Hydrocyclone separators failure cause and correction

Hydrocyclone separators are made of high quality polyurethane material. We use hydrocyclones on desander, desilter and mud cleaner. Many clients may face some problem during operation. Different manufacturer may produce equipment with different quality level, various failures will request certain solutions

Hydrocyclone separators

Hydrocyclone separators working performance with failure

1. There is no problem on the cone, however, cone’s Apex or nozzle is being blocked.

2. No drilling fluid flow in hydrocyclones.

3. The feed inlet pressure or head is low.

4. Dry particles are discharged from hydrocyclone. (water loss of particle surface)

5. There is vacuum phenomenon in manifold. (When the pipes enter into drilling mud tank, the head is too long)

6. Solids content is increasing

7. Gravity of discharge is too heavy

8. Drilling fluid loss is too much

9. Discharge of cones is not stable will vary along with feed inlet head

10. There is gas mixed drilling fluid in downstream of hydrocyclones

Desander cone

Causes and the corrections for above failure

1. The feed inlet or discharge port may be blocked, downstream port is too small. We can clean hydrocyclone jam, the pipelines, check the shaker screen if any damage
2. Feed inlet blocking will lead drilling fluid flow back via overflow pipe
3. Check centrifugal pump performance, including rotation, voltage; check shale shaker screen if any broken; check the pipes if any jam, such as solid sedimentation or valve off
4. The Drop in Apex is too small, confirm if we need more hydrocyclone
5. We can install the siphon eliminator
6. Cones capacity is insufficient. Or the particle size is too small, shaker screen opening is too fine
7. Hydrocyclone is overdue, we can increase discharge port size or install more cones
8. Drop in Apex opening is too large, we can decrease discharge out of cones or change smaller cones
9. There is invaded gas or air in fluid at feed inlet port
10. Set pass to let overflow mud flow into drilling mud tank to let gas vent

More features of cones

Hydrocyclone separator is rather easy to operate and maintain. Separation is achieved by power input, or feed in energy become internal centrifugal force. Compared to drilling fluid shaker and decanter centrifuge, the hydrocyclone separator discharge is wet materials.

When design hydrocyclones separator we need to consider simple design, no movable parts, easy maintenance, high separation efficiency.

Generally, when the solid particles diameter is over 10 microns and with ball-shape the cones efficiency will be at highest level.

We use hydrocyclones to achieve the least liquid loss and maximum cuttings removal. The issues impacting cones performance are cone diameter, angle, discharge port diameter, feed inlet head, plastic viscosity.

Please contact Aipu for more information or price offer