process are the celltrlfugal force ancl the length of tinle
during \vllich the pal-ticles are sul,jected to force,
By usillg lnultillles of gravity or gees to esI,ress the
centrifugal force ancl seconds to measure retention time,
tlle useful term "gee-seconds" can be produced by simple
multiplication.
If the pool volume i,s.reduced,the fine particles will not
be peinlitted to remain under the influence of centrifugal
 AND MUDlECHNOLOGP
THE CENTRIFUGE 187

force long enough to be removed with the coarse par- t -

BEFORE CENTRIFUGING
ticles.' Some of the slnaller barite particles \\.ill be re-
jected along with the clay i n this case. o ----- AFTER CENTRIFUGING
W
PARTICLE SIZES AND WEIGHTS w
LL
I n understanding the mechanical separation process
of a drilling mud, ~tis essential t h a t the distribution of -
t h e size of particles of various densities be considere(1.l V)
If a mutl contains weighting material having a specific

gravity of 4.2 and foi-nlation sollds having a specific
gravlty of '7.5, the process woultl present 110 probleal if
all of the particles were the sarne size and shape. Un-
fortunately, many of the ~ ~ a r i ~ u n - s u l f aparticles
te will
be snlaller t h a n some of the formation paiticles. The
separation process is affected 11y the size of the particles
a s well a s their specific gravity. Fig. 2 illustrates t h e
particle-distnbutioll situation t h a t might exist in a drill-
lng mud.
Q l ~ a r i t epossible \\,hen centrifuging a heavily weighted
w
W
LL
f slip the separation line back to the right of line 2 even
V)
G
-J
0
V)
PARTICLE SIZE-INCREASING
Fig. 2-Possible Types of Separation with the
Centrifuge
The cuives show t h a t i t is impossible to separate and
discard all of the clay solids ant1 retain all of the barite.
Frequently, a s ~ n u c l la s 15 percent of the harite present
i n a mud is less that, 10 lllicrolls in size."he ]lest best
al,proach, then, i s to separate all of tile clay possible and
retain a s muc1.l of the barite a s possible. The cut neces-
s a r y t~ nlake this type of separation ~1 auld be a t the
point where the curves intersect a t line 1. Some of the
clays \\.auld retained in the sludge and solne barite
would he rejected with the clay in the effluent.
CENTRIFUGE APPLICATIONS
Several considerations now become evident, and the
relationship between mud control and centrifuge process
hecomes significant. If the c u w e s sho\vn in Flg. 2 repre-
sent a \\.eightecI 12-11) per gal rnucl i n a fast-clrllling hole
m a k m g > alarge amount of sohds conle into the mud, t h e
mud engineer would clecicle t o make a cnt a s shown by
line 9. Here, he may actually throw some e s t r a barite
a w a y in his effort to relnove all of the drilled solids. H e
will conslcler t h e economy and t h e need f o r a certain s e t
of nlucl propelties under the existing drilling conditions
such a s depth, drilllng rate, and the type of lnud he will
need when the well gets deeper.
If the cuives i n Fig. 2 represent a 17-lb mud being
used while the drilling r a t e is medium, i t will be neces-
s a r y to take a cut a t the point where line 2 intersects the
cui-ve. This decision w o u ~ drequire the engineer to r u n
IReferences a r e a t the end of the paper.
-
1
0
*
PARTICLE SIZE INCREASING
Fig. 3-Particle-size Distribution in Centrifuged Mud
is Continually Changing
the centrifuge f o r longer periods of time until the drilling
r a t e slo\\rs do\\ n. The condition of the mud is all impor-
t a n t in such decisions. I t is necessary t o recover all the
mud, but ~t la more important to keep the best possible
mud properties. The nlud man may, therefore, have t o
t l ~ o u g hhe will knowingly discard valuable barite.
The fallacy of using Fig. 2 to esplain \\,hy different
separations a r e necessary should be emphasizetl by
p o ~ n t l n gout t h a t the d i s t ~ i b u t l o ncurves f o r particle
sizes i n a given mud a r e always changing (Fig. 3 ) . These
distributions a r e dependent on the drilling rate, mutl
weight, and the amount of time \vhicll the centrifuge h a s
already been run.
GUIDES FOR FIELD U S E
The practical application of a centrifuge is dependent
011 the engineer who nlust use it. He nlust be the same
man \\.ho 1s responsible f o r the care of the mud. He ]>lust
know the history of the mud and when he uses the cen-
trifuge, he must know why he is using it. The centrifuge
i s usually thought of a s a means of saving espensive
b a n t e , which is true. Honever, i t nlust be remembered
t h a t this is done by removing and d i s c a r d ~ n gclay (Fig.
4).
0
W
W
-
z
O
PARTICLE SIZE-INCREASING
Fig. 4-A Centrifuge Saves Barite by Discarding Clay
188 RAY WILLIAMSAND JOHN
MESAKOS

I
SOLIDS CONTENT O F MUD Table 4
Several means, a r e a t the disposal of the engineer f o r
determining the condition of his mud a s related t o solids Retort Method Indicates Mud I s Contaminated
content. They are:
1. Stoimer viscometer. Ideal Undesirable
2. F a n n V-G meter. Funnel Viscosity Funnel Viscosity
3. Hand centrifuge. 50 Seconds, 70 Seconds,
4. Oil retort..
The use of the oil retort is one of the better methods Percent Percent
of deteimining whether the mud is in need of centrifug- Oil 5 Oil 5
ing or chemical treatment. To use i t or any of the other W a t e r 64 W a t e r 64
testers properly, the mucl engineer must know w h a t t h e Solids 31 Solids 31
l~ropertieswill be when t h e mud is i n the best possible - -
shape. Suppose t h a t a funnel viscosity of 50 sec A P I 100 100
indicates t h a t the mucl is iust a s he wants it. H e will
also know t h a t some higher viscosity, perhaps 60 see,
indicates t h a t the solids content of the mud is approach- ADVANTAGES O F LOW-SOLIDS MUDS
ing a critical concentration above which the viscosity The advantages of low-solids, low-viscosity systems
will rise very f a s t ancl the mud will be in poor condition. a r e well known t o drilling engineers." Pumps r u n better
By using the oil retort, he can determine the icleal solids and p a r t s need not be replaced a s often. The pump dis-
content f o r t h a t mud. charges the fluid with less pressure buildup. The drill
stem i n which most of the pressure drop occurs can
Case I.
handle the same velocities a t reduced pressures. More
If a f t e r several days of drilling, the funnel viscosity
of the hydraulic horsepower which is expended inside
i s climbing towards 60 sec, there is a need f o r a solids-
the dl-ill plpe and collars can be delivered to the bit
content determination. T,he solids content of the mud
nozzles in t h e form of greater velocities. The cuttings
will usually he found to have increased. Table 3 shows
a r e removed more cluickly from beneath the bit teeth
sonie sample retort determinations.
and a r e not reground to finer particles. Velocities In the
annulus, too, a r e greater. This helps keep the hole cleaner
Table 3 and brings the c u t t ~ n g sto the surface faster.
Retort Method lndicates Mud Needs Centrifuging
These advantages exist I?ecause the light formation
particles a r e not present in the mud. The pump is not
required to circulate them through the system. The
Funnel Viscosity Funnel Viscosity
additional pressure t h a t must be used when t h e uncle-
50 Seconds, . 60 Seconds,
sirable solids a r e present is no longer needed and can
Percent Percent
be used to gain- other acl\~antages.
This removal of drilled solids with the centrifuge h a s
Oil 5 Oil 5 affected all phases of mud-engineering problems. New
Water 64 Water 61 approaches a r e now being made t o such situations a s
Solids 31 (ideal) Solids 34 (undesirable) lost c ~ r c u l a t ~ o settling
n, of cuttings, penetration rates,
- -
fluid velocities, and hole conditions.
Total 100 100 by volume
LOST-CIRCULATION EXAMPLE
Use of the centrifuge and a working knowledge of flow
This example \rould indicate t h a t the mud needs to be properties must go hand i n hand. This was sho\vn during
centrifuged. In actual practice, the mud engineer will a lost-circulation prol~lemon a wildcat well on t h e Gulf
leave a standing recommenclation f o r the crews t o main- Coast. Table 5 1s a list of pertinent well data.
t a i n the viscosity I~etween50 ancl 60 sec wit11 t h e centri-
fuge. A s f a r a s the crew is concerned, only the viscosity - Table 5
i s being controlled hy t h e centrifuge. Elther t h e solids
content, a s tlete~mineclwith the retort, o r the funnel Well Data Mud Data
viscosity'is a useful index to the mud inan i n keeping
t h e mud right. Depth, f t............. 11,985 Mud weight, Ib per ga1..17.0
Hole, in ................. 8% Fumlel viscosity, sec....62
Case 2 Drill pipe, in ......... 5 Plastic viscosity,
Now suppose t h a t the mud from Case 1 is found t o Pump stroke, in. 20 centipoises ................41
have increased in viscosity t o 70 see. The retort method Liner size, i n ....... 6 Yield point, 11) per
shows t h a t the solids content remains unchanged. This Strokes per min.. 43 100 sq f t......... .....23
would immediately indicate t h a t the lnud has been con- Gage pressure,
taminated and requires ~ h e i n i c a ltreatment r a t h e r than psi .................... 1,250
centrifuging. See Table 4.
 AND MUDTECHNOLOGY
THE CENTRIFUGE 189

As soon a s mud loss was recognized the p u n l p was P.u = [11-,925 ( 1 1 ) / 2 2 5 ( 3 . 5 ) ] + [ ( 4 1 ) (11,925) ( 2 . 9 ) /
slowed down from 43 strokes per min t o 28 strokes per 1,500 (.?.5)']
min. This effected a reduction in t h e gage pressure from p3 = 166.6 + 77.2
1,250 psi to 750 psi, o r 500 Ib. The annular velocity w a s
reduced fronl ft to 117 f t per Ps = 244 psi (bottom-hole circulating pressore a t 43
Closer scrutiny was made of the problem t o deterinine strokes per min of mud was reduced to 11 Ib
what the actual effect of slowing the pump down was per 100 sq f t )
in reducing t h e pressure of the circulating fluid a t t h e Conditioning this mud so t h a t the yield value was
I~ottomof the hole. Use was made of t h e pressure-drop lo\\,ered resulted ill a reduction of the bottom-hole circu-
equation f o r laminar flowing fluid^.^ lating pressure by 181 psi. This represents a sign~ficant
P = (lty/22.5P) + (?~1~/1,.500~~) ~mprovementin the hydraulic system. Besides solving
one particular lost-circulation problem, here is very
1Blt.evcin: definite proof of the effect of high yield points on cir-
P =pressure drop in pounds per square inch, over culating pressure. F o ~ ~ n a t i osolids n in the mud cause
the length being calculated. high yield points. Reducing the punlp pressure, a s is
n = 'plast'ic viscosity of the mud, in centipoises. the first tendency when mud is lost to the formation,
= total length, ill feet, of the diameter actually gives only limited assistance t o t h e problem
considered. a t hand. The 500-psi change in the standl~ipe gage
reading was in the most p a r t caused by reduced pressure
V z mean fluid velocity of tlle mud, in feet per drop inside the drill stem where the mud is in turbulent
second. flow. I n turbulent flow a large' decrease i n pressure
t y = ~ i e l i point
l of t h e mud, in pounds Per 100 sq ft. a c c o l , p a ~ e s only a small reduction in \7elocity The
D = bit size minus pipe outside diameter, in inches yield point of the mud is by f a r the most significant
f o r annular flow. factor affecting the pressure drop when the mud IS
i n laminar flow.
PI = [11,925 ( 2 3 ) / 2 2 5 (.?.5)] + [ ( 4 1 ) (11,925) (2.9)/ The practice of loading up a mud with lost-circulation
1,500 (3.5)'l materials In thief zones is f a s t losing favor in many
PI'= 4.25 psi ( ~ ~ o t t o m - h o lcirculating
e pressure a t 43 areas Tile presence of high collcentrations of sucll
strokes per mln 01. 178 f t Per min annulal; materials in a imparts flowing characteristics to
velocity) the mud w111c11 a r e more likely t o increase t h a n t o
P2 = [11,925 (2.3)/22.5 ( 3 . 5 ) ] +
[ ( 4 1 ) (11,925) ( 1 . 9 5 ) / decrease lost circulation. The materials t h a t stop loss
1,500 (2..5)?] of inud can also be the cause of lost circulation. The
p2 = 400 psi (bottolll-hole circulating pressure a t 28 best approach t o this problem i s based on having the
strokes per mill or 117 f t per 111111 annular mud in such cond~tiont h a t pressures resulting from
velocity) circulating the mud ~ v i l lhe minimized.
THE CENTRIFUGE IS VERSATILE; SAVES ON
This calculation revealed t h a t by slowing the mud WATER AND CHEMICAL
pump down from 43 s p ~ nt o 28 spm the pressure a t t h e The centrifuge is the best means by which the yield
hottom of t h e annulus was reduced 1 ) ~only 25 psi. I,oillt of a lnud can be kept to a lllil~lllul,, L~~~~
T h o u g l ~ circulation i s frequently regained 1 ) ~tllis chemical addltlons or large dilutions Lt<t~l \vater are also
method, the f a c t still :emains t h a t the pressure eserted effective but their espense olljectionable.
on a weakened formation had not been greatly altered. If the solids a r e not present in the mud, then the need
The approach to the problem mas i n l ~ ~ r O vthe
e f o r thlnl1ing c]lellllcals or water is ~lilllinlshed.This has
flow propel-ties of the mud. The centrifuge was used to lleen ill actual practice. w i t h a centrifuge at L\.ork
fui-ther reduce the solids in t h e mucl, and a small alnount
of water and chemicals were added f o r the purpose of
the fewer cllenlical adclitives are I,~
lnud to keep it con~itiolled.A centrifuged how-
reducing the y ~ e l dpoint of the mud. The weight of the ,,, require slightly larger allloullts of water-loss
mud was not altered from its original 17.0 lb per gal. colltrol alld agents such as ~ ~ i
A f t e r conditioning the mud, the yield point had heel1 of tile light solids which give the average lllud its
reduced from 23 l b per 100 sq f t to 11 113 100 sq f t . suspending alld low-\vater-loss cllaracteristics are re-
The funnel viscosity was 50 sec. ~novedby the centrifuge and must be replaced.
Calculations were again made with the new mucl ,
COMBATS CONTAMINATION
properties a s shown in Table 6. The centrifuge process allows fresh water to replace
Table 6 the salt-laden water i n a contaminated mud so t h a t t h e
Mud weight, Ih per gal .................................................. 17.0 contanlinant is removed. Considerable esperie~lceh a s
Funnel viscosity, sec.................................................... -50 been gained in treating out the cement from weighted
Plastic viscosity, centipoises...................................... -41 completion and packer muds. A high pH lime-base mud
Yield point, 11) per 100 sq f t............................................11 can be converted to a low pH conventional mud with
pulllp strokes p e r min.. .................................................. 43 the centrifuge.
190 RAP WILLIAMSAND JOHN
MESAROS
The history of a well near Bay Clty, Texas, i s also
the story of t h e versatility of a centrifuge. The cost of
drilling t h ~ very
s troublesome land-based well was o17er
a million dollars.
A high pH lime-lmse mud was used to drill through
2,000 f t of heaving Anahuac shale. During this tlme
cuttings did not appear on the shale-shaker screen.
Instead, soft mud balls were present in the nlud inclicat-
i n g the type of problem the fowlation was -presenting.
Fifteen hundred to 2,000 111 of lime were required each
tour t o keep t h e solids i n the system converted t o cal-
cium. On drilling out of the shale a t 7,500 f t , a protection
string w a s set and there was no longer a need f o r a
lime-base mud. A t this time the lime content of t h e mud
w a s 8 Ib per bbl.
T11e centrifuge continuously, processed the mucl and in
10 days the 8 Ih per bbl lime content was reduced t o just
a trace The pH of the nlud was maintained a t 11.5 t o
12.0 to preserve the starch which mas still present in
the mud. Later the pH was allowed to come down t o a
value of 9.5. T h ~ scentrifuged mud mas eventually used
a s a fine completion fluid. Not a drop of mud h a d - t o be
jetted away while drilhng from a depth of 7,000 f t t o
total depth, which was 14,500 ft.
Such low-solids centrifuged muds make very success-
ful packer muds. High-temperature gellation is not a
problem with such a fluid.
, SALVAGE RESERVE MUD
The Phillips Petroleum Company's centrifuges a r e
made t o l u n about 75 percent of t h e time t h a t drilling
is in progress. When the centrifuge is not used on the
circulating system i n t h e well, i t is frequently used t o
process lnud t h a t h a s been stored in a "duck's nest" or
small separatecl section of the resellre pit. This nlud
lnay be processed into a good high-density packer mud
which is stored in tanks f o r future use. I t may process
resenre mud ancl deliver the barite into the drilling well
f o r weighting-up purposes.
A t one time i t w a s the practice to locate discarded
weighted muds in nearby areas ancl deliver them t o a
central location i n the Chocolate Bayou Field. The cen-
trifuge would then retrieve the barite from t h e muds
f o r use i n weighting up or preparing other muds. The
total cost involved i n this method \\-as usually t h e $1.00
or $1 50 per bbl f o r hauling the mud. Muds n;eighing
1 lb per gal and up \\?ere processed in this manner and
u l t i n ~ a t e l y saved t h e company consiilerable sums of
money.
OPERATES DURING T R I P S
Sometimes drilling rates a r e so f a s t t h a t t h e centri-
fuge h a s difficulty keeplng the solids content down t o the
APPENDIX
CENTRIFUGE CALCULATIONS
The size of the pool volunle is a n essential factor in
obtaining the best separation. The volume of the pool is
determinedby t h e position of the effluent poi-ts a s shown
i n Fig. A l . This volume may be determined by a simple
amount consistent with good mud properties. The cen-
trifuge should then be allowed to run on the surface
s y s t e ~ nduring trips and other shut-down periods. This
type of operation will pemnlit the circulating mud
volume to be reduced sufficiently t o permit the use of
more water and barite without having t o jet away p a r t
of the weighted mud.
F o r example, during a t r i p 100 bbl of a 17-lb mud may
be centrifuged. The light clay solids and liquid a r e dis-
charged a s effluent and the barite is retulmecl t o t h e
pits a s a 23 111 per gal semi-fluid sludge \vhich is then
redispersed into the system hy agitation. The volume
of t h e 23 111 per gal mud i s 55 l>bl. W a t e r i s added t o
keep the \veight a t 17 Ib per gal in the mucl tanks. Room
h a s been made available f o r 45 bbl of water in t h e
system without t h e need f o r jetting. The water can be
added i n such amounts a s t o condition the mud so t h a t
the viscosity is lower, the flow properties a r e improved,
and p a r t of t h e light foimation solids have been
removed. The conditioned surface mud when circulated
through the hole again mixes with the rest of t h e mud
and the system h a s been improved while the pipe was
out of the hole.
CONCLUSIONS
To the mud engineer \vho works with \i.eighted muds,
the centrifuge h a s become a tool \\.it11 which he can make
and maintain better muds t h a n ever before. H e can
control the funnel viscosity a s well a s other properties
with the machine. To the operating companies the cen-
trifuge h a s proved t o be a means by which significant
reductions in well costs a r e effected by barite savings.
Drilling engineers see the centrifuge a s a means to
better penetration rates and fewer liole problems. Drill-
i n g crems like the centrifuge because i t is automatic ancl
foolproof. A s the centrifuge runs, the crews a r e aware
t h a t the machine is saving them the work t h a t would be
required to add new materials to the mud.
ACKNOWLEDGMENT
The authors wish to express their appreciation t o
Phillips Petroleum Company f o r permission t o publish
this paper.
REFERENCES
'Bobo, Roy A. ancl Hoch, R. S : The Mechanical Treat-
ment of Weighted Drilling Mlids, AIME P a p e r No.
290-G.
"obo, Roy A: Personal commun~cation,J u n e 1956.
"heless, N. H. and Ho\re, J a c k L: Low-Solids Muds
Improve Rate of Drilling, Cut Hole Time, Drillirty, 70,
Aug. (1953).
"Clark, E. H. JY:Bottom-Hole Pressure Surges While
R u n n ~ n gP ~ p e ASME
, P a p e r No. 54-Pet. 22.
calculation. The difference between the volume of a core
and the volume of a cone will be t h e volume of the pool.
Follolvlng a r e the calculations used to determine t h e
pool volume of a n 18-in. decanter-type centrifuge. ,
 A N D MUD TECHNOLOGY
THE CENTRIFUGE

80: 1
GEAR RATIO

X 1000=GEE -SECONDS
Fig. Al-Pool Volume is Dependent upon Position of Fig. AS-Efficiency of Barite Recovery from an
Effluent Ports 18-lb Mud
Volu~neof f r u s t r u m of cone = ?h TI!.
[( R + R')' +
% ( R - R')?]
N = revolutions per minute.
R' = 5 in. R = bowl radius, 111 inches.
R = 9 in.
H = 22.7 in. 2.84 = constant.
F u l l volume = 2 2 . 7 ~ / 4 [ ( 9 +
5)" ( 9 - 5)'/31 The two factors \vhich most affect the centrifuge
= 2 . 7 ~ / 4 [(14)" (4)'/3] process, therefore, a r e the centrifugal force (gees) and
= 5 . 6 7 5 ~ [ I 9 6 $ 5.51 = 5.61'5~ (201.5) tlie length of time during which tlie particles ape sub-
= 5.588.9 CIC.in. jected to t h a t force. Multiply~nggees and retention tiine
Less core = S.5SS.9 -r (5)"(7!2.;') = 8.588.9 - 1,782.9 in seconds provides the ternl, gee-seconds.
= 1 ,80~i ell ill. Gees x retention time in gees x pool volume x 60
Volume of pool = 1,806 crc ill. = 1,80!;/2S1 = 7.8 gal seconds = gallons per minute
Once t h e effluent ports a r e positioned and the pool flowing (feed r a t e )
or
volume is known, t h a t value is a constant. The retention gees x 468
time m a y be detei~ninedif the feecl r a t e is laiown. Gee-seconds = feed rate, gallons per minute
pool volume in gallons Fig. A2 shows the ,relationship between gee-seconds
Retention time = feed r a t e in gallons per ~ilinute and the centrifuge efficiency f o r maxinlunl barite re-
The answer is in minutes \vhich a r e usually converted t o covei-y from a n 18 lb per gal mud.
seconds t o avoid the use of fractions. This is done by
multiplying by 60. CENTRIFUGE ADJUSTMENTS
The r a t e a t which particles pass through the pool Tlie adjustments which can be nlade in order t o obtain
depends upon the r a t e of feed. The degree or fineness of t h e best efficiencies on the centrifuge are: 1, speed,
the separation will i n t u r n be dependent upon the time 2 , volunie of pool, S, locatlon of feecl plpe, 4, viscosity of
of retention. feecl, 5 , feed rate.
The centrifugal force t o which the particles a r e e s - Generally speaking, the follo\i<ng rules deteimine the
posed while they a r e retained in the 11okvl may be e s - type of separation obtainecl in t h e clecanter-type cen-
pressed a s n~ultiplesof gravity o r gees. The fornlula trifuge.
f o r detelqnining gees exerted hy a centrifuge is: Maxinluin gee-seconds = masimum barite recovery
(also r e t a ~ n smaximuni clays).
Gees = (2.84) (10.') (A7*)
or Mininlu~n gee-seconds = minimum barite recovery
Gees = L2.84 ( N ' R ) ] /100,000 (also liiaslnluni clay relnoval) .

DISCUSSION W l l l ~ a m sand Mesaros have shown t h a t the centrifuge

G. R. Gray (Drilling Fluids, Inc., Houston, Texas)
(written): Tlie savings i n barite made possible by t h e
use of the centrifuge on heavily weighted nluds have
been demonstrated in several previous papers. These
savings a r e significant and adequately justify the use
of the machine. I believe, however, t h a t other benefits
less easily proved m a p a c t ~ ~ a l leffect
y greater savings
i n drilling costs t h a n the obvious reduction in cost of
barite.
affords a tool f o r t h e inud engineer to use in nlaking a
better d.)-illuzg 111~~1.11111)rovedflow propel-ties can be had
through control of the solicls content. Would the authors
cite some esamples t h a t show the effect of t h e solids
content of t h e mud on r a t e of penetration in some Gulf
Coast fields ?
The centrifuge i s not only a device to salvage barite
but is also a means of discarding unwanted inaterials
in the mud. The authors have pointed out how t h e cen-
trifuge is used t o discard shale solids. Another example
192 AND JOHNMESAROS
RAY WILLIA~VS
is the use of the centrifuge t o reduce the density of a
saturated saltlwatdr mud by removing salt cuttings
while rock salt i s being drilled. Another instance i s t h e
removal of salt contamination a f t e r a salt-water flow.
Without the centrifuge, either continued large chemical
treatments or estensive dilution i s generally necessary
t o control mud properties a f t e r a salt-water flow.
The centrifuge can be used t o change the type of
drilling mud a s conditions i n t h e hole change with depth.
F o r example, a lime-treated ~ n u dcan be changed with
t h e centrifuge t o a lo\v-alkahnity mud when high tem-
perature begins to adversely affect the properties of
the lime-treated mud.
Periodic shutdowns t o condition mud a r e elinlinated
by t h e regular use of t h e centrifuge. Do the authors
have any d a t a on the importance of this f a c t o r ?
In thew calculation of the saving of barite the authors
imply t h a t the chemical costs a r e increased i n direct
propol-tion to the anlount of nlud t h a t is centrifuged.
What a r e the relative costs f o r materials required t o
control viscosity ancl filtration of, let u s say, a 17-lb per
gal mud with and without t h e centrifuge? Was t h e cost
of the centrifuge includecl i n the estimations made in the
p a p e r ? What can be done t o recover the oil from a n oil-
emulsion mud ?
How does the mud engineer lay out a program f o r
t h e operation of the centrifuge? What e x t r a attention
i s required ?
Mr. Mesaros (written) : The authors a r e in agreement
with Dr. Gray's statement t h a t barite recovery i s a n im-
portant economic factor t h a t i n itself justifies the centri-
fuge. I t is also agreed t h a t t h e other benefits of a centri-
fuged mud \vhich a r e less easily proved may effect greater
savings in d r ~ l l i n gcosts. I t must he remembered, how-
ever, t h a t the real purpose of the centrifuge i s t o remove
foimation solids from a nlucl so t h a t the 1?1ud will remain
i n good cond~tionf o r greater periods of time. All other
benefits and advantages from using the machine a r e
secondary ancl rdsult from the removal of the solids.
The solids-content vs. penetration-rate examples which
Dr. Gray requests a r e not available. They were not
needed to prove t h a t the centrifuge was a n effectlve
machine. T h ~ stype d a t a a r e difficult to produce in the
field because of the ~ m p o r t a n tp a r t t h a t bit weight,
punlping volumes, ancl general drilling practices play
i n penetration rates.
I t is generally accepted t h a t a low-solids mud will
permit f a s t e r drilling. The lower solids, of course, a r e
reflected a s good flow characteilstics in the mud which
in turn can be shown by calculation to produce lower
pressures when being pumped through the system. I t is
not necessarily true, however, t h a t a centrifuged mud
is always a low-solids mud. The centrifuge removes
foinlation fines which a r e i n a size range of perhaps up
t o 10 niicrons. These particular fines, we I~elieve,a r e
the ones \vhich first impart poor characteristics t o a
mud. The sands and all other coarse particles not i n this
range and which do not readily break down with agita-
tion can also build up in concentration until the mud h a s
to be conditioned by water dilution and jetting. This
coarser fraction of formation particles is retui-ned t o
t h e system \i-ith the barite sludge and does not affect
the mud properties a s readily a s the fines.
Phillips centrifuged muds (lo not always shuw a
decided decrease i n solids content over muds t h a t were
not centrifuged. This is pai-ticularly true of high-density
muds where only a small amount of fines c a n affect t h e
tnud adversely. Obset-vation of solids contents of niucls
can serve only a s a guide in their treatment, but the
proof of t h e effectiveness of the c e n t r ~ f u g eis found i n
improved flow properties of the mud.
Data were not collected to show the importance of
less shut-down time f o r mud conditioning due t o t h e
presence of the centrifuge. This fact 1s recognized ancl
is impoi-tant and a s was pointed out in the paper, t h e
tnud is always being conditioned while drilling takes
place. Also conditioning may be had by running t h e
centrifuge on the surface system cluring trips and other
non-circulating periods. We a r e sure t h a t mud-condi-
tioning time has diminished on rigs uslng centrifuges
11ecause the mud is supposecl to be 111 good condition
all the time. Less time is now used f o r circulatiori of
the lllud prior to logging or other non-drilling opera-
tions. This time used t o be a s much a s 8 o r 12 hours.
Now, i t is frequently one circulation or less.
The authors did not imply t h a t the cl~emicalcosts a r e
increased in dlrect proportion to the amount of mud
t h a t is centilfuged. The f a c t is t h a t fewer chemicals,
particularly d i s p e r s ~ n g chemicals, sl~oulcl be required
because the clays which they disperse a r e not present,
inasmuch a s they \\.ere removed mechanically. Filtra-
tion-control agents will be r e q u ~ r e dt o lower the water
loss a s usual. Sometinles the fines when removed from
the mud will upset the pal-ticle-size d i s t r i b u t i o ~suffi-
~
ciently to requlre a sack or t\vo more of D r ~ s c o s et h a n
would ordinarily be required had the fines been present.
Dr. Gray's request f o r d a t a of chemical cost require-
ments of a 17-lb lnud with and \vithout the benefit of a
centrifuge cannot be fulfillecl without further lengthy
studies. When t h e centrifuge \\,as first put into use in
1953 i n the Chocolate Bayou Field, a 30-day ol3servation
of cl~emicalrequirements of the mud let1 t o an estima-
tion t h a t about 80 percent fewer chemicals were re-
quired f o r daily maintenance. This figure i s not now
considered realistic because i t was based on factors ancl
conditions which were not t l v e test conditions. I n t h e
Chocolate Bayou Field mud costs per average well were
$125,000 prior t o the advent of the centrifuge. The
average cost today is about one half this amount. Here
again i t would be unrealistic t o suppose t h a t the cen-
trifuge effected all of this reduction. During the past
five years drilling techniques and equipment have so
improved t h a t it i s safe t o say t h a t t h e centrifuge only
contributed t o this mud-cost reduction.
We do not know how to recover the oil from emulsion
muds. The oil is valuable and the problem is not insur-
mountable. I t just has not been done yet.
 %,
The lnud engineer must r e n ~ e ~ n b einr laylng out a
centrifuge program t h a t he must still rely on his rnucl
engineering efforts to keep a good clrllllllg mud. He lllust
st111 use water and chemicals. He must also renienlber
that there a r e times t h a t the centrifuge need not be 1x11.
If the flow properties of the mud a r e gootl tile clay
solids a r e suffi~ientlylow, then furtheFuse of the centri-
fuge is wasteful. Every bake1 of lnud t h a t is centr~fuged
unnecessarily may contain $3 o r $4 \vorth of chelllicals
and 011. I n a day, $1,500 worth of chemicals inay be
wasted. It is necessary to have criteria f o r cletel-nlining
whell to stapt and' stop the lnachine. Ordinarily, the
viscosity, yielcl of the mud, and plastic
1 viscosity a r e goocl indicators of the need f o r centrifug-
lng. Generally, when the lnud needs to be jetted to make
(
I room f o r more water, the centrifuge should be ~ u n l l i n g
to maintain the required density while adding water.
One or more of the afore~nentionedflow properties should
be the guide f o r operation of the centrifuge.