Intro

MUD GAS SEPARATOR SIZING PROGRAMS

AEA method to caclulate

Mud carry over rate Mud carry over rate Liquid carry over rate
Mud gas separator
curve calculations curve
capacity

Simple method to calculate

Simple Method
Mud Gas Separator
Principals of Operation
Capacity

Page 1
 Intro

Liquid carry over rate

curve

Page 2
 Liquid Carry Over Curve
Zs 0.84 Ts 518.4 Rankine Rgas 0.00718 ppg
Tstd 560 Rankine Pstd 14.696 psia Rliquid 10 ppg
Pchoke 3000 psia Dsep 4 ft H 9 ft
Zstd 1 Dinlet 6 in

Mud Carry Over Rate (Vol Fraction & Circ Rate)

Mud Carry Over Rate for Qcirc

Fmud 3 6 9 12 15 18
5 0 0 0 0 0 0 0
0.05 2.7552E-09 0.00213 0.065636 0.2451 0.467917 0.685071
0.10 9.5253E-08 0.008409 0.164942 0.539003 0.980082 1.405217
0.15 3.9923E-07 0.015197 0.256732 0.812774 1.467968 2.102555 3 bbl/min
40.20 7.722E-07 0.020322 0.329392 1.049382 1.914143 2.761558 6 bbl/min
Mud Carry Over Rate bbl/min

0.25 9.8094E-07 0.022923 0.37778 1.237968 2.304641 3.368096 9 bbl/min

0.30 9.345E-07 0.02294 0.399885 1.369931 2.62532 3.906122 12 bbl/min
0.35 7.0466E-07 0.020796 0.395984 1.438405 2.861071 4.356338 15 bbl/min
30.40 4.2724E-07 0.017185 0.368414 1.438774 2.996041 4.695418 18 bbl/min
0.45 2.0636E-07 0.012902 0.321477 1.369773 3.014753 4.895796
0.50 7.693E-08 0.008694 0.261241 1.234959 2.904406 4.926541
0.55 2.0883E-08 0.005141 0.195108 1.044274 2.658697 4.756295
0.60 3.7494E-09 0.002571 0.131034 0.815215 2.283335 4.359842
2
0.65 3.8028E-10 0.001022 0.076364 0.572798 1.802679 3.730077
0.70 1.6659E-11 0.000291 0.036351 0.347268 1.265464 2.896132
0.75 1.9358E-13 4.9E-05 0.012664 0.168457 0.745269 1.944336
0.80 2.2405E-16 3.33E-06 0.002588 0.056262 0.328792 1.02949
10.85 2.6164E-21 3.72E-08 0.000185 0.009111 0.083737 0.349581
0.90 3.1892E-31 4.61E-12 9.72E-07 0.000249 0.005645 0.041331
0.95 4.7715E-61 8.82E-24 1.54E-13 5.83E-09 2.02E-06 8.03E-05
0.99 6.605E-300 1.7E-117 9.12E-68 9.39E-46 1.16E-33 3.91E-26
0
0 0.2 0.4 0.6 0.8 1 1.2

Vol Fraction of Mud

Liquid Carry Over Model (AEA)

Fmud 0.3 (1  Fm ud )Q c irc ZsTstdPc hoke

Qcirc
Zs
5
1
bbls/min
Qgas 
Tstd 560 Rankine 123 . 7Zstd TsPstd
Pchoke 3457.72 psia
Zstd
Ts
1
518.4 Rankine
where
Pstd 14.696 psia

Qgas 7.19 MMSCFD

Fm ud = Vol Fraction M ud upstream of Choke
M 1.5 bbls/min
Qc irc = Circulation Rate - bbl / min
Dsep 4 ft
Zs = Gas Compressibility Upstream of Choke
Ts = Gas Temperature Upstream of Choke -
Dinlet 6 in
Rgas 0.00718 ppg Rankine
Rliquid 16.5 ppg
H 4 ft
Pc hoke  Pressure Upstream of Choke - psia
A= 2.97612126
Zstd = Gas Compressibility at standard conditions
Qliq 0.076485 bbls/min
Tstd = Temperature at standard conditions - Rankine

Pstd = Pressure at standard conditions - psia

0. 0118 Dinle tH 0,6 liq 0.5

A  Q gas   Q gas 
D sep M gas    2.24  2 
0.9 0.35 0.5

Dsep  Dsep 
2

Where
M= M ud Carrry Over rate - bbls / min

= Fm ud  Q c irc

Dsep = Separator Diameter - ft

Dinle t = Inlet Diameter - in

gas = Gas Density - ppg

 0. 0118 Dinle tH liq
A
 Q gas   Q gas 
D sep M gas    2.24  2 
0.9 0.35 0.5

Dsep  Dsep 
2

Where
M = M ud Carrry Over rate - bbls / min

= Fm ud  Q c irc
Dsep = Separator Diameter - ft

Dinle t = Inlet Diameter - in

gas = Gas Density - ppg

 liq = Liquid Density - ppg

H = Height between inlet & Outlet - ft
Qgas = Gas Flow Rate = MMSCFD
Qliq = Liquid Carry Over - bbls / min
= M  (Exp  A)
 d)Qc irc ZsTstdPc hoke
. 7Zstd TsPstd

ion M ud upstream of Choke

n Rate - bbl / min

essibility Upstream of Choke

erature Upstream of Choke - Rankine

e Upstream of Choke - psia

pressibility at standard conditions

ure at standard conditions - Rankine

at standard conditions - psia

0. 0118 Dinle tH 0,6 liq 0.5

 Q gas   Q gas 

3
35
gas 
0.5
  2.24  2   
D sep
2
 D sep  

rrry Over rate - bbls / min

Q c irc

r Diameter - ft

meter - in

nsity - ppg
 0. 0118 Dinle tH liq
 Q   Q 
3

gas    2.24  2  
35 0.5 gas gas

Dsep 
2
Dsep  

rrry Over rate - bbls / min

Q c irc
r Diameter - ft

meter - in

nsity - ppg

Density - ppg

etween inlet & Outlet - ft

w Rate = MMSCFD

Carry Over - bbls / min

(Exp  A)
 Liquid Carry Over Curve Generator
Zs 0.84 Ts 518.4 Rankine Rgas 0.00718 ppg
Tstd 560 Rankine Pstd 14.696 psia Rliquid 14 ppg
Pchoke 3000 psia Dsep 4 ft H 4 ft
Zstd 1 Dinlet 6 in

Minimum SCR Rate for Range 5.00 bbl/min

Liquid Carry Over Curves for range of SCR

0.045
Mud Carry Over Rate for Qcirc
Fmud 5.0 5.1 5.2 5.3 5.4 5.5
0.04
0 0 0 0 0 0 0
0.05 0.00134592 0.001677 0.002068 0.002527 0.00306 0.003674
0.035
0.10 0.0057398 0.00692 0.008274 0.009814 0.011555 0.01351
0.15 0.01086821 0.012942 0.015293 0.01794 0.020903 0.024199
Liquid Carry Over Rate bbls/min

0.20 0.0150974 0.017885 0.021032 0.024562 0.028497 0.03286 5.0

0.03
0.25 0.01765285 0.020884 0.024529 0.028615 0.033169 0.038216
5.1
0.30 0.01832596 0.021707 0.025527 0.029816 0.034605 0.039921
5.2
0.025
0.35 0.01727944 0.020534 0.024225 0.028384 0.033042 0.038231
0.40 0.0149133 0.017815 0.021122 0.024868 0.029084 0.033805 5.3
0.45 0.01175849 0.014148 0.01689 0.020018 0.023564 0.027558 5.4
0.020.00838121 0.010181 0.012266
0.50 0.014665 0.017408 0.020524 5.5
0.55 0.00529158 0.006508 0.007935 0.009595 0.011515 0.013719
0.60 0.0028593 0.003574 0.004426
0.015 0.005432 0.006612 0.007986
0.65 0.0012491 0.001595 0.002017 0.002525 0.003132 0.003852
0.70 0.00040023 0.000527 0.000685 0.000881 0.001121 0.001413
0.017.8767E-05 0.000108 0.000146
0.75 0.000196 0.000258 0.000337
0.80 6.663E-06 9.75E-06 1.4E-05 1.99E-05 2.78E-05 3.83E-05
0.85 1.051E-07 1.71E-07 2.74E-07
0.005 4.28E-07 6.58E-07 9.92E-07
0.90 2.5163E-11 5.11E-11 1.01E-10 1.92E-10 3.57E-10 6.47E-10
0.95 3.2547E-22 1.28E-21 4.73E-21 1.65E-20 5.46E-20 1.72E-19
0.99 02.155E-109 1.7E-106 9.8E-104 4.3E-101 1.44E-98 3.8E-96
0 0.2 0.4 0.6 0.8 1 1.2
Volume Fraction of Mud From Choke
 Pricipal of Oper.

Simple Method - Principal of Operation

Vent

Inlet

Mud Seal Height

Mud gas separators are sized based on the lesser of two calculated capacities. These are the Separation Capacity, and
the Blowdown capacity

Separation Capacity
The separation capacity is based on vertical gravity separation. That is, the capacity is reached when the upward vertical
gas velocity exceeds the terminal falling velocity of a drop of liquid. Gas rates higher than the falling
velocity of liquid drops will carry liguid out the top. This capacity can be calculated using "Stokes Law"
1/ 2
ρ Mud − ρ Gas
V MAX= K
( ρ Gas )
Where

V MAX =Maximum allowable gas velocity ( API-12J )

K = Allowable velocity contstant

= 0 .12 - 0 . 24 for height of 5 ft
= 0 .18 - 0 . 35 for height of 10 ft
= usually use 0 . 15

ρ Mud = Mud density

ρ Gas = Gas density

The worst case mud density is considered to be 0.7 SG (represents oil/condensate).
The gas density is for a 0.7 SG gas (i.e. methane/ethane gas) at the operating pressure of the system. Gas density is
affected by the operating pressure of the separator. This program corrects the gas density to the pressure
available from the full liquid seal. This is a higher pressure than the separator will be actually operating at, but is
considered "worst case"

Blowdown capacity
The blow down capacity can be defined as the gas vent rate at which the vent line pressure drop exceeds the
Hyfrostatic head due to the mud seal. The mud seal hydrostatic head is dependent upon the density of fluids in the seal.
The blowdown capcity can be calculated by the following equation.

5 1 /2
( P12 − P2 2 ) d
)( )
T SC
Q sc = K
( P SC fd Gas <m Z m

Where

Q sc = Maximum allowable gas velocity ( SCF/d )

K = Gas Constant 38 . 774
Tsc = 60 0 F = 520 0 R
PSC = 14 .7 psia
f = Friction factor » . 006
T m = Mean temperature R
Z m = Compressibility 1 . 0
d Gas = Gas Specific Gravity
d = ID inches
L = Miles
P1 = Separator pressure
P2 = Exhaust pressure = 14 . 7 psia
Here, the separator pressure is the maximum available head due to the liquid seal height. The worst case fluid head
will come when the seal is provided by a 0.7 SG liquid (condensate/oil) and will have a gradient of 0.3 psi/ft.

Tank mounted mud gas separators using a dip tube seal may rely on a higher seal fluid gradient providing the tank
is continuously circulated with mud at at rate sufficient to dilute any kick liquids.

If a U-Tube seal is used, a gradient higher than 0.7 SG (0.3 psi/ft) can be used only if there is continuous injection
of fresh mud into the separator.

The Health and Safety Executive (Safety Notice 11/90) suggest that the liquid outlet line should be sized
to handle a minimum gravitational rate from the separator at 3 m^3/ min (6.3 bbl/min) of 1.44 SG (12 ppg) mud
of average viscosity.
Page 9
 ATMOSPHERIC MUD-GAS SEPARATOR EVALUATIONS

Blue numbers indicate where inputs are required

Black numbers indicate intermediate calculated values
Red numbers indicate output values

Suggested
Mud Gas Separator Details Suggested Criteria Value Base Case Sensitivity Cases

Separator Capacity Calculation

Separator type Vertical Vertical Vertical Vertical
Separator internal diameter (ins) 47.25 47.25 47.25 47.25
Liquid phase density (lb/ft^3) (0.7 SG for condensate) 43.68 43.68 43.68 43.68 43.68
Gas phase density (lb/ft^3) (.7 SG gas at sep pressure (Calc'd)) 0.0708 0.0708 0.0621 0.0589 0.0552
K (ft/s) .18 for vertical > 10 Ft high 0.18 0.18 0.18 0.18 0.18
Maximum allowable gas velocity (ft/s) 4.47 4.77 4.90 5.06
Separator flow area (ft^2) 12.18 12.18 12.18 12.18
Separation capacity (MMSCFD) 4.70 5.02 5.15 5.32

Blow-down capacity Calculation

Vent line internal diameter (in) 10.00 10.00 10.00 10.00
Vent line length (ft) 229.2 229.2 229.2 229.2
Height of liquid seal (ft) 15.91 7.92 5.00 1.67
Mean temperature of vent line (°F+460) 520.00 520.00 520.00 520.00
Standard temperature (°F+460) 530 530.00 530.00 530.00 530.00
Gas specific gravity 0.7 0.700 0.700 0.700 0.700
Mean compressibility factor 1 1.00 1.00 1.00 1.00
Friction Factor 0.006 0.0060 0.0060 0.0060 0.0060
Pressure at standard conditions (psia) 14.65 14.65 14.65 14.65 14.65
Pressure at end of vent line (psia) 14.65 14.65 14.65 14.65 14.65
Pressure inside separator (psia) uses 0.7 SG liquid unless constant mud column 19.42 17.03 16.15 15.15
Blow-down capacity (MMSCFD) 18.36 12.49 9.79 5.56

Mud Gas Separator Gas handling capacity (MMSCFD) 4.70 5.02 5.15 5.32
This is the lesser of the Blowdown Capacity and the Separation Capacity

Other Input data Required

Tank Diameter (ft) 4.00 4.00 4.00 4.00
Plate Thickness (in) 0.38 0.38 0.38 0.38
Mud seal Height (in) 190.90 95.00 60.00 20.00
Vent Pipe inner Diameter (in) 10.00 10.00 10.00 10.00
Vent Pipe Length (ft) 175.00 175.00 175.00 175.00
Number of bends in vent line 5.00 5.00 5.00 5.00
Increase in equivalent length of vent 54.17 54.17 54.17 54.17
For common smooth radius 90 Ells, (where 1.<r/D<4 ) each bend adds a pressure drop equivalent to 13 lenghts of pipe
diameter (Crane Co. Flow of fluids pp-27)
 AEA Method for Degasser Evaluation

1 Influx Height
Vbh 50 bbls Vbh
Hb 
Vann 0.0459 bbl/ft Vann
Hb 1089.32461874 ft

2 Influx gradient - psi/ft

Pd 843 SIDPP - psi
Pa 1589.1874 SICP - psi  Pd  ( mD)    Pa  ({D  Hb}m )
Rm 0.858 Mud Grad - psi/ft f 
Hb
D 16500 Well Depth - ft
Rf 0.173 psi/ft

3 Maximum Casing Pressure - psi

Tb 810 Rankine
 Pd  mD  Dm  fHb Pd  mD  D m  fHb  
2

Ts 560 Rankine
p max   
Zb 1 2  4
Zs 1 
Pmax 3457.7169 psi

4 Friction Factor - f
e 0.019685 Roughness (in)    
2

f  4.0 log 10 

d(D) 8 Vent Line Diameter (in)  3.7D
f 0.00619159953

5 Gas Vent Rate

Fmud 0.001 (1 Fm ud)Qcirc ZsTstdPc hoke
Qcirc 3.24 bbls/min Qgas 
123. 7ZstdTsPstd
Zs 1
Tstd 560 Rankine
Pchoke 3457.72 psia
Zstd 1
Ts 518.4 Rankine
Pstd 14.696 psia
Qgas 6.65 MMSCFD

6 Vent Line Exit Pressure - P1

14.696 14 .696
2
 TQ 2
gas s gas
2

V 201 Overall Vent Line Length 

P1(ft)   1. 06 4
2 4 D
Rgas 0.7 rel to air
P1 14.9733939216 psi

0 .5
100.6Q gas fρ gas VZ std T s
( [ ])
2
7 Vent Line Entrance Pressure - P2 P 2= P 1 +2

P2 16.8974790206 psi D5

 2

8 Separator Pressure - Psep 1.06TsgasQgas2 
Psep  P 2   
Psep 17.1432866026 psi  P2 D 4 
 9 Liquid Carry Over Rate
M 0.00324 bbls/min A
0. 0118 Dinle tH liq
0,6 0.5

 Q gas   Qgas 3 

Dsep 4 ft Dsep M gas 0.5 
0.9 0.35
 2  2.24  2   
Dsep  Dsep  
Dinlet 6 in
Where
Rgas 0.00718 ppg M= Mud Carry Over rate - bbls / min
Rliquid 16.5 ppg = Fm ud  Q c irc

H 4 ft Qliq = Liquid Carry Over - bbls / min

= M  ( Exp  A)
A= 28.8796663398
Qliq 9.29534E-16 bbls/min

Two Phase Equations

10 Reynolds Number
R 1.0190329E-12 11.41 fVliq Q liq 2
Pl  5
D
f 0.00046870215
¯Pg 2.20147902058 psi
¯Pl 4.6767399E-34 psi
¯Ptp 2.20147902058 psi
Ptp  Pg  Pl  20  PgPl 

11 Two Phase Gravitational Pressure Loss - Pgr

X 1.4575194E-17 tp   liqliq  (1 liq )gas
aliq 8.1489698E-15
Rtp 0.00718 2 phase ppg
Pgr 0.074901042 psi

12 Total Two Phase Vent Lin e Pressure Drop = ¯Ptot Pgr  0.0519 tpV
¯Ptot 2.27638006258 psi
Ptot  Pgr  Ptp

13 Blowdown Capacity
Single Phase Flow
Eq H Seal 8.15762200862 ft Psep  Pstd
With SF of 2 16.3152440172 ft Eq H Seal 
2 Phase Flow
0.3 psi / ft
Eq H Seal 7.58793354192 ft
With SF of 2 15.1758670838 ft

Separator Capacity
API K factor 0.18 m ud  gas0.5
Vm ax  K  
Asep 12.5663706144 ft2  gas 
Fluid ppg 8.33 ppg
Vmax 6.1283778475 ft/sec
Q  0.0864 Ase pVm ax
Q 6.65 MMSCFD
Safety factor 1.25
Qsafe 5.32 MMSCFD