Project Background

In May 2025, TR Solids Control received a technical inquiry from a drilling contractor operating in southern Iraq. The contractor was preparing for the second phase of a multi-well development program within a major onshore oilfield concession. The drilling program called for vertical and directional wells reaching depths between 3,800 and 4,600 meters, traversing unstable shale, high-permeability sandstone, and salt-anhydrite sequences.

Customer Operational Challenges

The contractor faced three primary challenges. First, mud weights ranging from 11.5 to 15.8 ppg were required to maintain wellbore stability across pressure-transition zones. Second, penetration rates of 12 to 18 meters per hour would generate cuttings volumes exceeding their existing two-stage solids control capacity. Third, local environmental compliance mandated cuttings dryness below 8% oil-on-cuttings prior to disposal, requiring a decanter centrifuge capable of fine-solids separation down to 5 microns. The legacy equipment had proven inadequate, with excessive dilution and non-productive time averaging 14 hours per well.

Technical Solution

TR Solids Control conducted a hydraulics and mass-balance analysis using the contractor's well plan and mud program. The analysis determined a four-stage solids control system with 1,200 GPM (4,542 L/min) minimum flow capacity was required. The proposed solution incorporated linear-motion shale shakers with API RP 13C-compliant screens, a dual hydrocyclone arrangement, and a variable-frequency centrifuge for barite recovery and fine-solids polishing. For equipment details, see the TR Mud Cleaning System product page.

Equipment Configuration

Installation and Commissioning

Fabrication was completed at TR Solids Control's Xi'an facility in July 2025. Following factory acceptance testing, all modules were shipped via Shanghai to Umm Qasr Port with overland transport to Al-Basrah. A two-person engineering team arrived on-site on August 18. Rig-up was completed in four days, including structural welding, electrical hookup to the 480V/60Hz power system, and integration with the existing mud tank farm. The system was signed off on August 23, and drilling commenced on August 25, 2025.

Operational Performance

During the 12-well program from August 2025 to March 2026, the solids control package processed an estimated 648,000 barrels of drilling fluid. Key performance metrics include:

• API 140 screens maintained average conductance of 3.2 kD/mm, with screen life averaging 110 circulating hours per panel
• Sand removal exceeded 92% for particles larger than 45 microns; silt removal exceeded 88% for 15-45 micron particles
• Centrifuges operated in barite recovery mode at 2,200 RPM and fine-solids polishing at 3,000 RPM — refer to the TR decanter centrifuge specifications
• Dilution rates decreased from 0.38 bbl/ft to 0.11 bbl/ft, a 71% improvement
• Mud-related NPT reduced from 14 hours per well to an average of 3.5 hours per well

Customer Feedback

"The TR solids control package delivered consistent performance across all 12 wells. Switching between barite recovery and fine-polishing modes on the centrifuges was particularly valuable. The reduction in dilution rates translated directly into lower mud cost per foot. The TR engineering team's support was professional and thorough."

API-certified shaker screens demonstrated superior durability, reducing change-out frequency by approximately 30%.

Future Cooperation

Based on the successful outcome, TR Solids Control and the contractor are in technical discussions for a follow-on scope covering an additional 18 wells in the 2026-2027 drilling campaign. The expanded scope may include a high-G drying shaker and an automatic flocculant dosing unit. TR Solids Control has also proposed an IoT-enabled condition-monitoring package for predictive maintenance of centrifuge rotating assemblies. For full system integration, refer to the TR Solids Control System overview.