Analysis of Downhole Instrument Damage Mechanism by Harmful Solids and Solids Control System Solutions

Feb 11, 2026

In modern oil drilling, especially in deep and extended-reach drilling (ERD) operations, the management of solids content in drilling fluids is not only about mud performance but is also a core variable determining the lifespan of expensive downhole tools. As the "kidney" of the drilling rig, a premium Solids Control System is responsible for removing harmful solids and protecting precision instruments.

 
Erosion Damage Mechanism of Harmful Solids on Precision Downhole Instruments
 
During the drilling circulation process, drilling fluids inevitably contain a large amount of rock cuttings. According to research reports on the impact of sand content on downhole tool reliability published by the Society of Petroleum Engineers (SPE), hard solid particles with a diameter greater than 20 microns are the primary cause of premature failure in downhole tools.
When the purification efficiency of a Solids Control System is low, these fine particles enter the borehole at high speeds with the mud, creating a severe "sandblasting effect" on the pulse generators and sensor seals of Measurement While Drilling (MWD) and Logging While Drilling (LWD) instruments. Research data indicates that for every 1% increase in sand content, the Mean Time Between Failures (MTBF) of downhole tools is shortened by approximately 50%. This physical erosion not only leads to signal transmission interruptions but also triggers expensive unplanned tripping, resulting in massive Non-Productive Time (NPT) losses.
 
Decisive Impact of High Efficiency Solids Control System on Mud Performance and Equipment Life
 
A scientifically configured Solids Control System must achieve stepped interception of different Particle Size Distributions (PSD). According to the API RP 13C standard defined by the American Petroleum Institute (API), the separation efficiency of solids control equipment directly affects overall drilling productivity.
An effective solids control workflow must not only remove coarse cuttings but also utilize the precision coordination of desanders, desilters, and high-speed VFD centrifuges to eliminate harmful solids above 5 to 7 microns. This multi-stage treatment ensures that the mud entering the hole maintains low sand content, preventing premature failure of Positive Displacement Motor (PDM) bearings caused by particle accumulation. Furthermore, a high-efficiency Solids Control System can significantly inhibit the thermal degradation of mud additives and maintain stable rheology, thereby ensuring a consistent Rate of Penetration (ROP) and significantly extending the service life of mud pumps.
 
KOSUN Technical Expertise and Leadership in Solids Control Since 1992
 
As a leading global expert in solids control, KOSUN has been dedicated to the research, development, and innovation of drilling fluid circulation and purification technology since 1992. With over thirty years of industry experience, KOSUN provides expert-level customized solutions for diverse geological conditions worldwide.
KOSUN’s high-performance shale shakers utilize advanced linear motion technology to generate ultra-high G-forces, forcibly discharging large amounts of harmful solids during the primary purification stage. For extreme environments, KOSUN's Arctic Solids Control System solves the industry challenge of equipment operation at temperatures as low as -40°C. From early single-equipment manufacturing to today’s integrated, intelligent, and modular Solids Control System solutions, KOSUN, with its deep technical heritage accumulated since 1992, continues to empower global customers to achieve safe and efficient drilling in harsh climates and complex formations.