A Programmable Logic Controller provides the automation backbone for modern shale shaker systems, enabling automated startup sequences, condition monitoring, alarm management, and integration with the rig control network. PLC control transforms the shale shaker from a standalone piece of mechanical equipment into an intelligent component of the drilling control system, providing operators with real-time data and automated responses that improve both safety and performance. Aipu Solids Control offers PLC-based control systems for its Hunter series shaker range, drawing on over 15 years of automation engineering experience and API Q1 certified manufacturing processes at the 50,000 square meter Xi’an facility.
PLC Architecture and Control Functions
The Aipu PLC system for shale shakers is built on industrial-grade controller platforms from leading automation manufacturers, selected for reliability in the vibration, temperature, and electrical noise environment of drilling operations. The PLC monitors motor current, vibration levels, bearing temperatures, and run status for each motor on the shaker, providing continuous oversight of equipment health. Control functions include sequenced motor starting with time delays between multiple motors to reduce peak electrical demand, automatic shutdown on detection of excessive vibration indicating a mechanical fault, and interlocking with upstream and downstream solids control equipment. For the Hunter-MG4D double-deck configuration with 5.4 square meters of total screen area processing up to 280 cubic meters per hour, the PLC manages independent monitoring of upper and lower deck motors with configurable alarm thresholds for each. The control logic includes a maintenance hour counter that tracks operating time for each motor, triggering alerts when scheduled lubrication or inspection intervals are reached. All PLC logic undergoes factory acceptance testing at the Xi’an facility, with simulation of normal operating conditions and fault scenarios to verify correct response before the system is shipped.
Integration and Remote Monitoring Capabilities
Beyond local control, the Aipu PLC system provides communication interfaces for integration with higher-level control systems. Standard industrial protocols including Modbus TCP/IP, Profibus, and EtherNet/IP enable data exchange with the rig control system, mud logging unit, and company man’s display. Critical parameters such as shaker run status, motor current, and alarm conditions are transmitted in real time, keeping the driller and mud engineer informed of solids control system status without requiring physical inspection of the shaker area. The PLC data can also be routed to a remote monitoring platform via cellular or satellite connection, enabling off-site technical support and performance analysis. For the Hunter-MG4T tandem configuration with 8.1 square meters and 420 cubic meters per hour capacity, the PLC provides coordinated control of all motors with synchronized monitoring across the shaker installation. Aipu has deployed PLC-controlled shale shakers in more than 30 countries, with field experience demonstrating that automated control and monitoring improves both safety through reduced personnel exposure to the shaker area and performance through consistent operation within optimal parameters.
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