What are the faults of shale shaker?

In drilling fluid solids control systems, shale shakers play a crucial role in purifying drilling fluid and separating cuttings from solid particles. shale shakers are susceptible to various malfunctions during operation, including those related to the vibrator, structural components, electrical system, screen mesh, and operating parameters. They are prone to various failures due to harsh drilling conditions (such as high loads, strong vibrations, and corrosive media), equipment aging, and improper handling and maintenance.

I. Poor screening effect

Poor screening results are a direct sign of a shale shaker malfunction, manifested as high solids content in the drilling fluid after screening, rock cuttings accumulation, and reduced separation accuracy, which directly increases the load on subsequent equipment.

- Screen problems: Mismatch between aperture size and solid particles (too large apertures allow fine particles to pass through, too small apertures cause clogging); screen breakage leads to material leakage; insufficient tension causes particles to slip, resulting in separation failure.

- Abnormalities in the excitation system: Improper angle of the eccentric block of the exciter, abnormal amplitude or frequency; bearing wear, lubrication failure, resulting in uneven vibration transmission.

- Feeding issues: Excessive feed volume leads to material accumulation; feed inlet misalignment causes material to concentrate on one side of the screen, resulting in low utilization.

II. Abnormal vibration (unusual noise, unstable amplitude)

Abnormal vibration manifests as screen body shaking, abnormal noises (such as metallic impact sounds), and unstable amplitude, which can easily lead to a chain of damage.

- Bearing failure: When the vibrator bearing is under high load, the lubricating oil deteriorates, becomes insufficient, or impurities enter, which can easily lead to bearing wear, ball breakage, and abnormal noise.

- Vibrator imbalance: Loose/broken or unevenly worn eccentric block bolts lead to an imbalance in excitation force, causing the screen body to sway and vibrate.

- Loose connecting parts: Loose bolts between the screen frame and the vibrator, and between the motor and the screen body, causing impact noise; aging and failure of the shock absorber, resulting in rigid collision between the screen body and the base.

- Motor malfunctions: Unbalanced motor current, rotor eccentricity causing additional vibration; improper belt tension leading to vibration frequency fluctuations accompanied by friction noise.

III. Damage to structural components

shale shakers are subjected to long-term vibration and material impact, making structural components such as the screen frame and crossbeams prone to fatigue damage.

- Screen frame cracking: Material fatigue and weld defects cause the screen frame to crack at stress concentration points; excessive feeding impact force can also cause it to break suddenly.

- Crossbeam deformation: The crossbeam material is prone to bending due to insufficient strength or overload, which leads to the collapse of the screen; loose connecting bolts will accelerate its wear and deformation.

- Damage to pressure bars and clips: Wear and breakage of screen pressure bars and loosening or corrosion of clips can both lead to screen failure, edge lifting and material leakage.

IV. Sealing failure and leakage

shale shaker seal failure can easily lead to drilling fluid leakage, mainly occurring at the junction of the screen frame and the base.

- Aging of seals: Rubber seals are easily swollen, hardened or cracked due to chemical corrosion from drilling fluid and high temperatures, thus losing their sealing ability.

- Installation deviations: Misaligned seals, deformed screen frames, or uncompacted screen edges can all create sealing gaps.

- Debris abrasion: Rock chips and metal impurities get stuck on the sealing surface, and wear down the seals during vibration, causing scratches and damage.

V. Motor Failure

The motor is the power source of the shale shaker. Failure will directly lead to shutdown. Common problems include failure to start, overheating and burning out.

- Electrical system problems: power line open circuit, contactor failure, overload tripping causes motor to fail to start; damaged winding insulation can easily lead to short circuit and burnout.

- Excessive mechanical load: The vibrator is stuck, the screen surface is blocked, which increases resistance and causes the motor to overheat; insufficient oil and wear of the motor bearings will reduce the speed.

- Environmental factors: On-site dust and drilling fluid clog the motor's heat dissipation holes; high-temperature environments accelerate insulation aging, causing malfunctions.

Troubleshooting shale shakers requires "first identifying the cause, then taking action": locate the fault by listening for abnormal noises and observing vibrations, and analyze the root cause based on the operation records; maintenance requires stopping the machine and disconnecting the power. Regular maintenance, such as lubricating the vibrator and inspecting the screen, can reduce the risk of failure at its source.