ENSCO Ensco 8505

HAMPCO H125 MUD GAS SEPARATOR OPERATING MANUAL SERIAL NUMBER HC1145-PV01

October 2010
FS52975 ISO9001

HAMPCO H125 MUD GAS SEPARATOR OPERATING MANUAL

SERIAL NUMBER: HC1145-PV01 TABLE OF CONTENTS SECTION 1
1.1 1.2 1.3 Function Principles of Operation Variation in Design

SECTION 2
2.1
2.1.1 2.1.2 2.1.3

Installation
Installation Procedures Hook Up Temperature and Pressure Monitoring

2.2
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5

Inspection and Maintenance

Hydrogen Sulphide Contamination Cleaning and Drainage Blast Chamber Material Thickness Checks Coating System Specification

SECTION 3
3.1 Drawing

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SECTION 1

1.1

Function
The Hampco H125 Mud Gas Separator (MGS) is of horizontal configuration to achieve substantially higher separation capacity than vertical units of similar size. It also incorporates special features to improve efficiency during well control operations and subsequent maintenance.

1.2

Principles of Operation
Drilling fluid returns through the choke & kill manifold during well control operations will contain formation liquids and gas in a complex multi-phase mixture whose behaviour is affected by the thermodynamic characteristics of its constituents. The MGS contains the drilling fluid returns in an enclosed positive-pressure environment allowing mud gas separation to occur. Separation is achieved by the agitation of the multi-phase fluid as it passes through a blast chamber and a series of internal slotted baffles. The Hampco MGS provides a large mud surface area which is the most influential variable in efficient mud gas separation. The capacity of the separator to handle gas is also determined by how quickly the vent line can handle the gas flow. The vent line creates a back pressure that is only counteracted by a hydrostatic liquid seal created via a dip-tube or U-tube arrangement. This seal capacity can be exceeded if the vent cannot accommodate the required gas flow and so the MGS internal pressure should be monitored and compared with the available liquid seal. This allows well kill operations to be controlled within the capacity of the separation system. The MGS is pressure rated to accommodate accidental filling of the vent line as a result of blockages in the mud return out of the MGS.

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1.3

Variation in Design
All Hampco mud gas separator vessels are built in accordance with ASME Boiler and Pressure Vessel Code, Section VIII, Division 1 with all material meeting the requirements of NACE MR-01-75 Standards for hydrogen sulphide service. These units are hydrostatically tested to 225 psi (15.51 bar) and have a calculated working pressure rating of 150 psi (10.34 bar). Any repair work involving cutting or welding on one of these pressure vessels must be done in compliance with all ASME Code requirements.

Baffle Plates

10in Vent Mud Seal Fill 8in Mud Outlet Drain or Instrument Nozzles Instrument Nozzles 8in Mud Inlet

Blast Nozzle

Hot Mud Injection

Figure 1 - Hampco H125 Mud Gas Separator

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SECTION 2
2.1
2.1.1

Installation
Installation Procedures The design of the supports, associated piping and their installations are outwith the scope of this manual, but general guidelines are described below.

2.1.2

Supports The Mud Gas Separator is usually supported by two saddles which would be welded or bolted to the existing rig structure. The estimated weight of the vessel when full of liquid at 1.4 SG is 7300Kg

2.1.3

Hook Up The feed line from the choke/kill manifold is connected to the 8 separator inlet connection. Mud is discharged from the separator via an 8" outlet which should lead to a dip tube or u-tube liquid seal and then directly to the shale shakers. The 10" flanged vent outlet on the separator should be connected to the vent line running to the top of the derrick.

2.1.4

Temperature and Pressure Monitoring Six (6) off, 2" ANSI 150lb flange nozzles allow for the installation of pressure and temperature sensors as specified by the client. See Figure 1, page 4.

2.2
2.2.1

Inspection and Maintenance

Hydrogen Sulphide Contamination Proper precautionary procedures must be exercised if H2S is suspected to be present in the vessel. The rig procedures relating to H2S hazards must be adhered to before carrying out any maintenance or service. In addition to being a health and safety hazard to personnel, H2S can cause material failure, and initiates corrosion. When exposure has not been sufficient to cause mechanical failure, some simple measures can be carried out to restore the separator to serviceable condition. The separator can be opened by unbolting the end plate and internally flushed or washed with water. All welds must be inspected by surface crack detection means in addition to visual. Coatings should be repaired in accordance with 2.2.5. Note: Gaskets are to be replaced whenever flanges are disconnected.

2.2.2

Cleaning and Drainage Any build up of solids at the baffle plates can be drained and flushed clean by removing the 2" ANSI 150lb blind flanges located in front of each baffle on the underside of the unit. The 2" inlet nozzle on the front manhole end plate flange may also be used for flushing/hot mud injection. A 4" nozzle located at the rear can be used for seal filling. See Figure 1, page 4.

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2.2.3

Blast Chamber The blast chamber can be inspected for any erosion or corrosion by removing the manhole end plate flange. Padeyes are fitted to the end cover and blast chamber to assist with this operation. Removable baffle plates allow full internal access to the vessel. Special attention should be paid to the blast tube and blast nipples as they are the principal components for overall efficiency of the separator. The blast chamber/nipple can be replaced or refurbished if required.

2.2.4

Material Thickness Checks The vessel and its internal components should be checked periodically to monitor and record the thickness of the various materials. The original and minimum thickness of each component is specified on Drawing Number 3585D013 contained in Section 3.

2.2.5

Coating System Specification Internal Surfaces Shotblast to SA 2.5 and apply the following coating system in accordance with the paint manufacturer's instructions using airless spray: Primer: Hempadur 85671-50900 (light red), 120 microns DFT. Mid-Coat: Hempadur 85671-11630 (off-white), 240 microns DFT. Top Coat: Hempadur 85671-50900 (light red), 360 microns DFT External Surfaces Shotblast to SA 2.5 and apply the following coating system in accordance with the paint manufacturer's instructions using airless spray: Primer: Hempadur 17630-19830 (light red) 75 microns DFT. Mid-Coat: Hempadur 45881-12170 (off-white), 280 microns DFT. Top Coat: Hempadur 55210-50800 (red), 320 microns DFT.

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SECTION 3
3.1 Drawing
Drawing Number 3585D013 Title Material Thickness Checks and Replacement Parts

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Hampco H125 Mud Gas Separator Operating Manual

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