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The Mud-Gas Separator (MGS) is a critical component in well control for handling gas kicks. It is the primary device for separating liquid-gas mixtures in most well control events. Poor separator designs and inefficient separation of gases from liquids in the MGS have resulted in the loss of lives and equipment and adverse environmental effects. Thus, the safe and efficient separation of gases from gas-cut drilling fluids in the MGS is vital. The design and operational efficiency of the MGS depend on certain key elements in its sizing, such as the vent line length and diameter, vessel internal diameter, hydrostatic head of the mud seal, and the vent line back pressure, amongst others. These design considerations and the industrial standards and regulations governing them are hitherto not fully understood. As a result, there is an associated risk in the operation of the MGS. This paper aims to comprehensively review and analyze key sizing and design considerations for the Mud Gas Separator for both Conventional and Managed Pressure Drilling Operations. Furthermore, industry standards, best practices, guidelines, and regulations on MGS design and operations are also reviewed. This study uses two primary methodologies: an extensive literature review and a stakeholder engagement consultation to meet the stipulated objectives. The results indicate that the sizing and design of MGS depend on various factors such as well depth, pressure and temperature regimes, formation fluid, and completion fluid systems. The study's outcomes also indicate that existing industry standards and regulations provide sufficient guidelines for various sizing and design considerations. The study also presents an analysis of existing industry recommendations on MGS design and sizing for special wellbore conditions, formation properties, and unconventional drilling applications like managed pressure drilling (MPD). The study provides further understanding of the MGS sizing and design from industry stakeholders’ perspective to minimize well-control risks associated with MGS.
The Mud-Gas Separator (MGS) is a critical component in well control for handling gas kicks. It is the primary device for separating liquid-gas mixtures in most well control events. Poor separator designs and inefficient separation of gases from liquids in the MGS have resulted in the loss of lives and equipment and adverse environmental effects. Thus, the safe and efficient separation of gases from gas-cut drilling fluids in the MGS is vital. The design and operational efficiency of the MGS depend on certain key elements in its sizing, such as the vent line length and diameter, vessel internal diameter, hydrostatic head of the mud seal, and the vent line back pressure, amongst others. These design considerations and the industrial standards and regulations governing them are hitherto not fully understood. As a result, there is an associated risk in the operation of the MGS. This paper aims to comprehensively review and analyze key sizing and design considerations for the Mud Gas Separator for both Conventional and Managed Pressure Drilling Operations. Furthermore, industry standards, best practices, guidelines, and regulations on MGS design and operations are also reviewed. This study uses two primary methodologies: an extensive literature review and a stakeholder engagement consultation to meet the stipulated objectives. The results indicate that the sizing and design of MGS depend on various factors such as well depth, pressure and temperature regimes, formation fluid, and completion fluid systems. The study's outcomes also indicate that existing industry standards and regulations provide sufficient guidelines for various sizing and design considerations. The study also presents an analysis of existing industry recommendations on MGS design and sizing for special wellbore conditions, formation properties, and unconventional drilling applications like managed pressure drilling (MPD). The study provides further understanding of the MGS sizing and design from industry stakeholders’ perspective to minimize well-control risks associated with MGS.
A kick simulator was used to plan for well control situations on a deep high pressure well. Results from the simulations were used to identify requirements and modify rigsite well control procedures. The result of the work is safer rig-site operations at little extra cost. Extension of this work to well design in general suggests the potential for safer well operations and simultaneous cost savings.
This paper was pfepared for presentation at the 1SS4 lADC/SPE Drlliing Conference held in Dallas, Texas, 15-18 February 19S4.This papsr was selected for presentation by an IADC7SPE Program Committee followkq review of information contained in an abstract eubmiftad by the aUtfW(S). C0ntWW3Of the paper, as presented, have not been reviewed by the Scwiiy of Petroleum Engineam of the International Asacn?iatiinof OWing Contractors and are aubjecf to wrectii by the author(s). The material, as prasented, does not necessarily reflect any pc.e.iticm of the IADC or SPE, thair offiiers, or mambem, Papers fweaantad at IwSPE rnaatlngs are subject to publicafkm rwiaw by Editorial Commiffaes of the IADC and SPE. Permission to copy is restricted to an abatract of not more than 3Xl words. Illustrations may not be copied. The abSfr9Ct should contain conspicuous acknowledgment of where and by whom tha paper is prmentad. Write Librerian, SPE, PO, Eox SSSSSS,RiihardwJn, TX 75WS-SSSS, U.S.A. Te!ex, 16SS45 SPEUT. AbstractA gas kick is removed from a weiibore by appiyhig well control procedure. The large volume of flammable gas brought to the surface is directed toward the mud-gas separator, MGS, where it is separated from the mud and safely disposed of. However, the gas flow rate may become so large that the MGS overloads. Under these circumstances, significant amounts of hydrocarbon will be released onto the rig floor causing a risk of explosion. This situation poses a serious danger to rig personnel and equipment. Advanced gas kick simulators are now available that can predict the flow properties of the fluids entering the MGS as functions of time during the well control procedure. The availability of such detailed information presents an opportunity to understand the response of the MGS to well control procedure. This detailed information allows the d$%~iQpW.C%t Qf m.odeis Of the .MGS th~t~.d-iC! .MGSparameters with greater precision than existing methods will allow. In this paper, models of the physical processes that occur at the MGS are developed. These models have been combined to produce an algorithm which, together with simulated well control data, can estimate MGS parameters as functions of time during the well control procedure. This algorithm will be useful to office based drilling engineers preparing rig safety cases during the well planning stage of drilling a well. The use of this algorithm will result in better seiection Ofweil control procedure, MGS operation and sizing, and better contingency plans for altering the well control procedure or MGS operation should the need arise.
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