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Unit 13, Ashley Group Base Pitmedden Road, Dyce Aberdeen AB21 0DP Tel: +44 1224 794200 Fax: +44 1224 725658 Email:
[email protected] Web: www.axiomprocess.com
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Photograph printed with kind permission of Statoil
Axiom Process Ltd is committed to delivering the world’s premier solids control technology. Axiom offers outstanding levels of expertise within the field of solids control, with a proven team of internationally recognised experts and a
demonstrable
track
record
of
leading
technological change within this challenging sector of the drilling industry. The engineering offered by the company is fully proven and accepted within the most challenging drilling environments throughout the world. The AX-1 Shale Shaker™ and associated
AX
Screening
System™ have revolutionised the performance deliverable by shale shaker technology, and consequently the expectations our customers have for the role of this technology. This has allowed the development of new fluid processing and drilling strategies which are returning previously undeliverable cost and operational benefits to our customers. Constant interaction with them is a defining feature of our business. Through this the full potential of this new and exciting technology is now being realised. • A privately owned, UK company engaged in the manufacture and supply of equipment to the upstream oil and gas industry. • Established in 2001 with the strategic objective of developing a shale shaker offering the industry a step change in fluid handling and solids separation performance. • Principals all have extensive experience in the business, having been responsible for the development of the VSM family of shale shakers and screens with Thule Rigtech.
VSM is a trademark of National Oilwell Varco Inc.
An introduction to the team… Marshall Bailey - Chairman. Focuses the company on developing an expert understanding of the application for which the company’s equipment is designed. He has applied this principle throughout his career specialising in solids control
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equipment design and development. Instrumental in establishing Thule United Ltd in 1977, Mr Bailey pioneered quantum changes in solids removal performance. After selling the business in 1997 and a period of reflection, Axiom was established in 2001, to introduce another quantum change in shale shaker design. After 33 years his enthusiasm and commitment is greater than ever.
George Fisher – Managing Director. Mr Fisher has over 20 years continual experience working within the solids control industry where, until the formation of Axiom in 2001, he was instrumental in the development and deployment of the very successful VSM family of shale shakers. Having since been involved in the conceptual and detailed designs of the AX-1 Shaker and AX Screening System, his focus is now on developing new business opportunities for this breakthrough technology.
Photograph printed with kind permission of Statoil
The AX-1 concept Philosophy Axiom Process Ltd has again proven that innovation comes not only from an unrivalled understanding of the application but also a determination to attempt what many others may consider the impossible. Representing the next generation of solids liquid separation equipment, the AX-1 Shale Shaker breaks the mould with respect to both raw throughput capacity and solids separation efficiency.
Concept The AX-1 Shale Shaker delivers the three things desired by both operator and contractor: • An ability to effectively handle the large circulating rates in respect to fast, top-hole drilling. • An ability to deliver improved separation through ‘sequential’ screening. This also results in improved screen life on the very fine meshes. • A user-friendly design with low-maintenance components. The AX-1 has been designed for clients who need cutting edge technology to meet both their daily challenges and to deliver improved return on investment. The key step change made with the AX-1 Shale Shaker is the ability to change the configuration of the machine depending on the nature of operation being carried out. There are two easily interchangeable operational modes available, parallel or series operation. This is achievable due to the innovative triple deck layout of the AX-1 and the unique flow distribution system built into the rear of the machine.
Ax-1 Shaker
Operation overview Parallel operation: In the parallel mode the 2nd and 3rd decks of the AX-1 can process fluid completely independently, therefore effectively doubling the fluid handling capacity of the shaker in comparison to traditional dual deck systems.
Returns
Drilled solids
Processed fluid
All of the fluid delivered to the AX-1 Shaker is processed through the coarse mesh top screen. The middle deck will process as much fluid as it is capable of, given the screen mesh size installed. The processed fluid from this deck is then diverted directly to the sump, bypassing the lower deck. Fluid and drilled solids, in excess of that processed by the middle deck, overflow via a weir to the rear of the machine and are diverted to the lower deck for processing. So, when configured for parallel operation, the AX-1 allows the maximum flow capacity through the primary solids control system, which in turn allows higher pump rates to be achieved in large hole sections; a situation which is becoming more desirable with the constant advances in the drilling industry.
Ax-1 Shaker
Series operation: When configured for series mode drilling fluid is processed through all three decks of the shaker in turn – this allows gradually finer screens to be sequentially fitted to each deck. Ultra fine screen meshes can therefore be used, giving maximum solids separation. In addition, the life of ultra fine screens is significantly increased by the protection they receive through series operation of the AX-1.
Returns
Processed fluid
Drilled solids
Trends in drilling fluid formulations Drilling fluids are more frequently being engineered to contain specifically sized particles. This can be either conventional loss circulation materials to combat significant down hole losses, or specifically sized material to bridge fractures and pore spaces. This allows higher fluid densities – often above the fracture gradient – to be employed. This results in: • Reduced whole fluid losses in depleted zones. • Reduced number of casing runs. • Increased margin of safety. The AX-1 allows for the use of these new fluid formulations by allowing the collection of sized particles from the middle deck, prior to screening of the drilling fluid on the lower deck to remove fine drilled solids.
Returns
Drilled solids Large Sized material
Fines
Sized material return to active system
Ax-1 Shaker
The benefits of the AX1 The AX-1 Shale Shaker delivers a number of clear benefits: Capacity: In parallel mode AX-1 delivers around twice the throughput capacity of the current brands of dual deck shakers.
Improved Separation: When configured for ‘series’ mode, the AX-1 becomes the ultimate fine screening machine. The ability to operate sequential screen sizes improves solid/liquid separation and reduces the attrition rate on the ultra-fine screens.
Flexibility: Whilst the AX-1 offers high capacity to contend with upper hole sections, an ability to switch to ‘sequential screening’ for smaller hole sections ensures the optimum in separation efficiency when it is most required.
The Future: An inherent ability to improve the handling of new fluid types through ‘selective screening’.
Reduced Footprint: Because the AX-1 delivers such a massive throughput differential, the number of machines required can be significantly reduced – resulting in a smaller installed footprint.
System comparisons: • Comparable fluid processing capacity. • Circa 50% reduction in package footprint. • Circa 30% reduction in package weight.
AX-1 key points
Feed chute
HVAC rear hood Control bridge
AX-1 Shale Shaker
AX Sump
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The benefits of the AX1
AX-1 key points Pneumatic and electrical control unit
The AX-1 Shale Shaker delivers a number of clear benefits: Feed chute Capacity: In parallel mode AX-1 delivers around twice the throughput capacity of the current brands of dual deck shakers.
HVAC rear hood
Improved Separation: When configured for ‘series’ mode, the AX-1 becomes the ultimate fine screening machine. The ability to operate sequential screen sizes improves solid/liquid separation
Control bridge
and reduces the attrition rate on the ultra-fine screens.
Flexibility: Whilst the AX-1 offers high capacity to contend with upper hole sections, an ability to switch to ‘sequential screening’ for smaller hole sections ensures the optimum in separation
AX-1 Shale Shaker
AX Screening System
efficiency when it is most required.
HVAC front hood The Future: An inherent ability to improve the handling of new fluid types through ‘selective screening’.
LCM Recovery System Reduced Footprint: Because the AX-1 delivers such a massive throughput differential, the number of machines required can be significantly reduced – resulting in a smaller installed footprint.
AX Sump
System comparisons: • Comparable fluid processing capacity. • Circa 50% reduction in package footprint. • Circa 30% reduction in package weight.
Ax-1 Shaker
Specifications of the AX-1 General Equipment Type Vibratory Motion Angle of Motion Speed of Vibration
Shale shaker Balanced elliptical Fixed Variable
Screening Configuration Screen Configuration
Triple deck Top deck Intermediate deck Bottom Deck
Pretensioned, multi-panel, site repairable Pretensioned, multi-panel, site repairable Pretensioned, multi-panel, site repairable
Screen Clamping
Top deck Intermediate deck Bottom Deck
Pneumatic Pneumatic Pneumatic
Screen Angles
Top deck Intermediate deck Bottom Deck
2º 7º 7º
Screen Angle Adjustment
None
Fixed
Screen Surface Areas
Top deck Intermediate deck Bottom Deck
2.01m/21.64ft 2.01m/21.64ft 2.01m/21.64ft
Electrically driven
Belt Drive
Pressure
80-90psi
Capacity
0.7cu.ft/min
Screen Types
Drive System Method
Air System Air Supply Requirements
Dry Operating weights (kg) and Dimensions (mm) Application Single Dual Triple Quadruple
Weight 3547 7983 11780 15777
Length 3101 3101 3101 3101
Screens - Boxed for Shipping Top Intermediate Bottom
6 off required 6 off required 6 off required
4.5kg each 4.5kg each 4.5kg each
Width 1870 4070 6270 8470
Height 1730 1730 1730 1730
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Specifications of the AX-1
Shale shaker Balanced elliptical Fixed Variable
AX-1 based design concept • Install sufficient shaker capacity to permit processing of fluid returns whilst utilising 200mesh or
When considering the design of new build solids control packages, or where major platform
General Equipment Type Vibratory Motion Angle of Motion Speed of Vibration
Solids control system design
finer screens.
upgrades are being considered, the Axiom AX-1 Shale Shaker design concept offers an
• Avoid use of hydro cyclone technologies
opportunity to completely re-evaluate the overall package, providing increased functionality in a
• Install high ‘G’ centrifuges for ultra fine solids removal
smaller, lighter and more cost effective envelope. 10
Screening Configuration Screen Configuration
10
Triple deck Top deck Intermediate deck Bottom Deck
Pretensioned, multi-panel, site repairable Pretensioned, multi-panel, site repairable Pretensioned, multi-panel, site repairable
Top deck Intermediate deck Bottom Deck
Pneumatic Pneumatic Pneumatic
• Maximize overall drilled solids removal efficiency.
Top deck Intermediate deck Bottom Deck
2º 7º 7º
• Minimize drilling fluid loss associated with the processes.
Screen Angle Adjustment
None
Fixed
• Cost effectiveness.
2.01m/21.64ft 2.01m/21.64ft 2.01m/21.64ft
• Minimize the overall system processing volumes and complexity.
Screen Surface Areas
Top deck Intermediate deck Bottom Deck
Screen Types
Screen Clamping
Screen Angles
2 3
7
3 4 3 1 4
2 3 4 5
5
6 7
Belt Drive
8
• Restricted fluid processing capacity of traditional shale shakers.
9 10
Pressure
80-90psi
Capacity
0.7cu.ft/min
• Reliance on secondary & tertiary solids separation processes.
Weight 3547 7983 11780 15777
11 12
• Inherent inefficiencies of hydro cyclones when processing weighted or viscous drilling fluids.
13
Flow Line Distribution Pod AX-1 Shaker Cuttings Screw Conveyor Cuttings Processing Area Degasser Degasser Pit Catch Tank Centrifuge Pit High 'G' Centrifuge Treated Mud Tank Pump Mud Return to Active
• Solids degradation within the transfer pumps. Length 3101 3101 3101 3101
Width 1870 4070 6270 8470
Height 1730 1730 1730 1730
• High liquid content of discharges from hydro-cyclone based processes.
Benefits of the Axiom AX-1 based design concept • Efficient primary solids control process.
Screens - Boxed for Shipping Top Intermediate Bottom
9 3
Limitations of current solids control package designs Electrically driven
12
8
6
• Minimize the solids control package footprint and weight.
Dry Operating weights (kg) and Dimensions (mm) Application Single Dual Triple Quadruple
There are six key design objectives associated with the Solids Control package:
• Minimize drilled solids degradation through secondary processes.
Air System Air Supply Requirements
13 11
1
Drive System Method
Solids control package – design objectives
6 off required 6 off required 6 off required
4.5kg each 4.5kg each 4.5kg each
• Minimal solids degradation within the surface system. • Reduced complexity of the system. • Reduced liquid discharges associated with the drilled solids. • Opportunity to contain or process the drilled solids. • Reduced size & weight for the solids control package. • More economical installation.
Fundamentally, there is no compromise in terms of the overall solids removal efficiency of the system.
Ax-1 Shaker
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Ax-1 Shaker
Project1
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Specifications of the AX-1
Shale shaker Balanced elliptical Fixed Variable
AX-1 based design concept • Install sufficient shaker capacity to permit processing of fluid returns whilst utilising 200mesh or
When considering the design of new build solids control packages, or where major platform
General Equipment Type Vibratory Motion Angle of Motion Speed of Vibration
Solids control system design
finer screens.
upgrades are being considered, the Axiom AX-1 Shale Shaker design concept offers an
• Avoid use of hydro cyclone technologies
opportunity to completely re-evaluate the overall package, providing increased functionality in a
• Install high ‘G’ centrifuges for ultra fine solids removal
smaller, lighter and more cost effective envelope. 10
Screening Configuration Screen Configuration
10
Triple deck Top deck Intermediate deck Bottom Deck
Pretensioned, multi-panel, site repairable Pretensioned, multi-panel, site repairable Pretensioned, multi-panel, site repairable
Top deck Intermediate deck Bottom Deck
Pneumatic Pneumatic Pneumatic
• Maximize overall drilled solids removal efficiency.
Top deck Intermediate deck Bottom Deck
2º 7º 7º
• Minimize drilling fluid loss associated with the processes.
Screen Angle Adjustment
None
Fixed
• Cost effectiveness.
2.01m/21.64ft 2.01m/21.64ft 2.01m/21.64ft
• Minimize the overall system processing volumes and complexity.
Screen Surface Areas
Top deck Intermediate deck Bottom Deck
Screen Types
Screen Clamping
Screen Angles
2 3
7
3 4 3 1 4
2 3 4 5
5
6 7
Belt Drive
8
• Restricted fluid processing capacity of traditional shale shakers.
9 10
Pressure
80-90psi
Capacity
0.7cu.ft/min
• Reliance on secondary & tertiary solids separation processes.
Weight 3547 7983 11780 15777
11 12
• Inherent inefficiencies of hydro cyclones when processing weighted or viscous drilling fluids.
13
Flow Line Distribution Pod AX-1 Shaker Cuttings Screw Conveyor Cuttings Processing Area Degasser Degasser Pit Catch Tank Centrifuge Pit High 'G' Centrifuge Treated Mud Tank Pump Mud Return to Active
• Solids degradation within the transfer pumps. Length 3101 3101 3101 3101
Width 1870 4070 6270 8470
Height 1730 1730 1730 1730
• High liquid content of discharges from hydro-cyclone based processes.
Benefits of the Axiom AX-1 based design concept • Efficient primary solids control process.
Screens - Boxed for Shipping Top Intermediate Bottom
9 3
Limitations of current solids control package designs Electrically driven
12
8
6
• Minimize the solids control package footprint and weight.
Dry Operating weights (kg) and Dimensions (mm) Application Single Dual Triple Quadruple
There are six key design objectives associated with the Solids Control package:
• Minimize drilled solids degradation through secondary processes.
Air System Air Supply Requirements
13 11
1
Drive System Method
Solids control package – design objectives
6 off required 6 off required 6 off required
4.5kg each 4.5kg each 4.5kg each
• Minimal solids degradation within the surface system. • Reduced complexity of the system. • Reduced liquid discharges associated with the drilled solids. • Opportunity to contain or process the drilled solids. • Reduced size & weight for the solids control package. • More economical installation.
Fundamentally, there is no compromise in terms of the overall solids removal efficiency of the system.
Ax-1 Shaker
7/5/09
Ax-1 Shaker
Project1
The AX screening system The AX Screening System has been developed to deliver significant improvements in performance, cost effectiveness and HSE compliance, based on the experience gained over the years by the principals involved in Axiom. As with the AX-1 Shaker itself, the design concept was developed from the principles of functionality, to deliver step-change performance.
There are three key differentiators of the AX Screening System:
1. Support frame: Unlike many other formats, the structural support for the screen is retained within the shaker basket at all times – thereby reducing manual handling over comparable screening systems. The screens rest upon removable extrusions which can easily be replaced to maintain optimum screen location.
2. Screen panels: Since the support frame provides the necessary rigidity, the pre-tensioned panels can now be manufactured without the requirement for the bulky and heavy frames common to other systems. • The AX screen panels are approximately half the weight of comparable composite framed screens and one third that of metal framed screens. • The lighter panels reduce the risk of handling accidents. • The panels connect together, removing the need to stretch into the back of the shaker to remove the rear panels. • There is reduced waste when the panels ultimately need to be disposed of.
Screening system
Overview
3. Screen to Screen Sealing: The AX screens are fitted with an interlocking hook and cam system which pulls the screens together, as the pneumatic clamping system inflates. The interlocked screens are located over a sealing bar between the screen interfaces – thereby reducing the risk of whole fluid bypassing the screens (as is the case with alternative screening systems).
The AX Screening System offers a number of advantages: Reduced cost: Screen failure due to wear mainly occurs on the rear screen panels (where loading is at its highest). By employing six panels per deck (versus four), Axiom’s system restricts damage to a smaller screen element.
Size & weight: Being very small and light, the AX Screening System reduces manual handling onsite as well as storage/transport requirements.
Environmental impact: Because the support element remains inside the machine, the only item which is discarded at the end of its life is the small, light site-repairable screen. Also the screen is fully recyclable, and Axiom offers this service if desired.
Flexibility: The AX Screening System concept offers enhanced levels of design flexibility – delivering greater customization and responsiveness to customer needs.
No compromise: While it is recognised that screen life can be improved through the use of alternative/coarser meshes, separation efficiency is often compromised. Axiom believe that screen life improvements can be achieved without such compromise and we therefore recommend that square mesh configurations be employed in most applications.
Screen manufacture Screen manufacture is carried out in-house at Axiom Process’s screen manufacturing facility in Aberdeen. The screens are then shipped to stocking point’s world wide. The entire process is PLC controlled ensuring consistency of the finished product and a high degree of reliability. AX shaker screens are manufactured and designated to comply with API RP13C.
Screening system The
Ax
Screening
System provides: Improved HSE considerations and greater life. Full reparability and lower screening costs per metre. Improved solids control means significantly lower drilling fluids cost per metre.
Ancillaries Screen Shuttle The Axiom Screen Shuttle allows the safe, efficient transportation and storage of new and used screens between locations. The shuttle is secured into a standard container, can be removed when the container is required elsewhere and does not affect the certification of the container.
Screen Rack Often screens can become damaged through poor storage. The Axiom Screen Racking System facilitates the efficient storage of both new and used screens onsite. The racks are normally installed in the shaker house for ease of access and to ensure the re-use of washed and repaired screens before new screens are taken from stock. There is little point searching for screen efficiency savings if perfectly usable screens are discarded due to damage inflicted through poor handling.
Screen Repair Plugs Screen repair is made as fast and efficient as possible with the use of the Snap-Fast™ Screen Repair Plug. The plug allows the screen to be used until around +/- 10% of the surface area is blanked off.
Screen Shuttle
Screen Rack
Repair Plugs
Contact information Head Office Axiom Process Ltd Unit 13 Ashley Group Base, Pitmedden Road, Dyce Aberdeen AB21 0DP Scotland Tel: +44 1224 794 200 Fax: +44 1224 725 658 Email:
[email protected] www.axiomprocess.com
Asia Pacific Regional Manager David Stephenson
[email protected] Tel: +60 122 411 940
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Unit 13, Ashley Group Base Pitmedden Road, Dyce Aberdeen AB21 0DP Tel: +44 1224 794200 Fax: +44 1224 725658 Email:
[email protected] Web: www.axiomprocess.com
