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Intelligence meets control

When every minute counts, the Weir Mud-Gas Separator Intelligent System helps you avoid well-control incidents.

The System

Ideal for managed-pressure drilling and under-balanced drilling operations, the Weir Mud-Gas Separator Intelligent System can accurately measure and control fluid levels within the mud-gas separator. An industry first, it provides operators with local real-time data, giving them far more time to prevent gas carryover from MPD/UBD operations, gas kicks, or well-control situations. It also prevents mud overflows through the vent line and flare or combustor.

The Mud-Gas Separator can be configured with a sensor for level detection only (MGS-ISL) or with a controller (MGS-ISC) as well. Employing wave-radar technology, the MGS IS system measures and communicates fluid-level data in real-time on site. This data is also accessible through a secure, Cloud-based portal anywhere, anytime.

In field tests, the MGS-IS has eliminated vent-line fluid discharges, mitigating fluid spills and saving thousands of dollars in ground contamination cleanup costs and non-productive time.

The Challenge

Operating in a cold, mountainous region of the Rockies, one customer was experiencing frequent incidents during high-pressure, nitrogen-aerated drilling operations. Frequently, the MGS would overflow, filling up the secondary eco tank, which would ultimately discharge through the igniter. Based on the previous placement of a single level alarm switch, operators only had 16 minutes to respond before the overflow from the system would be discharged to ground through the igniter.

The Solution

Weir proposed the installation of an MGS-ISL to monitor the levels on the mud-gas separator—not just from a single point, but from top to bottom.

The Results

After the MGS-ISL was installed, that 16 minutes of response time became three-and-a-half hours, plenty of time to manage levels and avoid discharge.

Since renting the system was very economical, they immediately added the MGS-IS to their remaining drilling fleet in the region.

Our solution eliminated overflows and non-compliance with environmental regulations, along with the associated costs of vacuum trucks, shut-down, and non-productive time—a savings of hundreds of thousands of dollars over the course of one year.

Part of an integrated suite of IS components, the MGS IS also uploads and records this information to a secure, Cloud-based portal, where it can be accessed anywhere, anytime.

Features

  • Integration with the Weir Pressure Control unit (WPC-IS), which can be deployed as a single product or integrate with multiple IS products, such as the Weir Vent-Gas Analyzer (VGA-ISF)Active kick and/or well control, providing liquid seal protection to prevent gas carryover, with total valve open-to-close actuation in less than 18 seconds
  • System integration capability with Pason, MD Totco, and other EDR platforms via WITS communication protocol
  • Available for rent, with service centers in every basin; fully inspected and recertified after every job
  • MGS conditional analysis and alarms
  • Automated MGS liquid-discharge control
  • Local and remote performance monitoring, connecting customers with data via text, email, or Cloud-based portal
  • Data that can be stored, shared, and reported for future reference
  • Optional sensors and software integration package that establishes the MGS-ISC/F as a wellbore return flow meter
  • Electric-actuated control system to optimize performance and minimize actuator cycles
  • Manual actuator override

Benefits

  • Replaces guesswork with more accurate measurements
  • Reduces environmental risks and costs of overflows
  • Improves kick-handling capacity
  • Provides convenient access to real-time data via local control panel
  • Reduces costs and non-productive time
  • Simplifies diagnostics and troubleshooting

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