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OPERATING & SERVICE MANUAL
P. O. Box 42842 Houston, TX 77242-2842 Global Sales/Technical Support Tel: 281-988-1866 Fax: 281-988-1889 1-800-654-0660
MANUAL PART #90-90-615 (REV. B)
MUD GAS SEPARATOR FOR ASSEMBLY
9620244
ii
DISCLAIMER
Recommendations made by M-I Swaco are advisory only. M-I Swaco shall not be liable under any guarantees or warranties, expressed or implied, in any manner or
form, AND ALL WARRANTIES, EXPRESSED OR IMPLIED, ARE HEREBY SPECIFICALLY EXCLUDED, and M-I Swaco shall not be liable for the failure to obtain any particular results from the use of any recommendation made by it or from the use of this material. In no event shall M-I Swaco be liable for incidental or consequential
damages.
iii
TABLE OF CONTENTS
SECTION 1 INTRODUCTION..................................................................................... 1
FIGURE 1. TYPICAL INSTALLATION VIEW............................................................. 2
SECTION 1.1 SYMBOLS............................................................................................... 3
SECTION 2 PRINCIPALS OF OPERATION............................................................... 4
SECTION 2.1 DESIGN .................................................................................................. 5
SECTION 2.2 OFFSHORE MUD GAS SEPARATOR ................................................... 5
FIGURE 2. OFFSHORE MUD GAS SEPARATOR VIEW ......................................... 6
SECTION 2.3 PERIODIC NONDESTRUCTIVE TESTING ............................................ 7
SECTION 3 DESCRIPTION........................................................................................ 8
SECTION 3.1 SPECIFICATIONS .................................................................................. 8
SECTION 3.2 DRAWINGS ............................................................................................ 9
FIGURE 3. TOP VIEW............................................................................................... 9
FIGURE 4. FRONT VIEW........................................................................................ 10
FIGURE 5. END VIEW ............................................................................................ 11
FIGURE 6. DETAIL A VIEW.................................................................................... 12
SECTION 3.3 VARIABLE HEIGHT CHART................................................................. 13
SECTION 3.4 NOZZLE SCHEDULE ........................................................................... 14
SECTION 4 INSTALLATION..................................................................................... 15
SECTION 4.1 PREPARATION .................................................................................... 15
SECTION 4.2 ERECTING THE VESSEL..................................................................... 15
FIGURE 7. ERECTING THE VESSEL VIEW .......................................................... 16
SECTION 4.3 CONNECTING MUD GAS SEPARATOR ............................................. 17
SECTION 5 OPERATION......................................................................................... 19
SECTION 5.1 FLOW LINE OPERATION..................................................................... 19
SECTION 5.2 BACK PRESSURE VALVE ASSEMBLY (OPTIONAL) ......................... 19
SECTION 6 MAINTENANCE.................................................................................... 20
SECTION 6.1 H2S PRECAUTIONS............................................................................. 20
SECTION 6.2 PREPARATION FOR EMERGENCY HOT WORK REPAIR................. 21
SECTION 6.3 GENERAL............................................................................................. 21
SECTION 6.4 EFFECTS OF CHANGING LINKAGE ARMS........................................ 23
FIGURE 8. CHANGING LINKAGE ARM VIEW ....................................................... 23
iv
SECTION 6.5 NOSE CONE ALIGNMENT................................................................... 25
FIGURE 9. FLOAT VALVE LINKAGE VIEW ........................................................... 25
FIGURE 10. FLOAT ARM & VALVE STEM ADAPTOR VIEW .................................. 26
SECTION 6.6 PRESERVATION.................................................................................. 27
SECTION 7 TROUBLESHOOTING .......................................................................... 28
SECTION 8 SPARE PARTS..................................................................................... 30
SECTION 9 DRAWINGS AND PARTS LIST ............................................................ 31
FIGURE 11. VESSEL ASSEMBLY TOP VIEW ......................................................... 31
FIGURE 12. VESSEL ASSEMBLY FRONT VIEW .................................................... 32
FIGURE 13. VESSEL ASSEMBLY DETAIL B VIEW................................................. 32
FIGURE 14. PARTS LIST FOR 9620244 .................................................................. 33
SECTION 9.1 DRAWINGS AND PARTS LIST FOR DUMP VALVE............................ 34
FIGURE 15. FLOAT-OPERATED DUMP VALVE VIEW............................................ 34
FIGURE 16. PARTS LIST FOR FLOAT-OPERATED DUMP VALVE........................ 35
SECTION 9.2 DRAWINGS PARTS LIST BACK PRESSURE MANIFOLD .................. 36
FIGURE 17. BACK PRESSURE MANIFOLD VIEW .................................................. 36
FIGURE 18. PARTS LIST FOR BACK PRESSURE MANIFOLD .............................. 37
APPENDIX A BACK PRESSURE VALVE ................................................................... 38
APPENDIX B TECHNICAL BULLETIN 152 (PURGE PROCEDURES) ...................... 39
1
SECTION 1 INTRODUCTION
The M-I Swaco Mud Gas Separator (MGS) is designed to provide effective surface control of mud and gas circulated from a well. “Free” gas can be vented to a safe point well away from the rig and mud can be returned to the pits in a controlled flow without “heads” of gas. Gas entrained in the mud as small bubbles can then be removed by the MI Swaco Degasser.
The MGS is especially important and necessary when large volumes of hydrogen sulfide are present in the returning mud and/or gas. If hydrogen sulfide is released to the atmosphere at the flow line and shaker, an extremely hazardous working condition will exist for rig personnel. Most of these toxic gasses are safely removed in the MGS and vented to the flare pit where they are burned. The remainder should be removed by the MI Swaco Degasser.
Another important use of the MGS is the handling of “trip gas”. When the quantity of gas carried to the surface is not enough to unbalance the mud column or to require circulating through a choke, drilling can continue by using a drilling head (to keep the gas from the rotary table area) and using the MGS to take the flow from the flow line manifold as shown in FIGURE 1 TYPICAL INSTALLATION VIEW on page 2.
With the protection given by the proper operation of the MGS and with good adjustable chokes, it is often safe to carry a smaller margin of excess mud hydrostatic head than would be possible otherwise and to benefit from faster drilling rates made possible by the decreased hydrostatic head.
2
FIGURE 1. TYPICAL INSTALLATION VIEW
3
SECTION 1.1 SYMBOLS
Instructions in the Operating Manual which concern operating safety are emphasized as follows:
This symbol draws attention to the safety measures to prevent personal injury.
ATTENTION !
This symbol draws attention to the safety measures that must be observed to prevent damage to the equipment.
NOTE:
This note draws attention to the general operating notes that should be especially observed.
The symbols shown on the packing should be noted. Their significance is as follows:
4
SECTION 2 PRINCIPALS OF OPERATION
The returns from a well include any gas and/or formation liquids which have entered the hole along with the mud. As the gas is circulated to the surface, smaller bubbles enlarge as the pressure reduces and these frequently accumulate in “heads” or massive pockets of gas each pushing a volume of mud ahead of it. As the circulating fluid leaves the well through the flow line or through a choke, it varies from “heads” of gas to just gas-cut mud. The rapid expansion of the gas pockets as they approach the surface gives tremendous velocity to the mud ahead of them which, if not controlled, blows mud all over the pit and may actually move equipment attached to the flow line or sitting in the line with it. Even worse, the gas then escapes to the air in the pit area creating a serious fire and health hazard.
The MGS receives these heads in the vessel where the mud and gas separate over internal baffles, venting the gas from an overhead outlet to a distant safe point at a much steadier rate and returning the mud to the pits with a minimum of gas.
A float ball in the MGS, at the surface of the mud, operates a valve in the mud return line, opening the valve as the fluid level rises to prevent overfilling and closing the valve as the fluid level drops. This creates a fluid seal that prevents gas from blowing out through the mud return line.
A Back Pressure Valve Assembly (optional item) can be installed in the gas vent line that may be used during severe heading to dampen the expansion and the surge effects and to prevent mud blowing into the gas vent line. If it is used, back pressure in the range of 15-50 PSI (1.1-3.5 kg/cm²) should be applied to the MGS vessel. This is because the float operated dump valve system becomes less efficient as the pressure drop across the valve increases. The increased operating safety factor at low pressure is preferable compared to a slight increase in capacity. If the Back Pressure Manifold is not used, provision should be made to install the 4 inch rupture disc on one of the openings available near the top of the MGS.
5
SECTION 2.1 DESIGN
All MGS vessels are built in accordance with the ASME Boiler and Pressure Vessel Code, Section VIII, Division I with all materials meeting the requirements of NACE Standard MR-01-75. All units are hydrostatically tested to 187 PSI (13.2 kg/cm²) and have a calculated working pressure rating of 125 PSI (8.8 kg/cm²) at 600°F (315°C). Any repair work that involves cutting or welding on the pressure vessel must be done in an ASME approved shop and must meet all the applicable ASME requirements.
SECTION 2.2 OFFSHORE MUD GAS SEPARATOR
An offshore version of the MGS is shown in FIGURE 2 OFFSHORE MUD GAS SEPARATOR VIEW on page 6. The vessel and Back Pressure Manifold assemblies are similar to the land version of the MGS. The MI Swaco Offshore MGS has overall dimensions of approximately 60.75 inches long x 69 inches wide x 216.4 inches high (1.54 m x 1.75 m x 5.50 m). It weighs approximately 6450 pounds (2930 kg) and may require additional structures to position the vessel at the proper elevation with respect to the mud tanks.
All operational features of the Offshore MGS are covered by this manual. Some operators elect to use a diaphragm back pressure valve in place of the standard lever operated valve. MI Swaco does not offer such a valve.
6
FIGURE 2. OFFSHORE MUD GAS SEPARATOR VIEW
7
SECTION 2.3 PERIODIC NONDESTRUCTIVE TESTING
Nondestructive services are available that can inspect separator vessels. The vessel wall thickness can be determined by ultrasonic or radiographic (x-ray) examination and the condition of critical welds can be verified by ultrasonic examination. These inspections should be made whenever the need is indicated by severe or extended use.
8
SECTION 3 DESCRIPTION
SECTION 3.1 SPECIFICATIONS
Operating Criteria: Minimum Operating Temperature: -4° F (-20° C) Maximum Operating Temperature: 212° F (100° C) Maximum Working Pressure: 125 psig (8.6 bar) Working Environment: H2S – Lethal Service
Capacity:
Gas 17.5 mmscf/d 495,545 cubic meters per day
Fluid 1,500 US gpm 5,678 liters per min Vessel Volume 715 cubic feet 20.2 cubic meters
Dimensions:
Overall Vessel Height 154 in 3,911.6 mm Flange to Flange
Skid Base Length 216.5 in 5,499 mm Skid Base Width 88 in 2,235 mm
Weight:
Approximate Dry Weight 15,000 lbs 6,800 Kg
Design & Fabrication Criteria:
ASME Pressure Vessel Code
Section VIII, Division I, Rules for Construction of Pressure Vessels Section IX, Welding and Brazing Qualifications
NACE Spec MR0175
Standard Material Requirements Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment
9
SECTION 3.2 DRAWINGS
FIGURE 3. TOP VIEW
10
FIGURE 4. FRONT VIEW
11
FIGURE 5. END VIEW
12
FIGURE 6. DETAIL A VIEW
13
SECTION 3.3 VARIABLE HEIGHT CHART
LEVEL A B C D E
4 275.94 [7009]
208.19 [5288]
131.94 [3351]
214.81 [5456]
129.81 [3298]
3 263.94 [6704]
196.19 [4983]
119.94 [3047]
202.81 [5152]
117.81 [2993]
2 251.94 [6399]
184.19 [4678]
107.94 [2742]
190.81 [4847]
105.81 [2688]
1 233.38 [5928]
165.63 [4207]
89.38 [2270]
172.25 [4375]
87.25 [2216]
14
SECTION 3.4 NOZZLE SCHEDULE
NO. SIZE RATING DESCRIPTION
N1 6 INCH 150 LB FLANGE RFWN 6 IN SCH 40 – ALTERNATE INLET
N2 8 INCH 150 LB FLANGE RFWN 8 IN SCH 40 – MUD DISCHARGE
N3 2 INCH 150 LB FLANGE RFWN 2 IN SCH 40
N4 16 INCH 150 LB FLANGE RFWN 16 IN SCH 40
N5 8 INCH 150 LB VALVE BUTTERFLY 8 IN H2S WAFER STYLE
N6 8 INCH 150 LB COUPLING GROOVED END SNAP VITON GASKET 8 IN
N7 8 INCH 150 LB FLANGE RFWN 8 IN SCH 40 – GAS DISCHARGE
N8 6 INCH 150 LB FLANGE RFWN 6 IN SCH 40 - INLET
15
SECTION 4 INSTALLATION
SECTION 4.1 PREPARATION
Select a site near the flow line which can be reached by a winch truck or a dragline. The site must allow for satisfactory routing of the piping from the flow line and the choke manifold to the separator, and the vent lines to a safe point for venting and/or flaring the gas. If possible, have the site for the separator leveled before installation. The MGS overall dimensions and weight are shown in SECTION 3.1 SPECIFICATIONS on page 8.
SECTION 4.2 ERECTING THE VESSEL
See FIGURE 7 ERECTING THE VESSEL VIEW on page 16. Install all handrail sections on the top of the skid. Open the expanded metal flooring, (Item 1). Connect a line (Item 2) to the lifting eye (Item 3) on the vessel. Raise the vessel just past the vertical position, place the support beam (Item 4) under the free edge of the vessel, and lower the vessel onto the beam. Close the flooring grates and place the support beams under them if required.
The unit is now ready for final placement. Lifting eyes (Item 5) are provided at each end of the skid. When the unit is placed as desired, be sure that the bottom of the skid is level and that the MGS vessel is vertical. Raise the upper section containing the vessel to assure good drainage of the return mud line back to the flow line or to the mud pits. To do so, remove the pins locking the upper and lower leg sections together, lift the entire upper section enough to reinsert the pins to provide the height required. This will raise the vessel a minimum of 1 1/2' to a maximum of 3 1/2' (8-inch mud discharge line approximately 7’-10 1/2' above base).
16
FIGURE 7. ERECTING THE VESSEL VIEW
17
SECTION 4.3 CONNECTING MUD GAS SEPARATOR
1. General
The recommended installation is shown in FIGURE 1 TYPICAL INSTALLATION VIEW on page 2. The portions supplied by MI Swaco are shown with a solid lines while the piping and two valves (Item 1 and 2) furnished by the operator are dashed lines. A 6-inch line should connect the flow line to the MGS. The 6-inch mud inlet line should branch off just ahead of a shutoff valve in the flow line (Item 1) and should have a shutoff valve near the point where the mud inlet line branches from the flow line (Item 2). Mud discharge from the separator requires an 8-inch line returning to the flow line or directly to the shaker or mud pits. Valve (Item 2) in the flow line is required to prevent gas from backing up the flow line when the well is flowing through the choke manifold and the MGS.
2. Choke Manifold Lines and B.O.P. Bypass Lines
The operator will provide the piping from the Choke Manifold and B.O.P. bypass to the MGS. The piping should be as straight as possible. If turns must be made, they should be made with tees with the end opposite the inlet closed with a plug filled with an abrasive resistant material such as pewter.
3. Mud Return Line
Before connecting the Mud Return Line, check that the 8-inch butterfly valve, shown in FIGURE 15 FLOAT-OPERATED DUMP VALVE on page 34, (Item 5) is positioned so that it closes when the operating lever is lifted. Be certain that this valve is operating correctly before continuing with installation of the Mud Return Line.
When the linkage is properly adjusted, less than the full available upward movement of the float should move the valve from fully closed to fully open. When the valve is closed the angle of the connecting arm at the valve lever should be at least 40 degrees.
The 8-inch Mud Return Line should be fabricated on location to connect from the 8-inch butterfly valve on the MGS vessel to the return inlet on the flow line, the possum belly of the shaker or the mud pits. It is essential that this line has enough slope so that it is self-draining at all points.
18
4. Gas Vent Line
The first section of gas vent line extends from the top of the vessel to a point near the 8-inch butterfly valve. An 8-inch swing pipe is provided to account for the various vessel heights that are possible with the adjustable skid. The swing pipe connects to the inlet of the Back Pressure Manifold Assembly (if installed) with a Victaulic coupling. MI Swaco supplies 10 joints of 4-inch line, each approximately 16 feet (4.3m) long and fitted with Victaulic couplings for use in the gas vent line to extend it from the Back Pressure Manifold Assembly to the flare pit.
ATTENTION!
THE GAS VENT LINE MUST BE INSTALLED WITH A CONTINUOUS GRAVITY DRAINAGE TOWARD THE FINAL EXIT POINT. DO NOT
ALLOW THIS LINE TO HAVE A LOW POINT WHICH CAN FILL WITH LIQUID. ANY SUCH ACCUMULATION DELAYS THE VENTING OF GAS
UNTIL ENOUGH PRESSURE BUILDS UP TO PUSH THE LIQUID AS FAST AS THE GAS IS COMING IN. THIS PRESSURE INCREASE MAY
CAUSE THE LINE TO POUND SEVERELY.
19
SECTION 5 OPERATION
SECTION 5.1 FLOW LINE OPERATION
When the well is being circulated through the flow line and heads of gas require use of the MGS, a circulating head of some type is used on top of the preventer stack. First open the 6-inch valve shown in FIGURE 17 BACK PRESSURE MANIFOLD VIEW (Item 4) on page 36 in the Back Pressure Manifold Assembly. To divert the flow to the MGS, open the valve as shown in FIGURE 1 TYPICAL INSTALLATION VIEW (Item 2) on page 2, then close the flow line valve, shown in FIGURE 1 TYPICAL INSTALLATION VIEW (Item 1) on page 2. This is the normal method of operation.
SECTION 5.2 BACK PRESSURE VALVE ASSEMBLY (Optional)
If the heads of gas are so violent that mud tends to be carried out the gas vent line, the Back Pressure Valve, as shown in FIGURE 17 BACK PRESSURE MANIFOLD VIEW on page 36 (Item 2) should be put into operation. To do this, adjust the movable weight (Item 14) on the valve arm to the closest position (least pressure) and close the main valve (Item 4). If mud carry over continues, move the weight (Item 14) away from the valve body (Item 1) until it holds enough back pressure to control the mud carry over in the MGS.
The Back Pressure Valve is also useful in controlling the operating fluid level in the MGS. When the conditions cause the fluid level to raise enough to lift the float near the maximum (outside float arm extension near its lowest possible point), the unit has too little reserve capacity for large heads. Increasing the back pressure by moving the weight (Item 14) away from the valve body (item 1) forces the mud out of the mud return line at a faster rate.
Similarly, if the 8-inch valve lets mud out too fast and allows gas to exit out the mud return line, decrease the pressure held by the Back Pressure Valve. It may even be necessary to fully open the 6-inch valve (Item 4) in the Back Pressure Valve Assembly.
20
SECTION 6 MAINTENANCE
CONTACT AN MI SWACO REPRESENTATIVE IF WELD REPAIR ON THE MGS IS REQUIRED AND BEFORE ANY WELDING IS STARTED. ONLY ASME CERTIFIED SHOPS MAY PERFORM WELDING TO THE
MGS.
SECTION 6.1 H2S PRECAUTIONS
IF IT IS SUSPECTED THAT THE MGS HAS BEEN EXPOSED TO H2S, THEN ONLY PERSONNEL THAT HAVE BEEN PROPERLY TRAINED
TO WORK IN H2S ENVIRONMENTS SHOULD BE ALLOWED TO WORK ON OR AROUND THE MGS.
In addition to being extremely toxic to humans and also flammable, H2S can produce sudden failure in many steels and is highly corrosive. When equipment exposure has not been severe enough to cause a mechanical failure some very simple measures will usually return a piece of equipment to serviceable condition. First of all, it should be flushed or washed with water and carefully inspected visually or by nondestructive testing. Any cracks, notches and other flaws should be removed. Finally, allow the MGS unit to sit open to the atmosphere for a period of several weeks and re-inspect for cracks. If desirable the unit may be filled with water and pressure tested to not more than 150 PSI (10.55 kg/cm²).
21
SECTION 6.2 PREPARATION FOR EMERGENCY HOT WORK REPAIR
1. Wear appropriate personal protective equipment.
2. Disconnect the inlet line(s) and gas vent line at the MGS vessel.
3. Connect a water line to a MGS outlet and fill the entire vessel.
4. Drain flush water.
5. Open all vents (all discharge valves and blind flanges) and let the MGS unit ventilate for at least one hour.
6. If any doubt remains as to the presence of H2S check with a portable H2S detector before proceeding with cutting or welding. Only AMSE code approved welders should be used to perform cutting and welding.
SECTION 6.3 GENERAL
1. Skid
a. Oil or grease the hinge pins that support the MGS vessel periodically. When washing the unit, flush the space within the hinges and re-lubricate.
b. Flush out the space between the leg sections with high pressure water. Lubricate with oil or grease.
c. Keep all ladders and railing sections in good condition.
2. Vessel
a. Replacement 8-inch dump valves must be specially undercut for satisfactory operation. These should be ordered from MI Swaco.
b. Once a satisfactory arrangement of the linkages to the 8-inch dump valve is found it should not be altered.
c. Check the linkage periodically to see that the valve has full travel within the range of travel of the float arm. The arm should not touch the housing of the stuffing box at either end of the travel.
d. Open the drain (N5) shown in FIGURE 5 END VIEW on page 11 at the bottom of the vessel to remove accumulated solids. Direct a high pressure water stream through other vessel openings as needed to wash the interior of the vessel.
22
e. Lubricate the stuffing box shaft at frequent intervals.
f. Lubricate the stem of the 8-inch valve.
g. Lubricate the pins in the float-valve linkage. Keep the linkage properly tightened to avoid excessive wear.
h. Inspect the float during each major cleaning to be sure it has not been damaged or collapsed.
i. Wash the baffles inside the vessel with high pressure water at the end of each installation and at regular intervals during a long installation.
3. Back Pressure Valve Assembly (Optional)
a. Keep the valve seat and face in good condition. Replace when worn.
b. Keep the weight slide and slide locking screw clean and lubricated.
c. Clean and dope the threads on the Dresser coupling bolts (Item 2), FIGURE 17 BACK PRESSURE MANIFOLD VIEW on page 36).
d. Inspect the Rupture Disc and replace if necessary.
23
SECTION 6.4 EFFECTS OF CHANGING LINKAGE ARMS
The recommended linkage is shown is solid lines and the linkage resulting from each change is shown in dashed lines, refer to FIGURE 8. In Case A, the float arm extension (a) is lengthened, in Case B, the connecting link (b) is lengthened, and in Case C, the valve operating arm (c) is lengthened. Each change shown is an increase in length of about one tenth. In all cases the valve is shown from fully closed to fully open. In some situations the effects indicated may be ones you need, or they may be the opposite of what you need so you can shorten the linkage instead.
NOTE:
THE BEST RESULTS CAN BE OBTAINED BY CHANGING ONLY THE FLOAT ARM EXTENSION OR ITS SETTING ON THE STUFFING BOX
SHAFT (CASE A). THE OTHER CHANGES SHOWN SHOULD BE MADE TO CORRECT A WRONG LINKAGE.
FIGURE 8. CHANGING LINKAGE ARM VIEW
24
Case A-Lengthening the float arm extension:
1. Reduces the travel of the float arm so a smaller change in mud levels moves the valve all the way. (Conversely, shortening (a) will increase the change in mud level between opening and closing the valve).
2. The motion of the float arm is still within the limits of the float nose cover at both extremes and still clears each side.
Case B-Lengthening the connecting link:
1. Makes the float arm extensions go higher to close the valve, if permitted by the nose cover. If not, the cover will stop the float before the valve is closed.
2. The valve is fully open before the float reaches its previously maximum upper position.
3. The total angle of travel of the float extension remains almost the same, but both ends are moved up, or the float is lower in the vessel at both end points.
Case C-Lengthening the valve operating arm
1. Makes the float arm extension move through a larger angle, particularly on the low end (float riding higher in the vessel).
2. If this interferes with the nose cover walls, it will keep the valve from fully opening at the high mud level, and may also keep the valve from fully closing at the low mud level.
3. The change in the angle of the connecting link will give a little more torque on the valve when it is being closed
.
25
SECTION 6.5 NOSE CONE ALIGNMENT
FIGURE 9 FLOAT VALVE LINKAGE VIEW and FIGURE 15 FLOAT-OPERATED DUMP VALVE VIEW on page 34 show the normal position of the Float Nose Cone, with the stuffing box, and the recommended linkage configuration.
FIGURE 9. FLOAT VALVE LINKAGE VIEW
26
FIGURE 10. FLOAT ARM & VALVE STEM ADAPTOR VIEW
27
SECTION 6.6 PRESERVATION
The following steps should be followed for preserving the MGS.
1. Thoroughly clean the inside of the vessel and U-tube by removing all mud and other contaminants.
2. Thoroughly clean all flange faces, blind flanges, companion flanges, shackle pins, fasteners and loose spool pieces by removing all mud, oil residue, metal chips, tape and other contaminants.
3. Dry all the cleaned surfaces.
4. Apply Cortex M-645 to the inside of the vessel and U-tube. Follow the Cortec instructions for spray and brush application. The approximate coverage of Cortec M-645 is 1,250 to 1,400 sq. ft. per gallon.
5. Apply Cortec M-645 to all flange faces, blind flange faces, companion flange faces and loose spool pieces.
6. Install flanges and spool pieces to vessel.
7. Apply Cortec M-646 to all shackle pins, fasteners and plugs.
8. Install and secure 1/2-inch thick marine grade plywood board to all exposed flange faces.
28
SECTION 7 TROUBLESHOOTING
PROBLEM PROBABLE CAUSE SUGGESTED REMEDY Readjust linkage to Float Valve as per FIGURE 9 FLOAT VALVE LINKAGE VIEW on page 25. Float Arm is bent and Float is too far down to fully close the Float Valve. Straighten the arm or change when out of service, meanwhile, lengthen the link “A” to close the valve with the float still riding high as shown in case A in FIGURE 9 FLOAT VALVE LINKAGE VIEW on page 25. Linkage may not allow enough torque to close the valve against the flow at mud levels. Check the angle of the operating arm “C” with the valve. Shorten “A” to increase the angle of “B” with “C”. When time permits add 1-1/2-2 gallons of oil or water in the float.
Gas blows out of mud discharge
Float valve not fully closed
Accumulated solids in the bottom may keep the float from reaching the low position, keeping the 8-inch valve from closing. Change the linkage temporarily to improve valve action. Clean the vessel and restore the linkage when possible. Readjust per Float Arm Linkage, FIGURE 9 FLOAT VALVE LINKAGE VIEW on page 25. Make sure the valve is fully open when the float approaches the highest position. Refer to Float Arm Linkage, FIGURE 9 FLOAT VALVE LINKAGE VIEW on page 25.
Mud Blows Out Gas Vent
8-inch Valve not fully open
Increase the back pressure in the vessel by moving the weight, Item 14, FIGURE 17 BACK PRESSURE MANIFOLD VIEW on page 36, further out on the back pressure arm.
29
PROBLEM PROBABLE CAUSE SUGGESTED REMEDY Pressure in Back
Pressure Valve Assy. (Optional)
If the float stays near the top of its travel and moderate back pressure does not help enough, check the 8-inch mud discharge line for obstructions. Make sure its angle is enough to keep it clean. If not readjust vessel height at first opportunity to give good drainage. Re-install gas vent line with continuous drainage toward the flare pit.
Gas Vent Line bumps or pounds with each head
Mud accumulates in low places
If there is several elbows or turns in vent line, eliminate as many of these as possible.
Fluid level maybe too high in vessel.
Float Valve needs to be adjusted. Refer to FIGURE 9 FLOAT VALVE LINKAGE VIEW
Separator “Pounds” badly during Heads
Back pressure may be low (Optional Backpressure Assy.)
Increase the back pressure at the Back Pressure Valve.
Too much pressure is being held.
Reduce the pressure held or use stronger Rupture Discs.
Back Pressure alve does not work freely.
Adjust and Lubricate Backpressure Valve until it works freely.
Rupture Disc Blows (Optional Backpressure Assy.)
Fluid level is being held too high in the vessel.
Look at “Gas blows out mud discharge” and “Mud accumulates in low places” sections.
Choke lines to the Separator Jumps
Too many elbows or turns in the line
Eliminate as many elbows as possible. Anchor down the line.
30
SECTION 8 SPARE PARTS
NO. QTY. PART NO. DESCRIPTION
1 8 1220375 STUD ALL THREAD 5/8 – 11NC x 3.25 INCH LONG 2 24 1220380 STUD ALL THREAD 3/4 – 10NC x 4.00 INCH LONG 3 8 1220381 STUD ALL THREAD 3/4 – 10NC x 4.25 INCH LONG 4 48 1220385 STUD ALL THREAD 7/8 – 9NC x 4.75 INCH LONG 5 16 1220400 STUD ALL THREAD 1-1/2 – 8UN x 10.00 INCH LONG 6 16 1304115 HEX NUT 5/8 – 11NC 7 72 1304116 HEX NUT 3/4 – 10NC 8 54 1304117 HEX NUT 7/8 – 9NC 9 32 1304122 HEX NUM 1-1/2 – 8UN
10 8 1445716 STUD ALL THREAD 3/4 – 10NC x 6.50 INCH LONG 11 6 1460001 SQUARE HEAD BOLT 7/8 – 9NC x 7.00 INCH LONG 12 3 3914800 GASKET MANWAY OVAL 11 INCH x 15 INCH 13 2 3915024 GASKET FLANGE RF 2 INCH x 150 LB 14 5 3916047 GASKET FLANGE RF 6 INCH x 150 LB 15 1 3916059 GASKET FLANGE RF 8 INCH x 150 LB 16 1 3916069 GASKET FLANGE RF 10 INCH x 150 LB 17 3 3916079 GASKET FLANGE RF 12 INCH x 150 LB 18 2 3919302 GASKET RING SS API RX-44
19 1 5816194 DISC RUPTURE 6 INCH 316 SS 60 TO 80 PSI 72 DEG. F
31
SECTION 9 DRAWINGS AND PARTS LIST
FIGURE 11. VESSEL ASSEMBLY TOP VIEW
32
FIGURE 12. VESSEL ASSEMBLY FRONT VIEW
FIGURE 13. VESSEL ASSEMBLY DETAIL B VIEW
33
FIGURE 14. PARTS LIST FOR 9620244
NO. QTY. PART NO. DESCRIPTION
1 1 - SHEET RUBBER 2 1 - TAPE FOAM 3 16 1220215 STUD THRD PLT GR B7 4 40 1305123 NUT HEX 5 56 1305124 NUT HEX 6 8 1405001 SCREW HEX HD 7 48 1405002 SCREW HEX HD 8 8 1405003 SCREW HEX HD 9 4 1492031 SCREW DRIVE SS
10 4 3916024 GASKET RING 11 1 3916035 GASKET RING 12 3 3916047 GASKET RING 13 3 3916059 GASKET RING 14 2 5015094 COUPLING GROOVED END 15 4 5035139 FLANGE BLIND 2 IN 16 1 5035155 FLANGE BLIND 4 IN 17 2 5035169 FLANGE BLIND 6 IN 18 1 5035284 FLANGE RFWN 6 IN 19 1 5035285 FLANGE RFWN 8 IN 20 1 5641357 VALVE BUTTERFLY 8 IN 21 2 8420143 DECAL 22 2 8420145 DECAL 23 2 8420207 DECAL 24 1 9620226 VALVE ASSY LINKAGE AND FLOAT 25 1 9620246 VESSEL TANK ASSEMBLY H2S TOGA 26 1 9620327 PIPE VENT LINE 8 IN 27 1 9620328 PIPE SWING 8 IN 28 2 9620329 ADAPTER 8 IN 150 LB FLANGE X 8 IN 29 1 9650360 NAMEPLATE
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SECTION 9.1 DRAWINGS AND PARTS LIST FOR DUMP VALVE
FIGURE 15. FLOAT-OPERATED DUMP VALVE VIEW
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FIGURE 16. PARTS LIST FOR FLOAT-OPERATED DUMP VALVE
NO. QTY. PART NO. DESCRIPTION
1 1 9105057 BALL FLOAT 2 1 9105500 ROD FLOAT 3 1 9105160 HEAD FLOAT NOSE 4 1 3916200 GASKET 16” ASBESTOS ASA 5 1 5641360 VALVE BFLY 8 IN MODIFIED 6 8 1444691 SCREW HEX HD 7 16 1305877 NUT HEX 8 1 3916059 GASKET 8’ ASBESTOS 9 1 9620220 SPACER FLOAT VALVE LINK
10 8 1444703 SCREW HEX HD 11 1 5035087 FLANGE 12 1 9620227 LINKS FLOAT VALVE (SET) 13 2 1305413 NUT HEX SS 14 6 1345188 WASHER FLAT 15 2 1407474 SCREW HEX HD 16 1 9105113 COLLAR LEVER 17 16 1444707 SCREW HEX HD 18 16 1305879 NUT HEX BLK 19 REF - BOX STUFFING
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SECTION 9.2 DRAWINGS PARTS LIST BACK PRESSURE MANIFOLD
FIGURE 17. BACK PRESSURE MANIFOLD VIEW
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FIGURE 18. PARTS LIST FOR BACK PRESSURE MANIFOLD
NO. QTY. PART NO. DESCRIPTION 1 1 9105797 VALVE BACK PRESS. 4” 2 1 5015005 COUPLING DRESSER 38-4” 3 8 1444699 SCREW HEX HD 4 1 5638033 VALVE BUTTERFLY 6” 5 1 5816190 DISC RUPTURE 6 8 1305877 NUT HEX BLK 7 16 1444669 SCREW HEX HD 8 24 1305876 NUT HEX BLK 9 4 3916037 GASKET ASBESTOS 757 4 IN
10 2 3916047 GASKET ASBESTOS 757 6 IN 11 8 1444673 SCREW HEX HD 12 8 5851455 INSERT ASSY FA7R 4 IN 13 REF 9620235 MANIFOLD WELDMENT 14 1 WEIGHT LEVER ARK
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APPENDIX A BACK PRESSURE VALVE
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APPENDIX B TECHNICAL BULLETIN 152 (PURGE PROCEDURES)
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