Mud gas separators are designed in such a way that mud and gas are effectively separated from well return fluid. The mud gas flow rate into the MGS fluctuated during the operation of gas kick circulation. It may grow to such a size that the mud gas separator is unable to adequately separate the fluids; in this case, the mud gas separator is referred to as an overloaded mud gas separator.

To operate the MPD, the well must be drilled closed-loop, a rotating control device must be installed on the return line, and an accurate mass flow metre must be fitted. A suitable mud gas separator must be fitted downstream of the choke manifold on the returned line. Depending on the operator’s procedure, the fluid coming from the well can be routed directly to the shaker until the gas ratio exceeds a certain limit. Returns can be diverted to the Mud Gas Separator, which separates the gas and transports it to the flare stack.

Managed pressure drilling (MPD) has been demonstrated to improve drilling operations in the conventional, narrow margin, high-pressure high temperature (HPHT), and, in particular, deepwater operations. Its success does not come easily, as the technical challenges the conventional drilling paradigm along with drilling contractors and operators’ policies and standards. The differences between conventional drilling techniques and MPD necessitate an understanding of how MPD equipment and practices coexist with and complement the equipment on a drilling rig. The addition of MPD equipment to a rig is intended to improve the primary barrier envelope without requiring secondary barrier equipment.

The primary distinction between MPD and traditional drilling is the addition of a “closed-loop” circulation system to the rig equipment, as opposed to the “open-loop,” or atmospheric system found on normal rigs.  MPD drilling requires a significant amount of gas to be drilled. Separators are utilised in these circumstances to separate the gaping pockets of free gas from the mud system. The MGS must be built to operate in a regulated manner. The Mud Gas Separators are classified into two types: atmospheric and pressurised. The atmospheric separator is standardised in design and is referred to as a “Poor-boy” or “gas buster” separator. The primary advantage of atmospheric MGS is that it simplifies operations by eliminating the requirement for control valves on both the mud and gas discharge lines. The pressurised MGS is meant to operate in conjunction with a moderated backpressure. To mitigate the possibility of high-level pressure in the pressurised MGS, the vent line length should be built using specialised equipment. Both MGS designs have as their primary objective the ventilation of the gas and the safety of the drilling fluid. Volume is also a major consideration during the design process. Due to the fact that more mud volume is required to mitigate the risk associated with gas circulation. When the complete amount of mud in the scenario is gone, the volume of the surface must be replenished with additional mud. In certain instances, a limited supply of mud will be delivered. The MGS should be able to salvage the massive amount of mud/gas.

The older MGS design is a small and short mid seal that is still visible on the internet search engine. The vent line can require the separation and parting capacities that beat their blowdown volume or capacity. This separator will have little gas maintaining volumes and capacities. At Kapwell, we make certain that the MGS is built and sized with improved fluid turbulence and the greatest retention time to cause the breaking out of drilling fluid.

For more information, contact Kapwell representative via email or call on 01224 969 262


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