Specification of GCF-G-455DG Oilfield PDF
Specification of GCF-G-455DG Oilfield PDF
GCF-G-455DG
Contents
1. Introduction and Product Desc. (5 Pages)
2. Technical Summary (2 Pages)
3. Principles of Operation (2 Pages)
4. Mechanical Spares (1 Page)
5. Electrical Standards (3 Pages)
6. GCF-G-455DG Data Sheets (3 Pages)
INTRODUCTION AND PRODUCT DESCRIPTION:-
Cost-Effectiveness:
The G-Centri-Force Engineering P Ltd high-performance G-455 decanter centrifuge provides the most
cost-effective solution available on the market for various Solid-Liquid Separation plants.
The motivation for processing drilling mud, drilling emulsions, and drilling fluids is easy to
understand: on oil platforms, in tunneling, or in other industrial sectors where drilling systems are
applied, continuous cleaning of these liquids is crucial in order to guarantee and enhance the
optimum processing of the drilling systems. Furthermore, constraints and requirements regarding
the environment (pollution of groundwater and seawater) are getting stricter, requiring continuous
treatment and separation of drilling mud, fluids, and emulsions.
Drilling mud has to fulfill multiple functions: It has to lubricate and cool the drill head and carry the
bits of rock and detritus away which are cut off. Drilling muds
are based on water, oil, or polymer along with various
additives such as stabilizers, flocculants, corrosion inhibitors,
defoamers, surfactants, detergents, lubricants, and more.
Modern drilling systems form a closed cycle from which no
solids are able to escape. As a result, any particle which gets
into the closed system has to be separated. Shaking screens
and hydrocyclones can separate out coarse particles, but a G-
Centri-Force Decanter separates small and fine particles. For a
better overview and understanding of how drilling mud, fluids
and emulsions are separated and processed using a G-Centri-
Force Decanter, please have a look at the process scheme below.
The G-455 range provides the most cost-effective, high-performance solution combined with the
lowest power consumption and life cycle costs available within the process industries., with both
very low (<1%DS) and very high solids contents. Whether you require lower life cycle costs, higher
cake dryness driven by 2 or 3 stage planetary gearbox.
Compact Design:
The G-455 is compact and efficient, and enables cost effective operation that conforms to strict
environmental legislation.
Benefits:
• Redu es sludge olu e
• Cost-effective performance
• Co ti uous ope atio
• Co pa t, odula desig
• Sta -Delta operating or PLC base.
Working Principle:
Separation takes place in a horizontal cylindrical bowl equipped with a screw conveyor. The feed
enters the bowl through a stationary inlet tube and is accelerated smoothly by an inlet Discharge.
Centrifugal forces cause
Sedimentation of the solids on the wall of the bowl. The conveyor rotates in the same direction as
the bowl, but at a different speed, thus moving the solids towards the conical end of the bowl. Only
the driest fraction of the cake leaves the bowl through the solids discharge openings into the casing.
Separation takes place throughout the total length of the cylindrical section of the bowl, and the
clarified liquid leaves the bowl by flowing over adjustable plate dams into the casing.
Depending on specification, GCF-G-XXXFD type decanters are equipped with a pulley system for a
fixed speed drive, or a variable speed turbo arrangement on the main drive enabling the operator to
adjust the bowl speed between 1000 and 4000 rpm within a few seconds Depends on decanter
model. This option, combined with variable conveyor speed, gives a new dimension to the use of
centrifuges for drilling fluids treatment.
The optimum speed for solids capture or for a specified cut-point depends on the composition of the
drilling fluid and the nature of the solids.
All GCF-G-XXXFD type decanters can be equipped with variable speed back drive. The differential
speed (relative conveyor speed) can be changed by operation of a simple changing the differential
speed parameters on PLC main control panel.
Up to a certain limit, a high differential speed improves solids capture (clarification) and increases
solids discharge capacity. The optimum differential speed is selected in each case according to solids
loading, required separation efficiency and required underflow density.
Design
A compact, in-line frame carries the rotating part with main bearings at both ends. Vibration isolators
are placed under the frame. The rotating part is enclosed in a casing with a cover and a bottom
section in which the solids and liquid outlets are integrated. All G-355 decanter centrifuges are
available in 2-phase versions and can be ATEX-compliant. They are also available for zones 1, 2 and
22. Sealed and purged decanter centrifuges are available for processing flammable feed. Decanter
centrifuge will be provided with Espey Seals for sealed decanters.
Scroll conveyor:
Wear protection in the form of tungsten carbide tiles, combined with cobalt, ensures a service life
that is at least double that of the standard configuration.
Materials:
The bowl, conveyor, inlet tube, outlets, cover, and other parts in direct contact with the process
media are made of AISI 316 and cylinders & Conical section made by High strength Duplex Stainless
Steel. The discharge ports, conveyor flights and feed zone are protected with highly erosion resistant
materials. The frame is made of mild steel with an epoxy paint finish.
Optimization:
The N range of decanter centrifuges can be adjusted to suit individual sludge dewatering and
thickening needs. You can obtain maximum separation efficiency by first varying the feed rate,
rotational speed, and polymer type and dosage. The optimal balance between liquid clarity and
solids dryness is achieved by varying the differential speed between the conveyor and bowl and the
pond depth in the bowl.
These are designed to give optimum performance under the widest possible range of applications
and operating conditions encountered in drilling fluid processing. Adjustments are easily made to
optimize performance at differing values of mud weight, viscosity, solids distribution, etc., and to
select the particle size cut-point in classification duties.
Pond Depth:
The radial liquid level in the bowl is controlled by interchangeable level regulating plates which are
specially designed to minimize turbulence in the overflow from the clarifying zone. A shallow pond
setting with a long beach gives dryer solids. A deep pond setting with a short beach gives a clearer
effluent.
In most cases Decanter centrifuges do a good job of separation without benefit of chemical additives.
However, some fluids containing a high proportion of colloidal fines, e.g. in drilling waste
applications, may need to be flocculated to make them separable. Flocculants chemicals are
expensive, so it pays to exploit the other tuning capabilities of the Decanter to the full in order to
minimize the dosage.
Application:
Decanter centrifuges are specifically built for oilfield applications, both onshore and offshore.
Adjustable operating parameters enable GCF-G-XXXFD type decanters to be employed for a wide
range of solids control purposes in drilling fluid systems including.
• Barite recovery from the active mud system or from surplus mud in storage,
• Separation of drilled solids from unweighted muds,
• Two-stage centrifugation, with barite recovery in the first stage followed by clarification of the
liquid phase for recycling to the active mud system,
• Treatment of drilling and reserve pit wastes to eliminate need for disposal of contaminated
liquid waste,
2. Lubrication Systems:
AUTOMATIC GREASE LUBRICATION
In contrast to the manual central lubrication system, the greasing system can be operated
automatically. This ensures uniform and reliable lubrication of the centrifuge. It prevents bearings
from being under or over-lubricated and eliminates short-term spikes in bearing temperatures and
excessive grease consumption. The function of the grease pump is controlled by the control system.
For the most stringent requirements, an oil-air lubrication system can be provided by additional cost.
CENTRAL LUBRICATION SYSTEM
Lubrication from a central manually operated pump. The lubricant is accurately dispensed through a
piston distributor to the designated greasing points.
3. Vibration Monitoring:
Vibration sensors transmit acceleration signals to an analyzer that sounds an alarm or shuts the
centrifuge down upon reaching the maximum permissible level.
Vibration Monitoring
4. Speed & Temperatures Monitoring:
SPEED MONITORING
Bowl speed and scroll differential speed are each measured by an inductive proximity switch and
shown on a digital display. Continuous monitoring of maximum and minimum values during
operation helps to minimize preventable failures and maintain acceptable safety standards.
TEMPERATURE MONITORING
Bearing temperatures are continuously monitored on GCF centrifuges by means of resistance
thermometers. Upon exceeding pre-set temperature limits – between 100°C and 130°C depending
on the individual application - , the centrifuge gives an alarm or shuts down. This preventive measure
safeguards against bearing failure or machine damage.
Temperature Monitoring
TECHNICAL SUMMARY:-
GCF-G-XXXFD TYPE DECANTER CENTRIFUGE- VFD MAIN & BACK DRIVE WITH PLC:
1. Type decanter GCF-G-XXXFD multiple purpose machine suitable for high speed or low speeds
depending on densities and volumes of solids. Used for high volume solids removal or barite
recovery.
All process contact parts in Duplex & stainless steel, conveyor hard-surfaced with sintered tungsten
carbide tiles, bowl sintered tungsten carbide solids discharge bushings. Heavy duty G52 (3.5
kNm) Three stage planetary gearbox.
The decanter is equipped with a VFD+PLC controller and belt-pulley for main drive and a belt
pulley system for the back drive, discharge funnels for solids and liquid discharge as well as a
gearbox overload switch, cover open switch.
2. Main drive motor 415 volts, 50 Hz, 3 phase 55kW/75Hp, 1440 rpm EExd 11C T4, foot
mounted on feed Inlet end below of bowl , VFD start and bowl speed regulation from the
recommended 1100 rpm to 3150 rpm.
3. Back drive motor 415 volts, 50 Hz, 3 phase 22kW/30Hp, 2900 rpm EExd 11C T4, flange
mounted on below of gearbox, VFD start and Differential speed regulation from the
recommended 0 rpm to 2900 rpm. Set points as per setting are depending of solid dryness &
liquid clarity.
4. The main PLC control panel with Main & Back drive, arrangement with A/C cooling. This main
panel installed 50meters from centrifuge, but on board control panel install on skid for
operating the centrifuge & other equipment.
5. All necessary piping, hoses and gauges, sensors as well as an EExd 11.B T6 RPM/temperature
monitoring switch to complete as per Flame proof standard.
6. Solid Screw conveyor motor with Gearbox, 415V, 50Hz, 3 phase, 2kw/3Hp, 1440 rpm EExd
11C T4. This RPM of the screw conveyor fix range 10rpm.
7. Electrical control system type EExd 11B T4 including main isolator, separate short circuit and
overload protection for all drives, control circuit, isolating transformers with primary and
secondary mcb's, timers, relays, indicator lights etc. Main drive start/stop, feed pump
start/stop, automatic safety shut down system.
8. Oilfield type skid unit with items 1-7 mounted sandblasted zinc coated and enamel finish.
9. VFD drive feed pump type progressive cavity, positive displacement fitted with belt type
variator complete with a 415 V, 50 Hz, 3 phase motor, 7.5 kW/10Hp, 1440 rpm EExd 11C T4.
Totally enclosed, direct start protection, suitable for Zone 1 specifications. The complete
pump unit is mounted on a skid assembly and includes couplings, guards, flanges and power
cable.
PRINCIPLES OF OPERATION
FEED
The feed suspension is introduced through an inlet tube to the feed zone of the conveyor where it is
accelerated and directed into the interior of the bowl.
The solids which must have a higher specific gravity than the liquid settle out at the inner wall of the
bowl almost instantaneously due to the high centrifugal acceleration normally in the range of 500 -
2300 g - leaving a clear inner ring of liquid.
SOLIDS DISCHARGE
The settled solids are conveyed axially towards the small end of the bowl by means of the screw
conveyor, which rotates at a slightly different speed than the bowl. On the way to the discharge
ports the solids are lifted out of the pond up along the dry beach. On the beach liquid drains off and
flows back into the pond. Where liquid cannot drain through the solids phase, dryness of the solids is
obtained by compacting (squeezing) the solids on the dry beach. The solids are finally discharged
from the bowl through the discharge ports into the collecting chamber of the casing that surrounds
the bowl. From there the solids are removed by gravity through the outlet funnel.
LIQUID DISCHARGE(OPEN)
The liquid phase forming a hollow cylinder due to the centrifugal force flows in a helical channel
formed by two adjacent flights of the conveyor and the bowl wall towards the large end of the bowl.
Some conveyors, axial flow or quasi axial flow conveyors, allow a more axial flow of the liquid.
DRIVE SYSTEM
The bowl is driven by a V-belt transmission on the shaft at the conical end. Power is transferred to
the conveyor by a planetary gearbox at the cylindrical end. Differential speed between the bowl and
conveyor is controlled by a separate motor connected by a V-belt transmission to the sunwheel shaft
of the gearbox (back drive).
The G52 (3.5 kNm DD) gearbox incorporated in the GCF-G-XXXFD type design has one of the highest
torque ratings in the industry and is protected against overload by a quick reset share pin
arrangement & set points of max torque on PLC.
CONSTRUCTION
GCF-G-XXXFD type Decanter centrifuges and their associated drive arrangements and electrical
controls are integrated and mounted on a typical oilfield sub-frame specially designed to withstand
long and hard use in the field.
The conveyor is specially designed for heavy duty, high torque applications, with erosion protected Y
design feed inlet. The bowl is built up in sections made of centrifugally cast Duplex stainless steel.
Materials and bowl geometry are designed to assure long-term continuous operation without risk of
clogging and with little need for field maintenance.
MATERIALS
All parts in contact with the process media are made of stainless steel. Heavy duty erosion
protection is provided in the form of replaceable tungsten carbide tiles.
Longitudinal strips on the inside of the bowl wall to prevent slippage and erosion.
Replaceable sintered tungsten carbide bushings in the solids discharge openings to prevent solids
build up in the collecting cover and erosion of the outside of the bowl.
MECHANICAL SPARE PARTS – 1 Year Supply
INTRODUCTION:
The selection of equipment for hazardous areas must fulfil the requirement of the zone. For electrical
equipment it is very easy to specify and establish whether the equipment is suitable for the hazardous area or not.
For mechanical equipment it is more difficult but there are some standards dealing with mechanical equipment
for hazardous areas.
This is a guideline for electrical and mechanical equipment for installation in hazardous areas. It also describes
some of the differences between the European standard (EN), the American standard (NEMA) and the Canadian
standard (CSA).
The electrical equipment is divided into four groups, hazardous area zone, gas group, temperature class and type
of protection.
Note that i USA a d Ca ada they do ‟t efe to zo es, ut lass, di isio a d g oup the e uip e t is suited fo .
Because NEMA and CSA are considering adopting the EN standard that terminology is used.
Zone 0: Comprises areas in which an explosive atmosphere is present constantly or for long
periods.
Zone 2: Comprises areas in which an explosive atmosphere is expected to occur only seldom
and then only temporarily.
Ele t i al o t‟d
This table shows the different gas groups and associated zones: -
NEMA/CSA EN
If a temperature class is required the equipment must not have a temperature over that specified, that means in
practical terms the selection of equipment which is classified for hazardous area even if it is a non-hazardous area
the equipment is to be installed in.
Electrical cont d
Mechanical equipment which must be divided into two groups, non-rotating equipment and rotating equipment.
The non-rotating equipment (pipes, frames and etc) have no classification.
Rotating equipment (pumps, centrifuges and etc) have a type of classification as follows: -
A combination of 4 enclosures of ASP manufacture EJB 51 certified to Zone 1 specification and approvals by INIIEX
(Cert. No. Ex 82-103-183).
The material used in the construction is of an aluminum alloy with low copper content which is robust and fit for
purpose. Pressure testing, heat dissipations and gland entry matrix is all certified to CENELEC standards.
This motor is selected for its durability in a gaseous/moisture-laden environment. The motor has been wound to
allow voltages ranging between 380V – 400V with frequencies of 50 or 60Hz, thus giving the full spectrum of use
within the global market.
The Binder brake is attached to the back drive motor to give a stationary position on the motor. The cast body is
robust in construction and offers flameproof/explosion proof protection, Zone 1 applications (EExde IIC T5)
approvals by BVS (Cert. No. EX81-001).
Final switches suitable for Zone 1 applications centrifuged to PTB (Cert. No: EX80-1019) approval is used to
monitor the over torquing of the gearbox and the rotating assembly cover. Again this is used as an alarm
function, shutting down equipment if there is a failure.
Ships Wire Braid (SWB) cable using a 4 wire system with a direct earth (3-phase & Earth). Cenelec and EN
standards apply and all cables to be of halogen free construction.
Glands of the Hawke type (EExde IIC) suitable for Zone 1 requirements. This should be specific to the enclosure
that it is to be terminated in.
NOTE: All cables are to be fixed to cable trays or equivalent (which is fit for purpose) by metal tie wraps and bound
in groups as per electrical specifications.
Details Specification:-
Application Oil & Gas Industries
18-20 M3/ Hours (70-80GPM)
20m3/hr at 2% feed solid w/w
Flow rate
16m3/hr at 6% feed solid w/w
10 m3/hr at 10% feed solid w/w
General information
Typical application Drilling Mud Application
Max. Design temp. 130 Degree Celsius
Min. Design temp. 0 Degree Celsius
Centrifugal G-ratio 2682 G
Total Length mm/inches 4548/167
Total Width mm/inches 1098/43
Total Height mm/inches 1005/39
Total Weight kg/Ib 3910/8620
Accelerating Time To Optimum Speed 1-2 Minutes
Running Down Time 10-15 Minutes
Design Counter Current
Base Frame,
Type Box beam profile
Mild steel for Base Frame
Material
AISI304 for base Frame (Optional)
Sludge outlet area Wear plate AISI 316
Casing assembly
Type Top Cover
Material AISI 316
Sludge outlet area Replaceable Wear plate
Gearbox
Gearbox type Planetary - Three Stage/two stage
Gearbox ratio 1:101/1:98
Gearbox Model G-101/G-98
Gearbox torque 8000 Nm
Lubrication Special Oil
Drawing
GA Drawing Foundation Drawing
Control panel Control panel Drawing
1 set Decanter Operator with Installation,
Instruction Manuals
Maintenance & Spares Parts
For more information please contact: