Every barrel of drilling fluid that leaves the wellbore is carrying cuttings, sand, and silt that don’t belong in your active mud system. Left untreated, these solids abrade pump fluid ends, clog downhole tools, and force crews to dilute with expensive fresh mud just to keep viscosity in range. A properly sized solids control package solves this at the source.
For drilling contractors, procurement directors, and mud engineers, investing in an optimized solids control system is not just an equipment purchase—it is a critical strategy for non-productive time (NPT) reduction and fluids cost containment. Failing to remove abrasive solids leads to rapid mud pump valve erosion, downhole tool blockages, and premature screen failures, driving up total cost of ownership (TCO).
Not sure where to start?
Send us your rig’s pump output (GPM) and we’ll recommend a matched shaker/desander/desilter configuration within 24 hours.
Why Solids Control Is Critical for Drilling Contractors
Many drilling problems are not caused by drilling equipment failure, but by poor drilling fluid management.Excessive Solids Increase Drilling Cost
When drilled solids remain in the mud system, they continuously circulate through:Mud pumps,Surface pipelines,Downhole tools,Drill bit nozzles.This creates additional wear.
What Is a Solids Control System and Why It Matters
A solids control system is a sequence of mechanical separation stages installed between the wellbore return line and the active mud tank. Each stage removes progressively smaller particles before the cleaned fluid is recirculated back down the hole.
The Four-Stage Cleaning Process
Shale shaker – removes the largest cuttings first, using vibrating screens.
Desander – removes sand-sized solids (roughly 45–74 microns) using hydrocyclone cones.
Desilter – removes finer silt (roughly 15–44 microns), also via hydrocyclones, positioned after the desander.
Mud cleaner (optional combined stage) – pairs a hydrocyclone bank with a fine screen to reclaim usable fluid from the desilter underflow before disposal.
1.1 Why Solids Control Reduces Mud Cost and Extends Equipment Life
Every stage you skip means those solids stay in circulation, where they:
Accelerate wear on mud pump fluid ends, liners, and valves
Increase differential sticking risk and torque/drag downhole
Force higher dilution rates, which drives up chemical and disposal costs
Reduce rate of penetration as mud rheology drifts out of spec
Operators typically recover the cost of a properly sized solids control package within the first few wells through reduced pump maintenance and lower mud consumption alone.
1.2 Shale Shakers — First-Stage Solids Removal
The shale shaker is the initial processing unit handling raw drilling return mud directly from the flowline. The piece of equipment your solids control system’s total capacity is built around — undersize it and every downstream stage inherits the overflow.
Linear vs Balanced Elliptical Motion Shakers
Linear motion shakers convey solids more aggressively and handle higher flow rates, making them the standard choice for most drilling rigs.
Balanced elliptical motion shakers offer gentler conveyance, often preferred where fluid retention on the screen (for finer separation) matters more than throughput speed.
G-Force Acceleration: High-G shakers (operating between 7.0 and 8.5) apply immense gravitational acceleration to shear fluid tension, maximizing mud recovery off the screen tailing end.
1.2.1 Screen Mesh Selection (API RP 13C Standards)
Screens are specified by API RP 13C designation rather than old mesh-count labels alone, since designation accounts for both wire diameter and open area — two screens with the same “mesh count” can have very different actual cut points.
1.2.2 As a starting point:
Coarser screens (larger API number) prioritize flow rate and are used in fast-drilling, high-ROP intervals
Finer screens improve solids removal but reduce total throughput and increase screen wear/replacement frequency
1.2.3 RIGRS Shale Shaker Specifications & Capacity Range
RIGRS supplies linear motion shale shakers sized for onshore drilling rig flow rates, with interchangeable screen panels and skid-mount or mud-tank-top configurations. Screens are available across a range of API RP 13C designations to match your target cut point.
Shale Shaker Technical Selection Table
| Parameter | Procurement Consideration |
| Processing Capacity | Match drilling fluid circulation rate |
| Screen Area | Determines separation efficiency |
| Vibration Mode | Affects solids removal performance |
| Motor Power | Influences reliability |
| Screen Type | Impacts operating cost |
| Maintenance Access | Reduces downtime |
1.3 Desanders & Desilters — Hydrocyclone Separation
When solids pass through initial shaker screens, secondary and tertiary hydrocyclone separation stages take over.Once cuttings-sized solids are out, desanders and desilters handle what the shaker’s screens physically can’t catch: sand and silt fine enough to pass through even a tight mesh.
Desander vs Desilter: Micron Removal Range
| Desander | Desilter | |
| Position in system | After shale shaker, before desilter | After desander |
| Removes particles down to | ~45–74 microns | ~15–44 microns |
| Cone size (typical) | Larger cones (e.g. 8″–12″) | Smaller cones (e.g. 4″–6″) |
| Purpose | Bulk sand removal | Fine silt polishing |
Desander Units: Utilizing larger 10” or 12” polyurethane hydrocyclones, desanders process high flow rates to remove medium-to-coarse sand particles (15 to 44 μm).
Desilter Units: Featuring banks of smaller 4” or 5” hydrocyclone cones (typically arrayed in groups of 8, 12, 16, or 24), desilters target fine silt particles (15to 47 μm).
Integrated Mud Cleaners: A mud cleaner integrates both desander and desilter hydrocyclone manifolds directly over a fine-mesh, bottom-deck vibrating screen. This compact “two-in-one” or “three-in-one” setup allows weighted drilling fluids to pass through the lower screen mesh while discarding dry solid tailings.
How Many Cones Do You Need? Sizing by Flow Rate
Hydrocyclone capacity is rated per cone, so total system capacity is a function of cone size and cone count, not a single unit spec. Undersizing cone count for your mud pump’s GPM output is the one of the most frequent solids control design issues we see in procurement inquiries — it leaves the system bypassing untreated fluid straight back to the tank.
RIGRS Desander/Desilter Cone Configurations
RIGRS builds desander and desilter units in multiple cone-count configurations, mounted individually or combined on a shared manifold, matched to your rig’s circulating flow rate.
1.4 Mud Cleaners — Combined Shaker + Hydrocyclone Systems
A mud cleaner pairs a desilter’s hydrocyclone bank with a fine screen underneath it, so the liquid that would otherwise be discarded with the hydrocyclone underflow gets one more pass before it’s sent to waste. For rigs using weighted mud, this reclaims barite that would otherwise be discarded along with the drilled solids — a meaningful savings on high mud-weight programs.
When a 2-in-1 or 3-in-1 System Saves Footprint and Cost
Combined desander/desilter/shaker skid packages reduce the number of separate mud tank cutouts required, simplify piping, and lower the overall footprint — a common request for rigs with limited tank deck space or mobile/skid-mounted operations.
1.5 Mud Agitators & Mud Tanks — Keeping Fluid Properties Stable
Hydrocyclones require consistent feed pressure to generate effective centrifugal separation. Centrifugal pumps feed mud into the desander and desilter manifolds at precise pressure baselines (0.25 to 0.35 MPa).
The processed fluid flows into multi-compartment mud circulating tanks, structured into distinct functional zones:
Sand trap compartments, where installed, provide additional settling space for heavier solids before further processing.Degassing & Desanding Compartment: Prepares fluid for hydrocyclone processing.
Suction & Mixing Tank: Houses high-shear mud guns and top-mounted mud agitators to keep barite and chemical additives suspended prior to pumping downhole.
Explosion-Proof Mud Agitators for Hazardous Zones
RIGRS supplies EAC and ATEX-rated explosion-proof mud agitators (NJ series) for compartments where flammable gas may be present, keeping active and reserve tank compartments continuously agitated to prevent solids settling and barite sag.
Mud Tank Compartment Design and Sizing
Mud tanks are typically divided into settling, suction, and reserve compartments, each sized around the solids control equipment mounted on top of it. Tank layout should be planned alongside shaker/desander/desilter selection, not after — retrofitting undersized compartments later is far more expensive than specifying correctly the first time.
Why Drilling Contractors Choose Integrated Mud Cleaning Systems
1. Reduced Equipment Footprint
For offshore and compact rigs, available space is limited.
Integrated systems provide:
Compact installation
Easier transportation
Faster commissioning
2. Improved Drilling Fluid Performance
A properly designed mud cleaning system helps maintain:
Density control
Viscosity stability
Lower solids concentration
3. Lower Operating Cost
By recovering drilling fluid and reducing dilution requirements, contractors can significantly reduce:
Mud chemical consumption
Waste disposal cost
Maintenance expenses
RIGRS Real-World Field Case Study:
1. Reducing OBM Loss in Middle East HPHT Operations
A regional drilling contractor operating in an onshore Oman field encountered high fluid maintenance costs while drilling 8-1/2” directional sections using a 12.5 ppg synthetic oil-based mud (OBM) system.
The Operational Challenge: The rig’s legacy solids control system suffered from low G-force output and plugged desilter cones. Ultrafine solids accumulated in the active system, driving up plastic viscosity and causing whole-mud carryover on cuttings. Fluid loss costs surged to $45,000 per 1,000 feet drilled.
The Technical Solution: The operator replaced the aging setup with a custom Skid-Mounted Mud Cleaner Package, featuring dual linear-motion shakers, a 2-cone desander, a 12-cone desilter, and a high-speed VFD decanter centrifuge.
The Result: Overall solids removal efficiency reached 98%, while high-value barite recovery increased by 35%. The contractor eliminated mud-related NPT and saved over $160,000 per well in fluid replenishment and cuttings disposal costs.
2. Solids Control Equipment for Extreme Cold Conditions
A drilling contractor operating in a siberian oilfield required solids control equipment for winter drilling operations.
The project environment included:
Extremely low temperatures
Remote transportation conditions
Limited field maintenance capability
RIGRS Arctic Solution
RIGRS optimized the solids control equipment configuration for cold-weather operation.
Low-Temperature Adaptation Design
Cold-Resistant Electrical System
Equipment configuration included:
Low-temperature rated motors
Cold-weather electrical protection
Improved starting reliability
Temperature-Resistant Materials
Selected components considered:
Low-temperature toughness
Impact resistance
Material stability
This reduced the risk of:
Structural cracking
Component failure
Unexpected shutdown
The customized solids control solution helped the contractor maintain stable drilling operations in extreme cold conditions.The equipment completed the first winter drilling campaign with stable operation and no major equipment-related downtime reported.
Factory Inspection Protocols & Technical Support Capabilities
Ensuring continuous performance in remote desert or offshore environments requires rigorous factory testing and robust aftermarket support:
Strict Factory Acceptance Testing (FAT) & Quality Control
Hazardous Area Certification: All electrical motors, control panels, and safety switches must hold verified IECEx, ATEX, or UL explosion-proof certifications suitable for Zone 1 or Zone 2 hazardous rig environments.
Dynamic Load & Vibration Proofing: Shakers undergo continuous 4-hour full-load factory testing to measure stroke amplitude, orbital consistency, and acoustic profiles (maintaining noise levels below 85 dBA).
Tank Integrity & Coating Specs: Mud tanks undergo full-capacity hydrostatic leak testing. Internal surfaces are grit-blasted and coated with high-build epoxy glass-flake liners to resist synthetic oil degradation and sour gas corrosion.
Applied Technical Services & Customization
Modular Skid Packaging: Equipment can be packaged into compact, winterized, or desert-duty skid structures designed to fit standard transport footprints.
BHA & Hydraulics Engineering Integration: Manufacturers provide complete system flow modeling to ensure centrifuge GPM ratings match high-pressure mud pump displacement parameters.
RIGRS Control Equipment – FAQ
Q1: What is the main difference between a desander, a desilter, and a mud cleaner?
A: The primary difference lies in hydrocyclone cone diameter and target particle cut point. A desander uses larger 10” or 12” cones to remove coarse sand (47–76μm). A desilter uses smaller 4” or 5” cones to extract fine silt (15–47μm). A mud cleaner combines both desander and desilter cone manifolds mounted directly over a fine-mesh bottom shaker deck, allowing weighted mud liquids to pass through while dry solids are discarded.
Q2: How do API RP 13C compliant screens improve shaker performance?
A: API RP 13C certification standardizes screen sizing parameters across manufacturers. It defines exact performance metrics for Cut Point (D50 rating), Conductance (fluid flow capacity), and Non-Blanked Screen Area. Using API 13C certified screens ensures predictable fluid separation, prevents screen blinding or mud pooling, and provides clear benchmarks for procurement evaluations.
Q3: Can a solids control system be configured for zero discharge (ZDL) requirements?
A: Yes. For zero-discharge drilling environments, the standard solids control circuit is expanded with a high-speed Decanter Centrifuge and a Vertical/Horizontal Cuttings Dryer. This closed-loop configuration strips free liquid from drill cuttings, bringing Oil-on-Cuttings (OOC) levels below $5\%$ by weight for safe handling and maximum base fluid recovery.
Q4: What mesh/screen size shale shaker do I need?
A: It depends on your formation and target flow rate — coarser API RP 13C designations favor throughput, finer designations favor solids removal at the cost of capacity and screen life. Send us your flow rate and mud program and we’ll recommend a starting screen designation.
Q5:Can solids control equipment be retrofitted onto an existing mud tank?
A: In most cases, yes — shakers, desanders, and desilters can be mounted on existing tank cutouts if the compartment layout and structural supports match. We can review your tank drawing before you order.
Q6: How long does a shale shaker screen typically last?
A: Screen life depends on:
Formation abrasiveness
Drilling fluid type
Operating hours
Screen quality
Regular inspection and correct screen selection can significantly extend service life.
Q7: How can I reduce solids control equipment maintenance costs?
A: Recommended practices include:
Selecting properly sized equipment
Using quality replacement parts
Performing regular inspections
Monitoring vibration performance
Maintaining spare parts inventory
Optimize Your Rig Fluid Systems & Request a Technical Quote
Customizing a solids control package to match your rig floor profile prevents costly downhole NPT, extends mud life, and keeps field operations compliant.
Whether you need standalone replacement shale shakers, custom hydrocyclone manifolds, or a fully integrated mud tank system, securing API-certified equipment backed by factory FAT testing ensures immediate operational reliability.
To get an accurate, engineering-reviewed quote, send us:
Mud pump flow rate (GPM) or rig horsepower
Target particle removal size / mud program (weighted or unweighted)
Existing mud tank dimensions and compartment layout (if retrofitting)
Hazardous area classification (explosion-proof requirement or not)
Operating region and any local compliance requirements
Email your specs to info@rigrs.com or use the inquiry form below — our engineers respond with a matched configuration within 24 hours.
Email: info@rigrs.com
WhatsApp: +8618615995257
