THE SPE IMAGE LIBRARY SPE 20430

Mud/Gas Separator Sizing

and Evaluation

20430

MacDougall, G.R., SPE,

Chevron Canada Resources Ltd.

December 1991

Summary. Recent wellsite disasters have led to an increased emphasis

on
properly sized mud/gas separators. This paper reviews and analyzes
existing
mud/gas separator technology and recommends separator configuration,
components, design considerations, and a sizing procedure. A simple
method
of evaluating mud/gas separation within the separator vessel has been
developed as a basis for the sizing procedure. A mud/gas separator
sizing
worksheet will assist drilling personnel with the sizing calculations.
The
worksheet provides a quick and easy evaluation of most mud/gas
separators
for a specific well application. A brief discussion of other mud/gas
separator considerations is provided, including separator components,
testing, materials, and oil-based-mud considerations.

Introduction

The mud/gas separator is designed to provide effective separation

of the mud and gas circulated from the well by venting the gas and
returning the mud to the mud pits. Small amounts of entrained gas
can then be handled by a vacuum-type degasser located in the mud
pits. The mud/gas separator controls gas cutting during kick
situations, during drilling with significant drilled gas in the mud
returns, or when trip gas is circulated up.

This paper discusses design considerations for mud/gas

separators. The purpose of this paper is to allow drilling rig
supervisors
to evaluate mud/gas separators properly and to upgrade (if required)
the separator economically to meet the design criteria outlined in
this paper, and to provide office drilling personnel with guidelines
for designing mud/gas separators before delivery at the drillsite.

Principle of Operation

The operating principle of a mud/gas separator is relatively

simple. The device is essentially a vertical steel cylindrical body
with
openings on the top, bottom, and side, as shown in Fig. 1. The
mud and gas mixture is fed into the separator inlet and directed
 THE SPE IMAGE LIBRARY SPE 20430

at a flat steel plate perpendicular to the flow. This impingement

plate minimizes the erosional wear on the separator's internal walls
and assists with mud/gas separation. Separation is further assisted
as the mud/gas mixture falls over a series of baffles designed to
increase the turbulence within the upper section of the vessel. The
free gas is then vented through the gas vent line, and mud is returned

to the mud tanks.

Operating pressure within the separator is equal to the friction

pressure of the free gas venting through the vent line. Fluid is
maintained at a specific level (mud leg) within the separator at all
times.
If the friction pressure of the gas venting through the vent line
exceeds the mud-leg hydrostatic pressure within the separator, a
blow-through condition will result sending a mud/gas mixture to the
mud
tanks. As one can readily see, the critical point for separator
blow-through exists when peak gas flow rates are experienced in the
separator. Peak gas flow rates should theoretically be experienced
when gas
initially reaches the separator.

Types of Mud/Gas Separators

Three types of mud/gas separators commonly are used today: closed

bottom, open bottom, and float type. The principle of mud/gas
separation within each type of vessel is identical. Differences can be

found in the method of maintaining the mud leg, as discussed

below.

The closed-bottom separator, as the name implies, is closed at

the vessel bottom with the mud
tanks, as shown in Fig. 1. Mud
by installation of an inverted
Fluid level can be adjusted by
the U-shaped bend.
return line directed back to the mud
leg is maintained in the separator
U-shaped bend in the mud return line.
increasing/decreasing the length of

Commonly called the poor boy, the open-bottom mud/gas

separator is typically mounted on a mud tank or trip tank with the
bottom of the separator body submerged in the mud, as shown in
Fig. 2. The fluid level (mud leg) in the separator is controlled by
adjusting the fluid level in the mud tank or by moving the
separator up or down within the tank. Mud-tank height can restrict the

maximum mud leg obtainable for open-bottom mud/gas separators.

Fluid level (mud leg) is maintained in a float-type mud/gas

separator by a float/valve configuration, as shown in Fig. 3. The
float opens and closes a valve on the mud return line to maintain
the mud-leg level. Valves can be operated by a manual linkage
system connected from the float to the valve, or the valve can be
air-operated with rig air. Mud-leg height can be controlled by
adjusting the float assembly.
 THE SPE IMAGE LIBRARY SPE 20430

There are some inherent problems in the use of float-type mud/gas

separators. The manual linkage separator has experienced
problems with linkage failure resulting in improper opening or closing

of the mud-return-line valve. Air-operated valves fail to function

if rig air is lost, resulting in no control of fluid level within the
separator. Mud-return-line valves are prone to plug with solids,
preventing mud flowback to the mud pits.

Because of these problems, float-type mud/gas separators are not

recommended and a closed-bottom separator is preferred.
Open-bottom separators are acceptable; however, one should be aware
that they are restricted to a maximum mud leg, somewhat lower
than the mud-tank height. Although float-type mud/gas separators
are strongly discouraged, these separators can be modified easily
for disconnection of the float, removal of the valve, and
installation of a mud leg in the mud return line.

For the purpose of this paper, a closed-bottom mud/gas

separator will be considered for all separator designs.

Sizing the Mud/Gas Separator

Table 1 shows a mud/gas separator worksheet to assist with the

sizing calculation. The mud/gas separator illustrated in Fig. 4 will
be evaluated for sufficient sizing in this paper.

Peak Gas Flow Rate. As discussed previously, the critical time

for separator blow-through exists when peak gas flow rates are
experienced. Mud/gas separator blow-through is defined as inefficient
separator operation resulting in a mud/gas mixture returning to the
mud tanks through the mud return line.

Two situations can cause separator blow-through.

1. Friction pressure of the gas venting through the vent line

exceeds the mud-leg hydrostatic pressure, resulting in evacuation
of
fluid from the separator. Friction pressure of the mud through
the
mud return line is considered negligible because of its short
length.

2. Vessel ID is too small, causing insufficient retention time for

the
gas to separate efficiently from the mud. This situation is
commonly called insufficient separator cut.

To estimate a peak gas flow rate properly, we must consider a

"typical" kick. The typical kick will depend on the well location,
depth, type size, and component ratios of influx. Kick data should
be based on previous offset well data and should be a realistic
worst-case gas kick. The well and kick data in Fig. 5 will be used in
this
paper.
 THE SPE IMAGE LIBRARY SPE 20430

The volume and pressure of the gas upstream of the choke must
first be calculated.

SPEDE

P. 279