Intelligent mud-gas separation and handling system

Abstract

A multi-phase fluid solution measurement and gas separation system is described. The system includes a substantially vertical fluid supply pipe that introduces the multi-phase fluid solution in a steady flow having a substantially calm and steady fluid surface to a mud-gas separation unit. The mud-gas separation unit includes measurement tools such as force sensors and level sensors to allow for a rheological model of the fluid to be calculated. The system also includes components for flaring or processing gas which separates from the multi-phase solution.

1 . A multi-phase fluid flow measurement system, comprising:
 a fluid supply pipe oriented in an at least partially vertical orientation, the fluid supply pipe being configured to carry a multi-phase fluid upward through the fluid supply pipe, wherein the multi-phase fluid has an upwardly-facing fluid surface;   a transfer pipe extending laterally from the fluid supply pipe, wherein the multi-phase fluid is pressurized sufficiently to flow through the transfer pipe while the upwardly-facing fluid surface is steady and remains steady as it enters the transfer pipe;   a barrier positioned to at least partially impede the flow of the multi-phase fluid through the transfer pipe; and   a level sensor configured to measure a depth of the multi-phase fluid as it flows from the transfer pipe.   
     
     
         2 . The multi-phase fluid flow measurement system of  claim 1  wherein the barrier is a Weir plate. 
     
     
         3 . The multi-phase fluid flow measurement system of  claim 1 , further comprising a mud-gas separator (MGS) unit coupled to the transfer pipe and configured to receive the multi-phase fluid. 
     
     
         4 . The multi-phase fluid flow measurement system of  claim 3 , further comprising a gas transfer conduit between the fluid supply pipe and the mud-gas separator unit. 
     
     
         5 . The multi-phase fluid flow measurement system of  claim 1 , further comprising a plurality of baffles in the mud-gas separator, wherein at least one of the baffles has a force sensor configured to measure kinetic energy within the multi-phase fluid. 
     
     
         6 . The multi-phase fluid flow measurement system of  claim 5  wherein the level sensor is configured to measure the height of the flowing fluid above one or more of the baffles. 
     
     
         7 . The multi-phase flow measurement system of  claim 6  wherein the multi-phase fluid flow measurement system is configured to determine the apparent viscosity of the multi-phase fluid. 
     
     
         8 . The multi-phase fluid flow measurement system of  claim 5 , wherein at least one of the baffles comprises an articulating member configured to articulate to change an angle of the baffle. 
     
     
         9 . The multi-phase fluid flow measurement system of  claim 8 , and associated with the  claim 3 c to determine the apparent viscosity of the fluid at different flow conditions. 
     
     
         10 . The multi-phase fluid flow system of  claim 9 , wherein the multi-phase fluid flow measurement system is configured to determine the rheological model of the multi-phase fluid. 
     
     
         11 . The multi-phase fluid flow measurement system of  claim 5 , wherein the level sensor comprises at least two level sensors, each on a different baffle, wherein the level sensors are configured to measure a change of at least one of density and rheology due to extraction of gas. 
     
     
         12 . The multi-phase fluid flow measurement system of  claim 11 , wherein the difference of fluid properties may be measured on the first and last baffle plate, the multi-phase fluid flow measurement system is configured to determine the flow rate of gas extracted from the multi-phase fluid. 
     
     
         13 . The multi-phase fluid flow measurement system of  claim 1  wherein the multi-phase solution includes at least one of mud and hydrocarbons. 
     
     
         14 . The multi-phase fluid flow measurement system of  claim 3 , further comprising a controller configured to release at least one of fluid or gas from the mud-gas separator in response to the level sensor determining that the fluid level has reached a predetermined level. 
     
     
         15 . The multi-phase fluid flow measurement system of  claim 3 , further comprising a gas line configured to carry gas out of the MGS unit released from the multi-phase fluid. 
     
     
         16 . The multi-phase fluid flow system of  claim 15 , further comprising a sensor configured to enable a determination of a type and amount of gas flowing through the gas line. 
     
     
         17 . The multi-phase fluid flow measurement system of  claim 15 , further comprising a compressor in the gas line. 
     
     
         18 . The multi-phase fluid flow system of  claim 17 , wherein the compressor is configured to feed a flare stack trough a variable choke orifice, the multi-phase fluid flow system further comprising a pressure gauge in the gas line, and means for controlling a choke orifice at least in part in response to a pressure measured by the pressure gauge. 
     
     
         19 . The multi-phase fluid flow system of  claim 18 , wherein the compressor, the variable choke orifice, the pressure gauge, and the means for controlling the choke orifice are configured to entrain adequate air flow versus the ejected gas flow at the nozzle. 
     
     
         20 . A mud-gas separation unit, comprising:
 an inlet configured to receive a steady flow of a multi-phase solution;   a baffle having a force sensor, wherein the baffle is positioned so that the steady flow impinges upon the baffle on an area affected by the force sensor;   a gas collection region above the inlet configured to allow gas to escape the multi-phase solution and collect in the gas collection region; and   an articulating member operatively coupled to the baffle and configured to change an angle of the baffle.   
     
     
         21 . The mud-gas separation unit of  claim 20 , further comprising a gas outlet and a fluid outlet, the fluid outlet being positioned at a lower portion of the mud-gas separation unit. 
     
     
         22 . The mud-gas separation unit of  claim 20 , further comprising a force sensor on one or more of the baffles to determine a fluid density of the fluid. 
     
     
         23 . The mud-gas separation unit of  claim 22 , wherein the force sensors are configured to measure the density of the multi-phase flow at  2  different baffles of the gas separator and determining the difference of fluid density from a first baffle and a second baffle, wherein the quantity of gas is associated with a flow rate from the inlet. 
     
     
         24 . The mud-gas separation unit of  claim 20 , further comprising a heater configured to apply heat to the multi-phase fluid as it enters the mud-gas separation unit. 
     
     
         25 . The mud-gas separation unit of  claim 24 , further comprising a temperature sensor configured to monitor a temperature within the mud-gas separation unit to prevent overheating. 
     
     
         26 . The mud-gas separation unit of  claim 20 , further comprising:
 a compressor;   an associated controller associated with the compressor, the controller being configured to influence the compressor; and   a glycol tower configured to receive fluid from the mug-gas separation unit to remove the water from the gas.