Drill Sim 20

Confidential
This proposal is confidential to Drilling Systems (UK) Ltd. Neither the

whole nor any part of this
document may be disclosed to any third party without the prior written
consent of Drilling Systems
(UK) Limited, Hurn View House, 5 Aviation Park West, Bournemouth
International Airport, Dorset,
BH23 6EW, UK. The copyright of this document is vested in Drilling
Systems (UK) Limited. All
rights reserved. Neither the whole or part of this document may be
reproduced, stored in any
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the prior written consent of
the copyright owner.
DrillSIM-20 Technical Proposal i
© 2007 Drilling Systems Ltd
TABLE OF CONTENTS
1. OVERVIEW
....................................................................................................
................... 1
1.1 INTRODUCTION
....................................................................................................
......... 1
1.2 ELEGANCE AND DESIGN
...................................................................................................
1
1.3
REALISM........................................................................................
............................. 1
1.4 COMPUTER EQUIPMENT
....................................................................................................
2
1.5 USER FRIENDLINESS
....................................................................................................
... 2
1.6 SIMULATOR
CONTROL.......................................................................................
............... 2
1.7 DIAGNOSTIC
SOFTWARE.....................................................................................
.............. 3
1.8 ENGINEERING RELIABILITY
................................................................................................ 3
1.9 STANDARD SIMULATOR
PACKAGE.......................................................................................
.. 3
1.10 TRAINEE OPERATING
CONSOLES.....................................................................................
..... 3
1.11 INSTRUCTOR CONTROL
STATION........................................................................................
.. 4
1.12 PORTABLE
LOGGER/PLOTTER:..........................................................................
................... 4
1.13 SIMULATION COMPUTER
...................................................................................................
4
1.14 INPUT/OUTPUT SIGNAL INTERFACE
....................................................................................... 4
1.15 INTERACTIVE SOUND
SYSTEM.........................................................................................
.... 4
1.16 TRANSIT
PACK.............................................................................................
................. 4
1.17 SIMULATION SOFTWARE
...................................................................................................
4
1.18 INTERCONNECTING CABLES
............................................................................................... 5
1.19 PRODUCT
SUPPORT.......................................................................................
.................. 5
1.20 OPERATIONAL
CAPABILITY....................................................................................
............. 5
1.20.1 Normal Operation
............................................................................................... 5
1.20.2 Operational Effects
............................................................................................. 5
1.20.3 Simulated Malfunction States
............................................................................... 6
1.21 COMPLEMENTARY TRAINING PACKAGES
.................................................................................. 6
1.22 DOCUMENTATION GUIDE
..................................................................................................
6
2. TRAINING APPLICATIONS AND OPERATIONAL
CAPABILITY............................................ 8
2.1 INTRODUCTION
....................................................................................................
......... 8
2.2 WELL CONTROL
TRAINING......................................................................................
........... 8
2.2.1 Causes of Kicks
..................................................................................................
8
2.2.2 Kick Warning
Signs.............................................................................................
8
2.2.3 Shut-in Procedures
............................................................................................. 9
2.2.4 Wait and Weight Method of Well Control
................................................................ 9
2.2.5 Driller's Method of Well
Control............................................................................10
2.2.6 Volumetric Method of Well Control
.......................................................................10
2.2.7 Bull-heading Method of Well
Control.....................................................................10
2.2.8 Concurrent Method of Well
Control.......................................................................10
2.2.9 Down Hole and Equipment Problems During Well
Control.........................................10
3. SIMULATOR EQUIPMENT
DESCRIPTION......................................................................... 12
3.1 INTRODUCTION
....................................................................................................
........12
3.2 SIMULATION COMPUTER
..................................................................................................1
2
3.3 INSTRUCTOR SIMULATOR CONTROL
STATION...........................................................................12
3.4 PORTABLE DRILLING & WELL CONTROL CHART PLOTTER
.............................................................13
3.5 SIMULATOR CONTROL
CONSOLES.....................................................................................
...13
3.5.1 Pumpers
Console.........................................................................................
......13
3.5.2 Remote Choke Control
Console............................................................................14
4. SCOPE OF
SIMULATION..................................................................................
................ 15
4.1 INTRODUCTION
....................................................................................................
........15
4.2 DRILLING FLUID CIRCULATING SYSTEM
.................................................................................15
4.2.1 Mud System Control
..........................................................................................15
4.2.2 Mud
Tanks............................................................................................
............16
4.2.3 Drilling Fluid
....................................................................................................
.18
4.2.4 Mud Pumps
....................................................................................................
..19
4.2.5 Standpipe Manifold
............................................................................................19
4.2.6 Choke Manifold
.................................................................................................19
4.3 BLOW-OUT PREVENTION AND WELL CONTROL
SYSTEM................................................................20
4.3.1 Surface BOP Controls
.........................................................................................20
DrillSIM-20 Technical Proposal ii
4.3.2 Drill String
Valves...........................................................................................
...21
4.4 SIMULATED EQUIPMENT AND OPERATIONAL MALFUNCTIONS
..........................................................23
4.4.1 Instrumentation Malfunctions
..............................................................................23
4.4.2 Fluid Handling
System........................................................................................2
3
4.5 WELL
CONTROL.......................................................................................
.....................25
.................................................................................................25
4.5.2 Types of Kick
....................................................................................................
27
4.5.3 Condition Dependent Kick
...................................................................................28
4.5.4 Multiple
Kicks.............................................................................................
.......29
4.5.5 Kick Influx Density
............................................................................................29
4.5.6 Influx Flow Rate
................................................................................................30
4.5.7 Reservoir Draw-down and Stabilisation
.................................................................30
4.5.8 Gas Expansion
..................................................................................................3
0
4.5.9 Gas Migration
...................................................................................................
31
4.5.10 Underground Blow-out
.......................................................................................31
4.5.11 Dynamic Pressures During Well Control
................................................................32
4.5.12 Kicks While Drilling Surface
Hole..........................................................................33
4.5.13 Kicks While Drilling
............................................................................................33
4.5.14 Kicks While
Tripping.........................................................................................
..34
4.5.15 Kicks While Out of the
Hole.................................................................................34
4.5.16 Driller's Method of Well
Control............................................................................35
...............................................................35
4.5.18 Bull-heading Method of Well
Control.....................................................................35
.......................................................................36
4.5.20 Concurrent Method of Well
Control.......................................................................36
5. SIMULATOR MANAGEMENT AND CONTROL
FACILITIES.................................................. 37
5.1 SIMULATION CONTROL TOOLS
...........................................................................................37
5.2
RUN/FREEZE..................................................................................
.............................37
5.2.1 Initial Conditions (Snapshot) Selection
.................................................................37
5.2.2 Snapshot Generation
.........................................................................................37
5.2.3 Time Rate Control
.............................................................................................38
5.2.4 Simulated Malfunction
Injection...........................................................................38
5.2.5 Data Logging
....................................................................................................
38
5.3 CONTROL AND DISPLAY
FACILITIES.....................................................................................
.39
5.3.1 Start-up Display
................................................................................................39
5.3.2 Configuration Menu Display Screen
......................................................................39
5.3.3 Rig Type Selection Display
Screen........................................................................39
5.3.4 BOP Configuration Menu Display
Screen................................................................39
5.3.5 Well-bore Geometry Menu Display Screen
.............................................................40
5.3.6 Mud System Menu Display
Screen........................................................................40
5.3.7 Rig Equipment Menu Display
Screen.....................................................................40
5.3.8 Run-time Menu Display Screen
............................................................................40
5.3.9 Malfunction Menu Display
Screens........................................................................40
5.3.10 Snapshot Utilities Control Screen
.........................................................................40
5.3.11 Units and Conversions Control Screen
..................................................................40
6. FACILITY
REQUIREMENTS..............................................................................
................ 41
6.1 ELECTRICAL POWER
SUPPLY..........................................................................................
....41
6.2 ENVIRONMENTAL CONDITIONS
...........................................................................................41
DrillSIM-20 Technical Proposal a
PHOTOS, DIAGRAMS & DRAWINGS
DrillSIM-20 showing Colour Plotter, Instructor Laptop, UPS, Student
Station Touch
Screen, Drillers Panel (blue), and Remote Choke Panel (orange)
DrillSIM-20 Technical Proposal 1
1. OVERVIEW
1.1 Introduction
The DrillSIM-20, developed and manufactured by Drilling Systems
represents the ultimate
in fully portable well control simulation. It is designed to meet the
training requirements of
Operators, Drilling Contractors and Service Company personnel for both
onshore and
offshore training requirements. Applicable to both entry level or
advanced engineering
skills training, the DrillSIM-20 can be used to instruct individuals or drill
crews.
The DrillSIM-20 provides the main well control operating capabilities of
the larger DrillSIM
rig floor range of simulator. In it’s basic configuration this Compact-
Portable simulator
comprises :-
• Two consoles
• Notebook Computer (laptop)
• Student Touchscreen
• Uninterruptible Power Supply (UPS)
• Colour Printer
• Transit Case
The consoles and computer equipment fit within a single transit case.
Consequently there
is no easier method of transport for a simulator of this sophistication.
This provides
Instructors with the opportunity to conduct training for their employees
or clients on a
geographically unrestricted area either at the well-site or in the
classroom.
1.2 Elegance and Design
The DrillSIM-20 is a truly refined product. The consoles are designed
with ergonomics and
ease of use in mind. The lay back and swinging support arms ensure
clear accurate vision
of the gauges. Trainees can use the simulator sitting down or standing
up when mounted
on a standard height desk or work top. The face plates are individually
engraved giving
clear decipherable labels and annotation. The faces of the consoles are
protected by the
protruding edges of the cabinet preventing the controls and lamps from
becoming
accidentally damaged during general handling. The simulator consoles
are easily removed
from the transit suit-case and set up as stand alone units within a few
minutes, ready to
run a training session. Drilling Systems has designed a product that is
functionally and
technically accurate, but equally as important, is aesthetically pleasing
to use and
consummate with the investment.
1.3 Realism
The DrillSIM-20 comes equipped with a two compact consoles which
perform the functions
similar to the equipment found on a modern rig floor simulator, which in
turn represent a
typical rig floor environment.
The simulator is controlled through an Instructor control station
provided on a laptop
computer. The graphics are fully interactive with the various drilling
controls and
simulated rig equipment. Furthermore, the DrillSIM-20 presents a real-
time view of downhole
operations. A scaled cross sectional view of the well-bore displays
down-hole
equipment, formations and the movement of drilling and formation
fluids in the well-bore.
Within the simulation environment, realism is further enhanced by the
use of electronically
generated sound effects which are fully synchronised with the various
operational activities
of the simulator.
1.4 Computer Equipment
The DrillSIM-20 laptop computer-based control station provides a fully
portable system for
the roving Instructor. It utilises the Windows operating environment to
drive the various
systems and simulation sub processes. This environment also eases the
Instructor’s
interaction with the system.
For the Student Station, a touchscreen is plugged into the notebook and
provides a wide
range of functions through the different screens.
1.5 User Friendliness
The DrillSIM-20 control software operates under the Windows
environment. This eases
familiarity and mastery of the system. The graphical user interface
(GUI) provides a user
friendly tool for the Instructor to set up exercises and control
simulation.
Although physically small each of the simulator hardware consoles with
their relevant
controls and instrumentation are representative of those found in the
field and are easy for
the student to master.
Interaction by the Student is via a touchscreen, with the GUI designed
for “oilfield” hands,
with large, clear buttons and switches.
1.6 Simulator Control
The Instructor, through his Laptop PC, is able to control the simulator
and monitor the
trainee's performance throughout various phases of an exercise while
remaining sufficiently
remote to conform to assessment requirements of the various
regulatory bodies, for
example the International Association of Drilling Contractors (IADC
WellCAP) or
International Well Control Forum.
The DrillSIM-20 simulation software is a fully integrated modular
package, designed to
interact with any operational actions. The simulator software allows the
trainee to observe
the consequences of his actions just as they would occur in the field.
The DrillSIM-20 set of initial conditions (well snapshot) defines all the
necessary
parameters to commence a wide variety of training exercises. Having
selected the desired
well snapshot, no further input is required. No pre-programming is
necessary. This leaves
the Instructor free to monitor trainee performance. New well snapshots
can be created by
the Instructor at any time for use in subsequent trainee exercises,
either at the base office
or ‘en route’ to the training location.
During the simulation exercise, no restrictions are placed on either
Instructor or Student.
DrillSIM-20 software is unique in that neither trainee nor Instructor
have to act in any predefined
sequence. Operational events such as well-bore influx or washed choke
occur as a
result of poor drilling practices or pre-configured conditions of the well
snapshot, thus
allowing the Instructor to enforce particular well control problems for
group training
sessions.
The Instructor can also change parameters of the well snapshot and
introduce simulated
malfunction situations into the exercise. Malfunctions such as
equipment failure or downhole
problems can be pre-configured in the initial well snapshot or activated
during the
course of the simulation exercise. These simulated malfunction cases
will then interact to
produce the appropriate effects on the instrumentation and consoles.
Repetition of exercises assists in retaining knowledge gained throughout
the well control
session. By placing the trainees in simulated dangerous situations the
Instructor has the
opportunity to evaluate competence under pressure. This type of
training develops logical
thought processes and builds confidence with troubleshooting skills
ensuring the trainee
reacts confidently in the event of similar situations being encountered in
the field.
1.7 Diagnostic Software
The DrillSIM-20 internal diagnostic software enables the Instructor to
perform a full test of
the various controls, gauges, lamps and switches on all the simulator
consoles, prior to a
well control session.
1.8 Engineering Reliability
The DrillSIM-20 simulation software implements the most current
industry mathematical
models available. To stay parallel with other Drilling Systems software
and simulation
products, the DrillSIM-20 uses the same simulation software used in the
highly developed
rig floor simulator, DrillSIM-20. Furthermore, use of the DrillSIM-20
may be integrated into
a sophisticated training environment with other Drilling Systems
established training
packages such as the Drilling Operations Trainer (DOT) and MudSIM for
drilling fluids
training. There is no competitive drilling training configuration that can
attempt to match
these integrated capabilities.
1.9 Standard Simulator Package
A full description of the standard simulator equipment is provided in
Section 5.
The following equipment and services are included in the standard
simulator package:-
• Trainee’s Operating Consoles
• Instructor Control Station (notebook)
• Portable Inject Printer (logger/recorder)
• Simulation Computer
• Input/Output Signal interface
• Interactive Sound System
• Transit Pack
• Simulation Software
• UPS
• Interconnecting Cables
• Operators Manual
• Spares Kit
• Product Acceptance Test
• Instructor Training
• Warranty
• Product Support
1.10 Trainee Operating Consoles
To provide a realistic training environment, the DrillSIM-20 control
consoles are
representative of instrumentation and controls found on a modern
drilling rig. Trainees are
provided with four consoles which enable him to undertake control of
simulated drilling and
well control exercises:-
• Pumpers Console
• Remote Choke Control Console (Swaco representation)
1.11 Instructor Control Station
The instructor is equipped with a powerful notebook (laptop) computer.
Extensive support
software provides the instructor with full monitoring and control over
simulation exercises.
In addition, this PC can be used in an off-line mode for exercise creation
and
administration.
Note – The exact specification of notebook is confirmed at Purchase
Order stage.
1.12 Portable Logger/Plotter:
A portable colour inkjet printer provides on-line plotting functions with
two selectable
modes:-
• Well Control plotting Mode
• Drilling Plotting Mode
This printer can also be used for general administration purposes in it’s
off-line capacity.
1.13 Simulation Computer
The DrillSIM mathematical model runs on the Instructor Notebook.
1.14 Input/Output Signal interface
A dedicated PC-based Input/Output Signal Interface system provides
the communications
between the Trainee’s operating panel instrumentation and the
simulation computer.
1.15 Interactive Sound System
The simulator is equipped with a fully interactive, electronic, sound
system which provides
audible feedback of rig equipment operations:-
• Rig sounds (12)
• Speakers (2)
1.16 Transit Pack
• One Durable Polypropylene Shell Suitcase (For all equipment)
DrillSIM-20 simulator modules are engineered to withstand everyday
use and the rigours of
transport by air, sea or overland. The specially designed simulator
consoles are sized to fit
into the single “Samsonite style, poly” suitcase which is completed with
foam inlays to
reduce the effects of shock and water ingress during transport.
If the simulator is to be shipped in advance (unaccompanied), then ABS
transit cases are
available as an option.
1.17 Simulation Software
A full suite of DrillSIM-20 software provides for the following simulator
functions:-
• DrillSIM Drilling & Well Control Mathematical Model
• Instructor Control Facility
• Input/Output Signal Interface Scheduling Utility
• Plotting & Logging Utility
• Hardware Diagnostics Utility
• Instrument Calibration Check Utility
• Well-snap Database Management Utility
1.18 Interconnecting Cables
All power and interconnecting signal cables are provided as follows:-
• Power Cabling including:-
4 x Power Cables
1 x Extension power lead
1 x 4 extension socket (with surge protect)
• Signal Cabling including:-
2 x Interconnecting 50 way Centronics I/O cables
3 x Interconnecting 36 way Centronics I/O cables
1 x Simulator Communications Cable
1.19 Product Support
Drilling Systems maintains a team of hardware and software engineers
providing technical
and user support to the purchaser during the warranty period. If
required, extended
support facilities are possible.
1.20 Operational Capability
1.20.1 Normal Operation
The simulation equipment is capable of providing a trainee with
appropriate levels of
training in the drilling and well control operations necessary to drill a
well down to a depth
of 30,000 ft.
During use of the Simulator, basic and advanced training can be given
in:-
• Blow-out Equipment Operational Control
• Blow-out Prevention
• Well Control
• Down-hole Well Control and Equipment Problems
Although the simulator has full drilling capability, emphasis is not placed
on these aspects
within this proposal which more correctly address training capabilities
for well control
training.
1.20.2 Operational Effects
During the course of an exercise, depending on the conditions selected,
the simulator is
capable of creating combinations of the following effects:-
• Kicks from High Pressure Permeable Formations.
• Pipe Surge and Swab.
• Kicks while Drilling, Tripping and POOH.
• Multiple Kicks.
• Lost Circulation.
• Formation Fracture.
• Underground Blow-out.
• Mud System Changes.
• Surface Sizing and Testing.
1.20.3 Simulated Malfunction States
In addition to the Operational Effects, the Instructor can introduce a
number of simulated
malfunctions which fall into the following categories.
• Well Control Equipment Problems, e.g. Pump failure or Choke Wash-
out.
• Down-hole Problems, e.g., Bit Nozzle Washout or Key Seat Sticking
• Instrument Problems, e.g. Drill-pipe Pressure Gauge Failure.
1.21 Complementary Training Packages
In addition to the range of Drilling and Well Control Simulators, Drilling
Systems has sold
over 70 PC based drilling engineering training packages world wide for
training personnel in
directional drilling, drilling operations and drilling fluids management.
The Drilling
Operations Trainer (DOT) has been used for training Shell well-site
drilling and petroleum
engineers at the Shell Training Centre in The Netherlands for since
1990.
In addition, the Mud Treatment Simulator, MudSIM, has been used in
interactive skills
training since 1992 by trainees attending the Shell's International's
Training Centre.
In 1995, the Drilling Management Trainer, DMT, was completed for
Shell International in
the Netherlands. The DMT is based around a 4 person syndicate group
using a networked
PC environment in the role of Driller, Mud Engineer, Drilling Supervisor
and Well-site
Geologist. All these PC based packages have received numerous
accreditations from
trainees and instructors as major contributory tools for enhancing the
learning and
understanding of advanced concepts of directional drilling and mud
management.
1.22 Documentation Guide
There are a number of documents in addition to this proposal that will
form part of the
overall contract documentation summarised as follows:-
The Simulator Acceptance Test Procedures Manual is reviewed and
signed off by both
the client and Drilling Systems, as a complete document by which the
simulator is deemed
to perform. Following manufacture, the client is invited to witness a full
schedule of initial
performance acceptance tests against this document. On successful
completion of the
tests, the Simulator Acceptance Test Certificate is executed by the client
and delivered to
Drilling Systems. This document then acts as the invoking key for final
payment.
The Simulator Operators Manual is a full reference manual on the
operations of the
Simulator and supplied during the Initial Acceptance Testing period.
The Well Control Training Manual was initially developed for Drilling
Systems by a
drilling consultant with over 20 years world-wide drilling experience.
Drilling Systems offers
the manual to any client wishing to make use of this technical
publication as part of the
well control simulation training programme. A copy of the manual is
available for review by
the client following execution of the contract.
The Simulator License and Technical Support Agreement provides the
legal
framework for the provision of the simulator. The simulator has a full
one year hardware
and software warranty. Thereafter an annual servicing fee is charged for
provision of
technical support for the software, release of new software upgrades
and remote support.
The Simulator Maintenance Contract: The simulator hardware
maintenance contract
provides on going support for the simulator hardware following
completion of the warranty
period. There is no annual maintenance charge, parts are recharged out
as consumed
together with any on site installation costs. The contract is geared
towards subcontracting
to a local electronics engineer, close to the simulator installation.
2. TRAINING APPLICATIONS AND OPERATIONAL CAPABILITY
2.1 Introduction
The DrillSIM-20 portable simulator exceeds the simulation equipment
standards set by
regulatory authorities world wide. Current simulation mathematical
models implemented,
provide the Instructor with maximum flexibility in basic and advanced
well control training.
This section describes the training applications that an Instructor can
call upon to provide
realistic training in drilling and well control.
The Instructor Facilities enable a wide range of training exercises to be
performed. This is
achieved through the generation of well snapshots, whereby parameters
defining
equipment type and performance, together with well and geological
characteristics, are
chosen to enable a specific training objective to be attained.
2.2 Well Control Training
The DrillSIM-20 meets world wide regulatory requirements for
simulation training
equipment. The equipment and software simulates a wide variety of
well control methods.
The simulation permits the kicking zone to be placed at any depth in the
well-bore. Lost
circulation zones can be selected at the bottom of the hole or at the
casing shoe. Trainees
can be faced with multiple kicks in the well-bore or underground blow-
out conditions
depending upon the exercise as set up by the Instructor and the
trainees own quality of
operational control.
Equipped with the Surface BOP and the optional Sub-sea BOP Controls,
the DrillSIM-20
provides the opportunity to train crews, how to handle kicks on land and
deep water
operations.
The DrillSIM-20 provides an excellent opportunity for demonstrating the
causes of kicks.
Such demonstrations assist trainees in the formulation of proper
procedures to prevent
kicks. Causes of kicks that can be demonstrated on the DrillSIM-20
include:
• Insufficient Mud Density
• Loss of Circulation
• Abnormal Formation Pressure
• Failure to Fill the Hole on Trips
• Swabbing
2.2.2 Kick Warning Signs
The Instructor can configure geological formations to provide transition
zone into a high
pressure reservoir. While drilling through the transition zone, trainees
learn methods of
abnormal pressure detection. As the formation pressure increases the
associated drilling
instrumentation displays the critical data needed to detect the abnormal
pressures. When
the kick zone is penetrated by the bit and formation pressure is greater
than the
hydrostatic pressure, formation fluid enters the well-bore. Throughout
this process drill
crews are taught to identify the warning signs of a kick.
When drilling with returns to surface, a kick cannot occur without any
warning sign. The
DrillSIM-20 instrumentation and simulated rig equipment react to a kick
situation in the
same way as the equipment in the field. The trainees must set up the
appropriate alarms
and observe the drilling instrumentation in order to recognise the kick.
Recognition of any
warning sign should result in an immediate flow check of the well.
Simulated kick warning signs that can be observed during drilling
operations include:-
• Penetration rate increase
• Increase in rotary torque
• Flow rate increase
• Pit gain
• Increase in background gas
In the tripping mode, the DrillSIM-20 implements the same
instrumentation and simulated
equipment as used in the field. The trainee is required to use the trip
tank and complete a
trip record when running in or pulling out of the hole. Formation fluid
influx should be
recognised by observing the trip record. A reduction in the volume of
fluid required to fill
the hole would require an immediate well-flow check. If the well is not
flowing, the drill
string should be run back to bottom and the circulated bottoms-up. It
may be necessary to
circulate the influx through the choke.
Simulated kick warning signs that can be observed during tripping
operations include:
• Trip tank volume increase
• Well-bore flow
• Loss of make-up fluid to the well
2.2.3 Shut-in Procedures
The DrillSIM-20 provides the features for practising both soft and hard
shut-in procedures.
The Instructor can use the simulator to show the various shut-in
procedures while drilling,
tripping or out of the hole. The correct procedures according to
company policy can be
implemented and practised by trainees.
The DrillSIM-20 provides a realistic rig environment requiring team-
work to properly close
in the well. In the drilling mode, the DrillSIM-20 can be used to
demonstrate the
importance of raising the drill string off bottom and ensuring the
necessary space out of
the tool joint in the BOPs. Once the pumps have been stopped the crew
can close in the
well using the proper procedures.
When the well is shut-in, the pressure stabilisation time will be
dependent upon the
reservoir parameters set by the Instructor. Low permeability wells will
take much longer to
stabilise than high permeability wells. Trainees record the stabilisation
of shut-in pressures
to interpret the actual point of stabilisation. From the information
acquired, gas migration
rates and influx gradients can be calculated.
Once pressure stabilisation occurs, a gas kick will continue to migrate
up the annulus and
increase the surface pressures. Gas migration rates can be accelerated
by the Instructor if
required. Trainees can be taught procedures for bottom hole pressure
maintenance while
the kill mud is being prepared.
DrillSIM-20 well control simulation enables the complete
implementation of the Wait and
Weight Method. This method allows for the circulation of kill mud and
removal of the influx
in one circulation.
Following an influx in to the well-bore, the well is shut-in and the
stabilised pressures
recorded. Calculation of the mud weight increase by the trainees is then
based on the
stabilised shut-in drill-pipe pressure. The mud density is then increased
to kill the well on
the Mud System Control Screen. Circulation of the kill mud is
commenced following the
proper line up of the standpipe and choke manifold and the mud
system. The simulator
displays the pressures on the drill-pipe and the casing, while the kill
mud is being
circulated. Trainees identify the position of the influx and kill mud from
the pressures and
data displayed on the Drilling Controls and Mud Instruments Console.
The sub-surface graphics screen displays movement of the influx within
the annulus and
the kill mud being displaced down the drill-pipe and up the annulus.
Mud tank volume
instrumentation will display an increase in volume as the gas
approaches surface. Once the
well is completely displaced with kill mud, the well is closed-in and the
final shut-in
pressures recorded. If the shut-in pressures are zero and no flow exists
on a flow check,
the well has been killed successfully.
During the well kill period the Instructor may accelerate the simulation
process faster than
real-time. Rather than attempting to recreate identical scenarios for
repetition, exercise
snapshots may be saved at any time. This provides the Instructor with
the flexibility of
repeating segments of exercises where trainees display difficulty in
specific areas. It also
allows them to leave the exercise at that particular point and start from
the same point at
some future time.
2.2.5 Driller's Method of Well Control
DrillSIM-20 well control simulation enables the complete
implementation of the Driller's
Method. The Driller's Method involves two circulation steps to kill the
well if a kick is taken
while drilling. In the first step trainees circulate out the influx using the
original mud
density and a constant bottom hole pressure. In the second step, kill
mud is circulated at a
constant bottom hole pressure. Trainees can be taught the procedures
of this method
including the interpretation of pressures at the various stages of its
implementation.
Typically the first step of the Driller's Method is used to circulate out trip
gas or a swabbed
kick once the string has been stripped or run back to bottom.
The DrillSIM-20 simulation allows for practice of the Volumetric Method
of Well Control with
or without drill-pipe communication. The simulator calculates the
various pressure and
volume changes of the gas as it moves up the annulus. Trainees are
instructed in the
proper line up of the trip tank and manifold systems to perform this well
control procedure.
Bottom hole pressure is maintained by performing a controlled fluid
bleed off during influx
migration. This controlled bleed-off can be performed dynamically while
circulating across
the well-head, or by the conventional method. Drill crews learn to
calculate the influx
migration rate and experience bottom hole pressure maintenance
procedures.
2.2.7 Bull-heading Method of Well Control
Under certain conditions the simulator enables Bull-heading of the influx
back into the
formation. Training to align manifolds and surface equipment and then
to perform this
method of well control can be undertaken. Numerical practice of
performing the standard
well control calculations can be proven on the simulator. The simulator
displays the
pressure and surface volume changes as the influx is forced back into
the formation. The
potential for loss of circulation always exists, therefore careful planning
is required prior to
implementation of this method.
2.2.8 Concurrent Method of Well Control
The simulator supports implementation of the Concurrent Method by
allowing the mud
density to be increased in stages as the kick is circulated from the well.
The mixing of the
weight material is controlled via the Mud System Control Screen. The
DrillSIM-20 software
tracks the various fluid density regions in the drill string and the well-
bore and displays
these regions on the graphics screen.
2.2.9 Down Hole and Equipment Problems During Well Control
The DrillSIM-20 enables a number of down-hole and equipment
problems to be simulated
during any well control exercise. Trainees can react to realistic problems
and sharpen their
skills by repeating the exercises several times. Presented with this type
of realistic training
they become far more confident in their own ability and therefore
become more competent
should a similar event occur in the field.
3. SIMULATOR EQUIPMENT DESCRIPTION
3.1 Introduction
This section provides a physical description of those items of equipment
which are supplied
as standard components of the DrillSIM-20 Simulator. The Technical
Specification
associated with the documentation will provide the detailed design
specification of the
Company's configuration requirements, and will form part of the legal
contract for the
deliverables.
3.2 Simulation Computer
Due to the advances in computing technology, in 2006, Drilling Systems
moved from using
a dedicated “flash-pack” processor to using the Instructor notebook to
run the
mathematical model.
3.3 Instructor Simulator Control Station
The Instructor’s simulation control facilities are executed within a
dedicated Pentium colour
laptop PC. This processor serves a number of purposes including the
following:-
• Instructor Control Facilities
• Mud System Control
• Driller's Window Graphics.
This processor also acts as the main storage medium for all simulation
programmes.
During start-up, some of the programmes are downloaded to the Flash-
pack simulation
The Instructor's control terminal implements mouse technology
providing a user friendly
environment for exercise configuration for on-line control of simulation
exercises. A
number of on-screen icons enable single "click-on" simulator control
entries, alleviating the
need to type out commands on a keyboard
Hot keys on the keyboard enable the Instructor or trainee to select
modes for graphics,
mud system control and Instructor facilities. The real-time Driller's
Window graphics are
displayed on the Instructor's Screen when the appropriate hot key is
activated.
3.4 Portable Drilling & Well Control Chart Plotter
The Drilling and Well Control Chart Plotter is a portable colour inkjet
printer. In well
control mode the plot provides the Instructor with a written record of
the capability of the
trainee to maintain bottom hole pressure, as the kick is circulated out of
the hole. In
drilling mode it provides a record of optimisation and drilling efficiency.
The following parameters are continuously sampled and stored in a
buffer for transfer to
the plotter every 30 seconds:-
Drilling Mode: Well Control Mode:
Pump Stroke Rate Pump Stroke Rate
Penetration Rate Pit Deviation
Rotary Table Speed Casing Shoe Pressure
Rotary Torque Drill-pipe Pressure
Pump (Total) Stroke Rate Casing Pressure
Standpipe Pressure Bottom Hole Pressure
3.5 Simulator Control Consoles
The simulator comprise four portable consoles which provide trainees
with their operating
environment:-
• Pumpers Console
• Remote Choke Control Console
3.5.1 Pumpers Console
The Pumpers Console is equipped with the basic controls required for
drilling and well
control. The console includes controls for the draw-works and pumps.
Two throttle controls are fitted to the console for the following
functions:-
• Pump 1 SPM
• Pump 2 SPM
Two switch controls are fitted to the console for the following
functions:-
• Pump 1 (On/Off)
• Pump 2 (On/Off)
The Drum Clutch and Driller's Brake are simulated by means of a toggle
switch and
miniature brake handle, for the raising and lowering of the drill string
and control of
weight-on-bit.
The drilling instrumentation on the face of the Console includes three
digital displays:-
• Pump Pressure (a toggle switch between Tap 1 and Tap 2 is also
provided)
• SPM
• Total Strokes (A reset button for Total Strokes is also provided)
3.5.2 Remote Choke Control Console
The Remote Choke Control Console is designed to resemble a Swaco
remote choke
console.
In its standard configuration the remote choke console consists of the
following controls
and instrumentation:-
• Choke Open/Close Valve
• Choke Rate Adjustment
• Pump 1 Selector Switch
• Pump 2 Selector Switch
• Total Strokes Reset Push-button
• Drillpipe Pressure Gauge
• Casing Pressure Gauge (or optional Choke Pressure Gauge)
• Kill Line Pressure Digital Display
• Choke Position Indicator
• Digital Display for SPM
• Digital Display for Total Strokes
4. SCOPE OF SIMULATION
4.1 Introduction
The simulation programmes within the DrillSIM-20 are wide ranging and
allow the
Instructor to vary the performance and scope of simulation in a number
of key areas. The
simulator offers immense flexibility in the software and simulated
drilling equipment to drill
a well and perform well control exercises. This is a key difference to
other simulators that
offer a restricted list of options and exercise scenarios that can only be
selected with predefined
characteristics. The DrillSIM-20 provides user friendly mouse driven
facilities
enabling Instructors to easily set up simulation scenarios and control
the simulation
exercise. The simulator does not lead the trainees through the
operation, but allows them
to think for themselves and learn from their mistakes. The learning
value is substantial
since each individual is now accumulating skills training within the
classroom environment.
This section describes:-
• Mud System Control
• Circulating System
• Blow-out Prevention and Well Control System
• Equipment and Operational Malfunctions
• Down-hole Effects
• Well Control
4.2 Drilling Fluid Circulating System
In addition to the extensive range of equipment which is controlled
directly through the
trainee operator’s control consoles the simulation accounts for a range
of other rig
operations for which there is no physical simulated hardware equivalent
and act to enhance
the depth of training. Many of these functions are related to the mud
circulating system.
These are controllable by the trainee or instructor via a series of Mud
System Control
Screens included within the Instructor’s Control Terminal.
4.2.1 Mud System Control
Mud System Control Screens facilitate control over certain operations of
the mud system
and auxiliary rig equipment. Mud System Control is available through
the Instructor PC.
The following functions are catered for:-
• Monitoring & control of density of the mud in the Reserve Tank
• Control of capacity of the Reserve Tank
• Monitoring & control of volume of mud contained in the Reserve Tank
• Monitoring & control of density of the mud in the Active Tank
• Control of capacity of the Active Tank
• Monitoring & control of volume of mud in the Active Tank
• Dump the entire contents of the Mud Tank
• Monitoring and reset control of relief valve settings for all mud pumps.
• Monitoring & control of the status of the following valves;
Reserve Tank Pump to Active Mud Tank.
Reserve Tank Outlet to Mud Pumps.
Active Tank Outlet to Mud Pumps
Riser to Flow-line Valve
Flow-line to Trip Tank Valve
Flow-line to Shaker Valve
De-gassed Tank Outlet to Trip Tank
Make-up Water Outlet to Active Mud Tank.
Activating the transfer pump between the , reserve mud tank and the
active mud tank<, BR>causes changes to the contents and density of
the active mud tank. A reduction in reserve
tank volume will also be seen. Tank contents includes the volume of
accumulated sol, i,, , ds
from drill cuttings.
In addition the following can be displayed:-
• Properties of the Active Tank Mud (I.e. plastic viscosity and yield
point).
• Properties of the Reserve Tank Mud (I.e. plastic viscosity and yield
point).
4.2.2 Mud Tanks
The mud tank and solids control equipment included in the simulator
offers experience in
the principles of circulating fluid control. The system is capable of
demonstrating the
importance of volumetric and material balances of drilling fluids.
During an exercise, if any of the, following situations occur as a result of
simulated process
conditions, the relevant Mud System alarm activates, depending on the
limits set. Alarm
situations result in an audible alarm tone, accompanied by an
identifying alarm light.
• Mud Pit Gain/Loss.
• Change in Mud Flow Rate.
• Trip Gain /Loss
In addition, the Instructor can set process conditions that cause the
alarms to activate.
Alarm malfunctions can also be triggered by the Instructor.
The surface mud tank equipment includes the following:-
• Active Mud Tank
• Reserve Mud Tank
• Trip Tank
• Strip Tank
• De-gasser Tank
4.2.2.1 Active Mud Tank
Density, plastic viscosity and yield point properties of the mud are all
catered for in the
tank systems.
The contents of the active tank are defined by a volume of mud
available for circulation
and a volume of settled solids created by an accumulation of returned
drill cuttings not
removed by the solids removal equipment. Solids in the tank are not
available for
circulation through the mud pumps. The effect of solids build up is
therefore to reduce the
available volume for the storage of circulating mud.
The quantity of drill cuttings returned to the active tank depends upon
the efficiency of the
solids removal equipment and ranges from 0 to 100% of cuttings
brought to the surface.
An Instructor defined parameter determines the percentage of solids
allowed to settle in
the active tank remaining after solids removal. This percentage
accumulates in the active
tank. The remainder of the solids, not removed and not settled, is held
in suspension in the
circulating mud contained in the tank. Accumulated suspended cuttings
alter the density of
the mud contained in the tank. Cuttings assume a constant density.
The volumes of solids and both volume and density of mud is updated
dynamically
depending upon the volumetric resultant of flows into and out of the
tank. Flows to and
from the tank may consist of combinations of the following:-
• Return line mud flow-rate.
• Return mud flow-rate from the degasser.
• Trip Tank Fill/Drain flow.
• Make up water flow.
• Reserve and Active tank flow-rate, depending on levels in both tanks.
• Tank outlet flow-rate through the pumps.
The trainee can change these conditions through either the optional
Mud System Control
Console or by requesting changes through the Instructor. In addition,
he has the facility to
'dump' the contents of the tank into the disposal pit. This operation
immediately empties
the tank of both mud and accumulated solids.
4.2.2.2 Reserve Mud Tank
Both the volume and density of the mud contained in the reserve mud
tank are defined in
a well snapshot. The trainee, through the mud system control screens,
or through the
Instructor's Laptop PC, is able to change both properties prior to, or
during the course of
an exercise.
Flow out of the reserve tank is either by transfer pump direct to the
active mud tank or via
the mud pumps to the active system. Pumping mud from the reserve
tank to the active
tank results in an instant change in the density of the active tank mud.
4.2.2.3 Trip Tank
The contents of the trip tank are the dynamic resultant of flows into and
out of the tank
due to:
• Fill Flow
• Pump Flow
• Dump Flow
Fill flow rate is fixed when the fill valve is opened. Reverse flow is
inhibited. Dump flow rate
is fixed to the disposal tank when the dump valve is opened, provided
that there is a
volume of fluid within the trip tank.
Pump flow rate can be varied by the Instructor. When the well is full,
the pump will
circulate fluid across the well back into the trip tank.
If the flow-line to trip tank valve is open and the shaker valve closed
and return flow
exists, mud is diverted into the trip tank until it is full. Thereafter,
further flow is an
overflow and loss to the active tank volume is registered.
The density of mud contained in the trip tank is always assumed equal
to that of the active
tank mud. Returned cuttings to the trip tank are ignored and effectively
lost from the
simulation.
The content of the simulated Trip Tank (volume and mud density) is
defined in a well
snapshot. However, during an exercise the trainee can make-up, pump
out or utilise the
tank contents, as required, from the Drilling Controls and Instruments
Console where the
following facilities are provided:-
• Tank level Indicator (0 to 50 Bbls).
• Dump Valve, Open/Close push button.
• Fill Valve, Open/Close push button.
• Trip Tank Pump, ON/OFF push button.
4.2.2.4 Strip Tank
The contents of the strip tank are the dynamic resultant of flows into
and out of the tank
due to:
• Fill Flow
• Pump Flow
• Dump Flow
Fill flow rate is fixed when the fill valve is opened from the trip tank.
Reverse flow is
inhibited. Dump flow rate is fixed to the disposal tank when the dump
valve is opened,
provided that there is a volume of fluid within the trip tank.
Pump discharge flow-rate can be varied by the Instructor. When the
tank is full, the pump
will transfer the fluid back into the active tank.
The density of mud contained in the strip tank is always assumed equal
to that of the
active tank mud.
The volume of the simulated strip tank is defined in a the well snapshot.
However, during
an exercise the trainee can fill, pump out or dump the tank contents, as
required, from the
Drilling Controls and Mud Instruments Console where the following
facilities are provided:-
• Strip Tank Level Indicator (0 to 50 Bbls).
• Fill Valve, Open/Close push button.
• Dump Valve, Open/Close push button.
• Strip Tank Pump, ON/OFF push button.
4.2.2.5 Degasser Tank
Flow out of the choke manifold is either direct to the active system via
the degasser tank
or directed to the trip tank in the case of stripping operations. The
appropriate valves can
be aligned on the mud system control screen. When the trip tank is full
the mud can be
dumped or pumped back to the active system. Returned cuttings
circulated through the
choke manifold are ignored and effectively lost from the simulation.
4.2.3 Drilling Fluid
The simulator enables trainees to gain experience in handling a fluid
which exhibits the
properties of a typical drilling mud. Fluid properties ascribed to the
drilling mud are those
of density, yield point, plastic viscosity, consistency factor and
compressibility. The
simulated drilling mud is non-Newtonian in character, because the
effective viscosity varies
with shear rate.
A mud density is chosen to provide sufficient hydrostatic head as a
counterbalance against
formation pressures, preventing an influx of formation fluids into the
well-bore. A high mud
density may risk formation fracture and lost circulation, thus attention
must be paid to
selecting the correct mud weight.
The mud system make-up water supply is controlled through the mud
system control
terminal with feed water rate set during exercise preparation.
Mud compressibility is observed when fluid is pumped into a closed
volume e.g. during a
leak-off test. Fluid compression is accounted for inside the drill string
during normal
circulation. While compressing mud by pumping, the resulting pressures
are a function of
the volume of closed section of network, volume of mud pumped and
mud weight.
Excessive pressures produced by compressibility may result in
formation fracture or blown
pump pressure relief valves.
The drilling fluid provides for the buoyancy effects on the drill string,
casing or liner present
in the well.
4.2.3.1 Density Tracking
Effects of fluid density on circulating pressure losses and down-hole
hydrostatic head
pressures provide basic training in surface equipment limitations and
well control
techniques. The density of fluid, whether it be circulating mud, cement
or influx fluid in all
parts of the flow network and storage tanks, is monitored dynamically
in response to
student or Instructor actions.
The density of fluid may be different at various points through the
circulating network.
Each section of fluid of the same fixed density, up to thirty are allowed,
is treated as a
'slug'. Once established, the progress of the slug is monitored as it is
transported through
the network. The position of the leading and trailing edges of the slug
are updated
dynamically, dependant on the flow rates and geometry of each section
of the network.
All slugs in the drill string will transfer to the annulus only through the
bit. Density and
volume changes due to pipe washout and twist-off are not catered for.
Slugs created down-hole due to kick influx take on the density of the
influx. No account of
density changes due to mixtures of circulating and kick fluid are
accounted for.
During tripping operations which are defined by the removal of one or
more stands from
the drill string, all mud down-hole will take on the density of that
contained in the active
tank. Assuming that a complete circulation has been completed prior to
commencement of
tripping.
4.2.4 Mud Pumps
The mud pumps are positive displacement units. Two mud pumps are
provided and
controlled from the Driller's Control Console. The Instructor can select
pump
characteristics: duplex; triplex; liner; stroke; efficiency and pop valve
setting.
The driller demands a pump speed using the speed control and sees the
current SPM on
the SPM display. The resulting pressure is a function of the mud
properties and the
resistance of the flow path.
Depending on the efficiency of the controller, the position of the speed
control will need to
be varied to achieve a given SPM according to the pressure delivered.
Mud pump relief valves can be reset by the trainee using the
Instructor's terminal
commands or through the Driller's Window and Mud System Control
Console. Relief valves
can not be reset unless the pump speed controllers are completely off.
4.2.5 Standpipe Manifold
The Standpipe Manifold is designed to provide maximum flexibility with
any simulated
exercise and is arranged so that:-
• Either Mud Pump can be lined up with the standpipes, choke manifold
or kill line.
• The Standpipe Manifold can be connected directly to the Choke
Manifold.
• The Standpipe Manifold can be isolated from the Standpipe.
• The Standpipe Manifold is operated by a number of manually operated
valves.
4.2.6 Choke Manifold
The purpose of the chokes and manifold assembly is to provide training
in the correct
operation of this equipment during well control, and to allow exposure
to choke
malfunctions. A choke is a valve used to apply resistance to flow. This
resistance creates a
back pressure to control down-hole pressures when a kick is circulated
from the well.
The choke manifold is an arrangement of valves, lines and chokes
designed to control the
flow of mud and kick fluids from the annulus during the killing process.
The operation of two pairs of chokes are simulated. One pair are remote
chokes operated
by applying hydraulic pressure, the other pair are operated manually.
The Choke Manifold is provided with the following facilities:-
• One Manual Choke.
• Manual Choke Inlet and Outlet Isolation Valves.
• One Remote Choke.
• Remote Choke Inlet and Outlet Isolation Valves.
• Outlet Valves to Flare and Degasser.
• One Choke Line Inlet
• Connection to Standpipe Manifold
• Connection to Kill Line
The Manual Chokes have an on/off switch operation to indicate either
fully open or fully
closed. Control of the Remote Choke is achieved from the Remote
Choke Control Console
where indication of casing and standpipe pressure is also provided.
The throttling effect achieved when the Choke Manifold is in operation is
simulated. The
trainee can circulate out gas, oil and salt water influxes from the well-
bore. Proprietary
mathematical models developed for the Swaco choke simulate the flows
through the choke
and determine the respective pressure losses during well killing.
Simulator design assumes degassing by the Poorboy Degasser to be
100% efficient. No gas
is returned to the Mud Tanks during well control operations.
Choke sounds provide an example of the noise made by a fluid as it
passes through the
choke. The sounds are dependent on the type of fluid passing through
the manifold.
• A low frequency, low amplitude squeal is heard whenever mud or a
liquid kick influx is
circulated.
• A high frequency, high amplitude squeal is heard when gas is
circulated.
4.3 Blow-out Prevention and Well Control System
DrillSIM-20 is very precise in it’s simulation of operation of the blow-out
preventers to
ensure that actions by the driller create accurate responses on the
control system
instrumentation. Simulation modelling is in accordance to API
specifications 16D and RP53.
These models can be customised to meet any regulatory requirement
world wide.
4.3.1 Surface BOP Controls
The purpose of the Surface BOP Controls is to provide training in the
use, sizing and testing
of a typical surface BOP stack, used in land, jack-up and platform
operations.
The driller controls the opening and closing of the BOP stack elements
consisting of:-
• Annular Preventer.
• Upper Pipe Ram.
• Blind/Shear Ram.
• Lower Pipe Ram.
• Kill Line Valve.
• Choke Line Valve (HCR Valve).
Displays for:-
• Accumulator Pressure
• Annular Pressure
• Manifold Pressure
• Rig Air Pressure
• Hydraulic Fluid Flow.
• Accumulator pump running lamp.
• Additional controls:-
• Push to Operate Push-button
• Flow Meter Reset Push-button.
• Manifold Pressure Raise & Lower push buttons
• Annular Pressure Raise & Lower push buttons
The surface BOP is based upon a 13 5/8", 10,000 pi stack. Control of
the Stack is achieved
from the Surface BOP Control Console which is similar to those normally
encountered on a
rig floor. Furthermore, operation of the BOPs affects the remainder of
the Simulator in a
manner paralleling that of a live situation.
The behaviour of the closing elements is governed by the position of the
drill-string
elements and tool joints within the stack. Their operation is also
governed by possible
malfunctions.
When the PUSH TO OPERATE is held ON the supply of air is fed to the
spring-centred pilot
valves so that they become capable of moving the accumulator 4-way
hydraulic valves
which control the closing of the BOP elements.
Hydraulic fluid continues to flow until the actuator reaches the end of its
travel. If the valve
is moved to its other position, reverse flow begins.
Once a hydraulic valve has been engaged the actuator continues to be
driven even if the
pilot valve and master valve are released. Completion of actuator travel
is shown by no
further fall in accumulator pressure or register of fluid flow on the flow
meter. Successful
closing of the BOP unit is confirmed by flow or pressure testing.
The key parameters which govern the sizing of the accumulator, the
pump and the
actuators are available for the Instructor to change for training
purposes.
Apart from Instructor interference for training purposes, the pipe rams
are correctly
changed automatically to suit the diameter of the tubulars being
handled. The pipe rams
will seal on drill-pipe and heavy drill-pipe in the same string. They will
not seal on collars,
tool joints or the kelly. Pipe rams will seal on tubing but not on joints.
Pipe rams will seal
on casing.
The Instructor can activate malfunctions which inhibit the normal
working of the BOP stack
and set a flag which determines whether the lower pipe rams have been
correctly changed
to suit the size of the tubulars being handled.
4.3.2 Drill String Valves
Drill-string valves are used to prevent the movement of influx fluid up
the drill-string.
Training can be provided in the operation of drill-string valves during
well control.
Three types of drill-string valve are available to the trainee and
include:-
• A float valve is selectable at the start of an exercise and becomes a
permanent fixture of
the string.
• The inside BOP and the safety valve are selectable on the Instructor's
terminal during an
exercise, should the student request them.
• Upper and lower kelly cocks can also be activated from the
Instructor's laptop PC.
When a non-return valve is operational, a shut-in drill-pipe pressure is
obtained by
circulating slowly until the valve is cracked open.
4.4 Simulated Equipment and Operational Malfunctions
The simulator provides for a wide variety of typical equipment and
operational malfunctions
to sharpen the troubleshooting and problem skills of the trainees.
Malfunctions can be
customised to improve performance with in-house company procedures.
4.4.1 Instrumentation Malfunctions
The instrumentation provided on the various the DrillSIM-20 consoles
reacts in a similar
manner to that encountered in field equipment. The Instructor can
initiate the following
malfunctions:
• Total Loss of Reading.
• Instrument Stick (the instrument remains at value set at time of
malfunction.)
• False Reading (calibration offset).
The instruments which can be affected are as follows:-
Drilling Controls and Mud Instruments Console:
• Pump Pressure indicator.
• Mud Pump 1 SPM Indicator
• Mud Pump 2 SPM Indicator.
Note: Malfunction of any SPM Gauge will also affect the associated SPM
Counter.
Remote Choke Control Console:
• Drill-pipe Pressure Indicator.
• • Casing Pressure Indicator.
4.4.2 Fluid Handling System
The Instructor can initiate the following malfunctions relating to the
Fluid Handling
System:-
4.4.2.1 Mud Pump Malfunctions:
Both pumps are subject to the following
• Pump 1 Total Failure
• Pump 1 Low Pumping Efficiency
• Pump 2 Total Failure
• Pump 2 Low Pumping Efficiency
4.4.2.2 Choke Malfunctions
Choke operation is subject to plugging, washout and seizure
malfunctions. The effect of a
washout is to cause a larger area of flow than that set. A flow restriction
is present when
material transported from the well plugs the choke orifice.
A seized choke remains in its seized setting regardless of control
actions. This applies to
the Remote Choke.
The simulator enables the following choke malfunctions:-
• Remote Choke Valve Fail Plugged
• Remote Choke Valve Wash-out.
• Remote Choke Valve Seizure.
• Manual Choke Valve Wash-out.
• Manual Choke Valve Plugged.
4.4.2.3 Surface BOP Stack Malfunctions
The following malfunctions may be activated by the Instructor:-
• Annular Preventer Actuator Failure.
• Annular Preventer Leak
• Blind Ram Actuator Failure.
• Upper Pipe Ram Leak
• Lower Pipe Leak
• Lower Pipe Ram Actuator Failure.
• Accumulator Pump Auto Switch Fail.
Failed actuators do not respond to control actions. The actuator remains
in the state is was
in when the failure malfunction was activated.
4.4.2.4 Subsea BOP Stack Malfunctions
The following simulated malfunctions may be activated by the Instructor
if the subsea BOP
is supplied:-
• Annular Preventer Actuator Failure.
• Annular Preventer Leak
• Blind Ram Actuator Failure.
• Middle Pipe Ram Actuator Fail
• Middle Pipe Ram Leak
• Lower Pipe Leak
• Lower Pipe Ram Actuator Failure.
• Accumulator Pump Auto Switch Fail.
Failed actuators do not respond to control actions. The actuator remains
in the state it was
in when the failure malfunction was activated.
4.5 Well Control
This part of the Supplement to the DrillSIM-20 specification defines
those aspects of the
simulation which deal specifically with the well control and phenomena
occurring
underground. It assumed that industry accepted procedures will be
adopted in controlling
the various phenomena discussed.
Well kicks are defined as the influx of fluid consisting of gas, oil or salt
water into the well
bore by a pressure under-balance. An influx occurs when a high
pressure, permeable, fluid
bearing formation exerts a pressure in excess of annular pressure at the
same depth.
One of the geological formations defined in an initial condition set is
designated a potential
kick zone. For an influx to occur, the well depth must be such that it is
within or greater
than the depth of the designated zone, i.e. the kick zone should span an
area of exposed
bore-hole.
Formation pressure increases with depth depending on the pore
pressure gradient.
The simulation constantly monitors pressure in the annulus created by
all the effects listed
above and checks for under-balance in the region of the potential kick
zone set in the well
snapshot.
The Instructor has the facility to inhibit any influx irrespective of its
cause. This may be
used if the student is to be trained in aspects of drilling which would be
unnecessarily
confused by the occurrence of a kick.
A kick influx will only occur when under-balance occurs in the annulus
over the area of hole
designated as a potential kick zone.
• The potential kick zone defined in the geology is therefore assumed to
possess fluid at a
pressure equal to the gradient, multiplied by the depth of the zone.
• The well snapshot configured prior to exercise establishes the depth of
the bore-hole in
relation to the depth of the kick zone. It is possible for the well depth to
be greater than,
equal to, or less than the depth of the kick zone.
Under-balance may occur by combinations of one or more of the
following:-
• Drilling into high pressure permeable formations or faults
• Reduced Equivalent Circulating Density (E.C.D.)
• Low mud weights in annulus.
• Low mud hydrostatic head in annulus.
• Swabbing.
• Lost circulation
4.5.1.1 Drilling Into High Pressure Permeable Formations or Faults
Each well snapshot will contain definition of underground formation
characteristics and
pressure gradients. One of the ten formation layers will be defined as a
transition zone. All
formations above this zone will be subjected to a normal pressure
gradient, while all
formations below it will possess an abnormal gradient. The abnormal
gradient may be
greater or smaller than the normal gradient. While drilling through the
transition zone,
formation pressure will gradually change to that of the abnormal
gradient. If a high
abnormal gradient is selected, then an under-balance may occur,
depending on the mud
weight selected for drilling through the normally pressured zone.
The pressure exerted by a kick formation in the normal pressure zone
may be sufficient to
induce an influx if annulus pressure falls for any reason.
4.5.1.2 Reduced E.C.D.
The pressure at any point in the annulus is equal to the sum of the
hydrostatic heads
exerted by the mud columns plus the frictional pressure losses
downstream of that point.
The resultant down-hole pressure may be related to a head of mud,
sufficient to equal the
two components outlined above. This is known as an equivalent
circulating density
(E.C.D.).
This frictional effect changes as a function of flow rate and geometry of
the downstream
network. It is therefore possible for a balanced or over-balanced
annulus to become underbalanced
when flow rate or down-hole resistance is reduced.
An influx occurs at a rate depending on the magnitude of the imbalance.
4.5.1.3 Low Mud Weights in the Annulus
The hydrostatic pressure in the annulus at any point is a function of the
hydro-static head
exerted by the column of fluid and the density of the fluid above that
point.
Low annulus pressure created by fluids of low densities may therefore
result in a kick influx
to the annulus if a hydrostatic under-balance is achieved.
The presence of low density mud or the presence of oil, gas or water
already in the annulus
may be sufficient to induce such an influx.
4.5.1.4 Low Mud Hydrostatic Head in the Annulus
The annulus pressure at any point is a function of the hydrostatic head
exerted by the head
and density of the fluid column above that point.
A reduction in the level of fluid may result in an under-balance in the
annulus which is
sufficient to induce a kick influx. The rate of influx is a function of the
magnitude of the
under-balance.
Low mud level in the annulus may be due to the drill-string being
withdrawn during
tripping-out or through lost circulation due to formation fracture.
4.5.1.5 Swabbing on Trips
Down-hole pressures exhibit a drop when the drill-string is withdrawn
from the bore-hole.
The magnitude of the drop depends on the geometry of the drill-string
within the annular
space and the speed of withdrawal. The reduced pressure at the bit may
be sufficient to
create an under-balance and induce an influx to the annulus.
Once hoisting is stopped the swab pressure will reduce to zero. The
influx may then stop as
the hydrostatic head pressure in the annulus is sufficient to prevent any
further influx.
Consequently, the influx will only occur while hoisting. This is most
common during a
tripping out operation.
While tripping out, the volume of influx due to the swabbing effect will
accumulate in the
annulus. If the density of the influx fluid is less than that of the annular
mud, then the
annular hydrostatic head pressure in the region of the potential kick
formation is reduced.
Eventually, if no corrective action is taken by the driller, the well flows,
due to the underbalance
created by the reduced hydrostatic head, of gas in the annulus.
4.5.1.6 Lost Circulation
When the trainee allows the local hydrostatic pressure down-hole to
exceed the fracture
pressure of an exposed formation, fracture is simulated and mud is lost.
When the formation fractures, circulating mud is lost into the fractured
formation. A loss of
part or all of the return flow and, depending on down-hole pressures a
loss of mud from
the annulus occurs.
When fracture occurs, the rate of loss will be governed by the pressure
difference across
the fractured zone.
Fracture occurs at one zone. Lost circulation only occurs as a result of
fracture. It does not
occur as a result of an exposed low pressure permeable formation.
The fracture pressure of the formations is set up in the well snapshot
via the Instructor's
Laptop PC.
Exposed permeable formations, having formation pressures lower than
the local mud
pressure become blocked and caked with mud so that no appreciable
loss occurs.
Lost circulation is simulated in two ways:-
• As a consequence of formation fracture.
• As an Instructor injected malfunction.
Fracture occurs when the local annular pressure exceeds the formation
fracture pressure.
This may occur because of:
• High weight mud in the annulus.
• High circulating pressures.
• Pumping into a closed hole (leak off testing).
When this Instructor set malfunction is activated, a fraction of the
current return flow is
lost. This fraction may be varied and includes total loss. Formation
fracture, which leads to
loss of circulation, can be inhibited for training purposes by the
Instructor.
4.5.1.7 Failure to Fill the Hole on Trips
The simulator keeps an accurate track of the fluid level in the annulus
during tripping
operations. Drops in annulus fluid level caused by the trainee's failure to
fill the hole during
tripping operations will result in loss of hydrostatic pressure. This loss in
hydrostatic head
can be significant enough to cause an exposed reservoir to flow
formation fluid into the
well-bore.
If the well is filled after a small influx is taken there may be sufficient
hydrostatic pressure
to overbalance the kick zone pressure. Migration and expansion of the
kick may take some
time before being recognised. History has proven that these types of
kicks are usually not
recognised until the drill collars are in the rotary table or the string is
completely out of the
hole.
The DrillSIM-20 can trip the entire drill string from the hole. A kick
recognised whilst out of
the hole results in closure of the blind rams and a volumetric bleed of
the well as the gas
migrates to surface.
To prevent mistakes in keeping the hole full, trainees can mix up a
heavy slug in the
reserve tank and pump it prior to commencing the trip. In this way the
trip tank pump can
be left circulating across the well continuously whilst pulling pipe.
Respective hole fill
volumes can be recorded from the trip tank gauge or the Driller's Data
Display.
4.5.2 Types of Kick
The simulator caters for three different types of kick influx fluid to
provide the student with
a means of recognising the characteristics of each when the well is
closed in together with
an appreciation of the problems associated with the killing of wells
kicking with different
fluid types.
Each geological formation layer defined in a well snapshot is assigned a
contained fluid
type consisting of one of the following:-
• Gas
• Oil
• Salt Water
The specific gravity and viscosity for each type of kick fluid is also
defined in the well
snapshot by the Instructor. The dynamic well-bore fluids model
assumes the Instructor set
reservoir temperature and calculates the compressibility factor for the
gas at the top of the
reservoir. Gas compressibility is then used to determine the new volume
of expanded gas.
One of the geological layers defined in the well snapshot is marked as a
potential kick zone
for the exercise. If the kick zone is exposed by the bore-hole and under-
balance exists an
influx occurs, the magnitude of which depends on the viscosity for the
fluid type and
formation permeability. Flow rate is less with increases in kick fluid
viscosity and low
permeabilities.
Once in the annulus the volume of influx will affect the hydrostatic head
of the annular
column to a degree dependent upon the fluid density. When corrective
action taken by the
trainee to shut-in the well and prevent further influx, the surface
pressures stabilise.
Generally, the casing pressure exhibits a higher value than that of the
drill-pipe. The
difference is a function of the difference in densities between the influx
fluid and annular
mud displaced prior to the kick. The geometry of the annulus in the
region of the kick zone
also contributes to the difference by virtue of the influx height. The less
dense the influx
fluid the greater the casing pressure as the hydrostatic pressure exerted
in the annulus is
lessened, allowing more of the formation pressure to be exhibited at the
surface.
Knowing the down-hole geometry, the kick influx volume and the
standpipe and casing
pressures, the student is able to estimate the density of the influx fluid
following shut-in
and stabilisation. From the density estimated the fluid type can be
assumed.
All fluid types are handled assuming single phase flow characteristics.
Oil influxes will be
assumed dead containing no dissolving gas. Influx expansion during
migration will only
occur in the case of a gas or optional steam influx.
4.5.3 Condition Dependent Kick
Condition dependent influxes provide the trainee with experience of
possible kicks due to
normal or malpractice of surface controls.
During normal circulation whether for drilling or well control bottom hole
pressure is equal
to the annular hydrostatic head plus the downstream frictional pressure
losses.
During normal drilling the pressure loss occurs in the annular space
between the drill-string
and bore-hole.
During a well control circulation the pressure loss exerted by the choke
and associated
pipe-work is added. Frictional pressure losses are related to flow-rate.
The magnitude of bottom hole pressure changes according to and
depending on flow-rate
and the resistance to flow. Consequently it is possible that a balanced or
overbalanced well
may become under-balanced when the mud pumps are stopped and the
frictional losses
fall to zero.
If a potential kick zone is exposed to the open hole then this under-
balance results in a
kick influx in to the annulus. By resuming circulation the influx is again
halted by the
increased pressure loss and consequent increase in bottom hole
pressure.
Down-hole pressures are monitored dynamically for changes due to
both hydrostatic and
frictional pressures. Whenever under-balance occurs and a kick zone is
exposed to the well
bore an influx occurs provided that the Instructor has not inhibited the
kick through his
control terminal.
Once an influx has occurred, the volume and rate of influx depend upon
the student's
speed and proficiency in controlling the well.
4.5.4 Multiple Kicks
The simulator provides for multiple kicks to give the student experience
in taking in
additional volumes of kick fluid during the process of killing a well.
Control of circulation flow-rate and surface equipment resistances
influence down-hole
pressures. These effects may be sufficient to achieve under-balance in
annular areas
exposed to potential kick zones. Unless inhibited by the Instructor this
under-balance
results in a kick influx from the kick zone to the annulus.
Once recognised the trainee commences to kill the well and circulate
out the influx fluid
using his chosen method of control. If he allows under-balance to occur
again by careless
operation of the mud pumps or choke valves then a secondary kick will
occur.
Down-hole pressures are monitored dynamically for changes due to
both hydrostatic and
frictional pressures. Under-balance may occur at any time resulting in
an influx to the wellbore.
The volume and rate of influx depends upon the proficiency and speed
in initially
controlling the well.
A maximum of two separated influx volumes may exist in the annulus at
any instant in
time. Multiple slugs of gas influx are all subject to gas expansion and
migration.
4.5.5 Kick Influx Density
The simulation includes accurate influx density calculations allowing for
training on the
effects of surface pressures while killing a kicking well. Determination of
influx fluid density
and hence type will assist trainees to prepare themselves for handling
the influx when it
arrives at surface. Furthermore it may dictate the method of well
control used to reduce
casing shoe pressures in long open hole sections or require bull-heading
of the acid gas
influx back into the formation.
A volume of influx fluid in the annulus is treated as a slug of a known
density according to
its type. The hydrostatic head pressure exerted at bottom hole
comprises the sum of the
individual pressures exerted by each fluid slug in the annulus. The
component pressures
depend upon the density of individual slugs.
If influx fluid density is less than that of the mud it displaced then the
total hydrostatic
head created in the annulus is reduced. Consequently, during shut-in
there is a greater
imbalance between kick formation pressure and annular hydrostatic
pressure. This is seen
as an increase in casing pressure indication at surface.
Knowing the gain in pit level, the annular geometry and the difference
between drill-pipe
and casing pressures, the student is able to estimate the influx fluid
density. This is
essential to his deciding the course of action for circulating out the
influx. The density of oil
or salt water contained in the kick zone is Instructor defined.
Potential gas influxes are assigned a density depending on the depth of
the zone. As the
volume of a gas slug expands while being transported up the annulus,
there is an
associated drop in density so that a weight balance is maintained. The
density of gas within
a slug is assumed constant throughout its length.
4.5.6 Influx Flow Rate
The magnitude of the formation fluid influx is dependent upon down-
hole conditions.
The presence and magnitude of an influx flow-rate can be estimated
from surface
manifestations. The nature of the influx and its size determine the
approach to be adopted
during well control.
An influx fluid may be either gas, oil or water. The flow characteristics
of an influx fluid are
assumed to be that of a normal fluid in steady radial flow based on
D'Arcy's law.
4.5.7 Reservoir Draw-down and Stabilisation
DrillSIM-20 simulates the decay and recharge of a formation during it’s
flow into the well.
Standard reservoir engineering equations are used to build this
simulation model.
The phenomena of draw-down and stabilisation are detectable when the
well is shut-in, as
the surface pressures increase due to natural recharge of the formation.
The pressure of the formation immediately surrounding the hole falls at
a rate dependent
upon the actual influx flow-rate taking place.
When the well is shut-in, the pressure will recharge with time until it
equals the pressure at
the reservoir periphery. The rate of recharge is a function of
permeability.
The formation pressure surrounding the hole falls with flow and rises
with time. It will fall
until no further flow occurs because the under-balance at the bottom of
the hole has
temporarily been lost. It will rise until it achieves the normal formation
pressure as defined
by the formation pressure gradient.
This feature enables formation flow testing and evaluation.
4.5.8 Gas Expansion
An influx of gas into the well-bore from a high pressure formation is
under extreme
pressure, equivalent to the pore pressure of the formation from which it
originated. Due to
this high pressure, the gas bubble is under compression and expands in
volume when
exposed to lower hydrostatic pressure forces, higher up the well.
When the well is closed-in, the volume of gas is contained and hence its
pressure is stable.
Expansion is possible if the system allows outflow either towards the
surface or by loss due
to formation fracture.
While circulating out the kick by one of the preferred methods,
expansion is allowed under
controlled conditions. Mud is displaced from the annulus to the surface
storage tanks and
pits, resulting in a net gain in their contents equal to the amount of
expansion. The
displaced mud reduces the hydrostatic head exerted on the gas bubble.
Consequently,
casing pressure rises to that of the bubble itself when gas reaches the
surface. This
pressure can reach a maximum possibly approaching that of the kick
formation.
The surface and down-hole pressures respond dynamically to the
volumes, heads and
densities of down-hole fluids and control of pump speeds and chokes.
Gas expansion assumes Charles Laws including compressibility and
temperature. No
account is taken of heat transfer between the gas volume and the
ground surrounding the
well-bore however the simulation models the influx temperature
reduction at a rate less
than the geothermal gradient reduction as the influx moves up the well-
bore. Temperature
of the moving influx is dependent on pumping and migration rates.
4.5.9 Gas Migration
The simulator's gas migration model enables training and experience of
the hazards
associated with gas migration during well control procedures.
An influx of gas into the well bore from a high pressure permeable
formation is initially of
the pressure and density of gas remaining in the formation. When the
well is closed-in,
flow of fluid in the drill-string and annulus due to pumping or from the
kick zone, is halted.
However, the gas bubble 'floats' (migrates) to the surface as a function
of time by
displacing the heavier mud above it.
Provided that expansion is not allowed to occur by re-opening the well,
the pressure
exerted by the gas bubble may reduce because the influx temperature
is reducing. Casing
pressure gradually increases as the bubble moves up the annulus until
near full formation
pressure is indicated.
Down-hole pressures and drill-pipe pressures are subjected to similar
changes.
Consequently it is likely that lost circulation due to formation fracture
will occur prior to the
bubble reaching the surface. Lost circulation may result in reduced
hydrostatic head in the
annulus and further influx from the kick zone. Underground blow-out is
possible under
these conditions.
The number of separate bubbles existing in the annulus at any instant is
limited to two.
Migration of both bubbles is catered for.
The rate of migration of gas bubbles is linear and is Instructor defined
over the range 0-
3,000 ft/hr.
Migration only occurs while the well is shut-in and expansion is
inhibited. Whenever
expansion occurs a gas bubble assumes the volume and density
resulting from the
expansion. This results in a lower ultimate casing pressure when the
bubble migrates to
the surface.
Shut-in bottom hole pressure is equivalent to the hydrostatic head
exerted by the annular
mud column below the bottom bubble plus the pressure exerted by that
bubble.
Consequently, if no expansion takes place, bottom hole pressure can
attain a value
approaching twice that of the kick formation pressure.
4.5.10 Underground Blow-out
The simulator provides the trainees with experience of the various
sequence of events that
would lead to underground blow-out.
The mathematical model dynamically monitors down-hole conditions for
kick influx from
high pressure permeable formations and for formation fracture resulting
in lost circulation.
It is possible for both phenomenon to occur simultaneously. Once this
situation occurs
influx fluid from the kick zone may flow and be lost to the fracturing
zone above, hence an
underground blow-out occurs.
The effects of one of the two contributing effects can perpetuate the
initialisation of the
other. E.g. A gas kick induced to the annulus due to hydrostatic under-
balances, if not
controlled adequately can create annulus pressures due to expansion or
migration in
excess of the fracture pressure of one of the exposed formations. Part,
or all, of the influx
flow-rate may then be diverted to the fracture zone until the annular
space between the
kick and fracture zone is filled with gas. The back pressure exerted to
the kick zone is then
dependent totally on the fracture pressure as it will have lost
hydrostatic pressure due to
the mud column. This constitutes a drop in annular pressure which
increases influx flowrate.
Conversely, a fracture occurring due to high annular mud densities or
increased circulating
pressure can result in loss of returns and a fall in annular mud level.
The resultant reduced
hydrostatic head pressure may be sufficient to induce an influx from the
potential kick
zone.
Both the kick and fracture functions are totally independent in their
operation. Down-hole
pressures and flows are determined according to the effects of all
component flows and
restrictions defined in this document.
Provided that both the fracture and kick inhibit functions are de-
activated the occurrence of
an underground blow-out depends on the geology defined in the well
snapshot and the
reaction of the trainee during his control of the simulator.
Surface gauge indications and responses depend on the resulting flows,
levels and
pressures determined by the flow network for individual situations.
Exact definition of
surface instrument responses is therefore impossible to define due to
the large number of
permutations. The occurrence of underground blow-out effectively
marks the end of a
simulation exercise.
4.5.11 Dynamic Pressures During Well Control
The simulator can be used to provide training and experience in the
magnitude and
responses of pressures encountered during normal, abnormal and
hazardous
operations.
Three basic indications of the performance of the hydraulic system are
simulated during
normal rig operation.
• Pump Stroke Rate.
• Drill-pipe Pressure.
• Casing Pressure.
With these limited facilities he is able to monitor performance, diagnose
malfunctions or
anticipate and control impending hazardous situations in both forward
and reverse
circulating modes.
Pressure due to frictional losses, hydrostatic head of fluid columns or
gains from high
pressure fluid bearing formations are dynamically calculated at crucial
points throughout
the surface and down-hole circulating network.
During normal circulation, while drilling, surface pressures arise form
frictional pressure
losses through the drill-string, bit nozzle and annulus. These pressures
are relative to mud
flow-rate and efficiency. In this situation drill-pipe pressure indication
registers the total
pressure loss while casing pressure indicates zero.
The occurrence of a kick influx from a high pressure fluid bearing
formation assists in
transporting the mud column contained in the annulus to the surface.
Consequently, the
annular frictional loss due to pumping is reduced. The standpipe
pressure falls in
accordance with the ratio of component flows from the pumps and kick
zone into the
annulus.
While an influx is occurring, stopping the mud pumps will result in a
further fall in drill-pipe
pressure depending on the bottom hole pressure and hydrostatic head
exerted by the mud
column in the drill-string. This may result in zero reading of drill-pipe
pressure if the
formation is 'drawn down' dramatically.
Following a correct shut-in procedure both drill-pipe and casing pressure
rise with time
until stable values are achieved. The rise is due to the recharging of the
kick formation
increasing the bottom hole pressure. The steady state values following
shut-in allow the
trainee to estimate the density of the influx fluid.
If the influx fluid is oil or salt water then these steady state pressures
are sustained while
the well is closed in. A gas influx results in a gradual rise in surface and
down-hole
pressures due to migration.
While circulating out the influx through the chokes, surface and bottom
hole pressures
depend upon circulating flow rate, frictional pressure losses and choke
position.
There is a time delay between changing the choke position and seeing
the resulting
pressure change on the 'drill-pipe' pressure gauges (which are slaved
off the standpipe
manifold gauge). The 'casing' pressure gauges (slaved off the choke
manifold gauge)
respond almost immediately to changes in the choke position.
The simulated well control circulation path under consideration is down
the string, up the
annulus and through one of the chokes - the annular preventer or upper
pipe ram being
closed.
Pressure changes caused by altering the choke position take some time
to be reflected
back around the circulating path to appear on the drill-pipe gauges. The
occurrence and
extent of this time delay is an important training detail. If the choke
operator does not
allow for the time delay he may over-react in his use of the controls,
end up chasing the
pressure changes and failing to control the well.
The duration of the pressure delay is a function of the length of the path
tr, avelled by the
'pressure change' through the f, luids being circulated.
4.5.12 Kicks While Drilling Surface Hole
The simulator caters for kicks from shallow formations while drilling
surface hole. If
equipped , with, , a, surface or sub-sea diverter system the necessary
procedures can be taken
to divert the kick while displacing the well with heavy mud.
4.5.13 Kicks While Drilling
The purpose of taking kicks while drilling with the simulator is to
demonstrate to the
student the phenomena experienced when an influx of formation fluid is
obtained while
drilling and to instruct him in the initial shut-in procedures taken as a
preliminary to well
control.
The simulator produces a number of warning signs which can be
recognised by the driller
, including:-
• Pit Level Gain
• Flow Rate Increase
• Penetration Rate Increase
• Rotary Torque Increase
• Drill-pipe Pressure Decrease
Primary indications that a kick is occurring are an increase in flow-rate
leaving the well
while pumping at a constant rate and an increase in pit volume.
When one or more of the warning signs are observed, steps are usually
taken to shut-in
the well.
Containment of a fluid influx is dependent upon the students
performance while closing in
the well. The volume of influx depends upon his speed of response
during the shut-in
procedure.
When shut-in, both drill-pipe and casing pressure rise to stable
readings. The stabilisation
time depends upon the recharge characteristics of the formation.
Pressures over the long term may not remain constant but increase due
to gas migration.
Gas migration is an Instructor defined option. The student should
recognise this situation
and take steps to bleed off the extra pressure.
The shut-in drill-pipe pressure and the shut-in casing pressure may
differ depending upon
the type and size of the kick.
After the preliminary shut-in procedures have been taken, a standard
method of well
control such as Driller's or Wait and Weight Method may be adopted on
the simulator.
4.5.14 Kicks While Tripping
The simulation can demonstrate the phenomena experienced when an
influx of formation
fluid occurs while tripping and to instruct trainees in the initial shut-in
procedures and
methods of well control.
Kicks while tripping are due to two possible causes:
• Formation fluids being swabbed in while hoisting the drill-string.
• Low mud level in the annulus, due to displaced drill-string.
The primary surface symptom of a kick while tripping is improper hole
fill up from the trip
tank. While hoisting the drill-string, a pressure reduction down-hole will
occur due to
swabbing. This pressure reduction may be sufficient to induce an influx.
The mud level in the hole should decrease by a volume equivalent to
the amount of metal
removed. If the hole does not require the calculated volume of mud to
bring the mud level
back to the surface, it may be assumed that a formation fluid has been
swabbed into the
hole.
The well will not begin to flow of its own accord until enough fluid has
entered to reduce
the hydrostatic pressure to an amount less than the formation pressure.
Should the
formation pressure exceed the hydrostatic pressure, the kick may soon
become
uncontrollable if quick action is not taken by the driller.
Containment of a fluid influx is dependent upon the student's
performance while closing in
the well. The volume of influx depends upon his speed of response
during the shut-in
procedure. The simulator provides controls for the installation of a drill-
pipe safety valve
and an inside BOP for kicks taken while tripping. When shut-in, both
drill-pipe and casing
pressure rise to stable readings. The stabilisation time depends upon
the recharge
characteristics of the formation.
Pressures over the long term may not remain constant but increase due
to gas migration.
Gas migration is an Instructor defined option. The student should
recognise this situation
and take steps to bleed off the extra pressure.
After the preliminary shut-in procedures have been taken a standard
method of well
control may be adopted if the kick has migrated above the bit. Pressure
control methods
are more difficult to accomplish if a well starts flowing while a trip is
being made. If the
pipe can be stripped to the bottom, a threatened blow-out can be
controlled with the mud
that was in use while drilling before the trip. If the pipe cannot be
stripped in the
volumetric method must be used to systematically bleed fluid from the
well and maintain a
constant bottom hole pressure.
4.5.15 Kicks While Out of the Hole
Typically kicks recognised while out of the hole are a result of a swab
when the trip initially
started or failure of the driller to fill the hole. The simulator caters for
the complete
removal of the drill string from the well and is capable of well control in
this situation.
Specific scenarios can be set up by the Instructor to strengthen the
trainee’s skills in
handling situations of this nature.
4.5.16 Driller's Method of Well Control
The simulation provides the capability of killing the well using the two
circulation Driller's
Method.
The slow circulation rate pressure test will have established a pump
pressure at a selected
kill rate. A guide line pressure equal to the slow rate pressure plus the
shut-in drill-pipe
pressure is used to circulate out the kick fluids. Establishing the true
constant drill-pipe
pressure is by initially maintaining casing pressure constant for the first
few minutes of
circulation or until stable. At this time the drill-pipe pressure can be
recorded and
maintained constant until all kick fluids are disposed from the well.
Maximum casing
pressure and pit volume are seen when the gas reaches surface. This
circulation is
completed using mud of the weight present when the kick occurred.
The kill mud weight is mixed in the reserve tank, the original contents
of the active tank
dumped or transferred and the kill mud is then introduced to the drill-
string pumping from
the reserve tank. The lighter mud from the well enters the active
system from the
degasser tank.
When kick fluids are removed from the annulus, mud of the density
required to contain the
formation pressure is circulated to remove and replace the lighter fluid
in the well. Casing
pressure is held constant by adjusting the choke while the drill-pipe is
filled with the new
mud then drill-pipe pressure held constant until the kill mud reaches
surface. Casing
pressure gradually decreases to zero as the annulus is filled with mud of
the kill weight.
The wait and weight method is based on the premise that drilling fluid
of the required
density can be prepared in a reasonably short time while the well is
maintained in a shut-in
condition.
On recognising a kick, the well is shut-in and the shut-in pressures
recorded. An increase
in mud weight required to kill the well is calculated.
The contents of the active tank are dumped and replaced with mud of
the required density,
mixed in the inactive tank.
As a preliminary action to commencing drilling the slow circulation test
will have
determined a slow circulation rate pressure to be used in well control.
The choke is opened and the pump pressure brought up to the initial
circulating pressure
(slow circulating pressure plus the shut-in drill-pipe pressure).
The casing pressure is held constant until the pump is at the kill rate.
Adjustments to the
choke are made to bring the drill-pipe pressure to the initial circulating
pressure.
Circulation is continued until heavy mud is obtained at the surface.
Pumping is stopped and
shut-in pressures noted. If shut-in pressures are not zero then a further
increase in mud
weight is required.
Experience has also shown gas will migrate a significant amount before
well killing can
commence. The simulation allow for the migration and the necessary
bleed-off of pressure
required to maintain bottom hole pressure constant.
4.5.18 Bull-heading Method of Well Control
The simulator can be used to provide training in handling an influx of
formation gas by the
method of forcing the gas back into the formation.
Several warning signs may accompany an influx while drilling. On
recognising these signs
the well is shut-in and shut-in pressures recorded.
If the influx is determined to be formation gas, bull-heading can be
employed. Gas influx
size can be estimated from surface readings.
Bull-heading describes the technique of forcing a gas back into the
formation by pumping
down the annulus.
The Kill Line valve and the discharge valve from the mud pump, housing
down sized, uprated
mud pump liners, is opened and a mud volume in excess of volume of
influx is
pumped into the annulus.
Flow from the drill-string is blocked by closing either the lower kelly
valve or installing an
inside blow-out preventer if the kelly is not in use.
The kill line valve is closed and the shut-in pressures observed. If the
gas has been forced
into the formation, shut-in pressures are equal to the formation
pressure minus hydrostatic
head.
A standard method of well control may then be employed using a kill
mud weight
calculated from the shut-in drill-pipe pressure. The well is successfully
killed with the shutin
pressures are zero.
In a kick situation if circulation is impossible due to a plugged drill string
or no pipe in the
hole constant bottom hole pressure must be maintained whilst the influx
migrates to
surface. The simulator handles the gas migration to surface in these
situations.
Calculations are prepared to bleed a specific volume of fluid from the
well at various
intervals in order to maintain a constant bottom hole pressure.
Using the Mud System Control Terminal the trainee can direct the flow
from the degasser
tank to the trip tank to provide a smaller tank the Strip tank to
accurately gauge the bleedoff
volumes.
Once the gas reaches surface original or heavy mud can be lubricated
into the well through
the kill line whilst maintaining a constant bottom hole pressure.
4.5.20 Concurrent Method of Well Control
The simulation is capable of handling up to 30 different fluids in the
drill-pipe and annulus
enabling implementation of this method of well control.
Due to limited mixing rates of field equipment the reserve tank mud
density can be
adjusted in stages to enable this method to be performed. The
simulation model tracks the
various fluid regions in the well and maintains track of the hydrostatic
pressure of each
region.
Once these regions of fluid are returned to surface and enter the active
mud tank the mass
balance of the system will generate a fluid of the same density
depending upon the
volumes of each density.
5. SIMULATOR MANAGEMENT AND CONTROL FACILITIES
The DrillSIM Simulator Control Facilities have been developed over
many years taking into
account the needs of instructors and other simulator users. Through the
dedicated PC
terminal an instructor is able to easily set up simulation exercises,
control the exercise,
monitor trainee performance and save and retrieve exercise well-snaps
at any time. Menu
systems allow the user to manoeuvre around the system with ease. A
number of onscreen
toolbars and icons enable "click-on" simulator control entries, alleviating
the need to
type out commands on a keyboard.
5.1 Simulation Control Tools
The DrillSIM-20 simulation control facilities include the following:-
• Run/Freeze
• Snapshot Selection
• Initial Conditions (Snapshot) Generation
• Time Rate Control
• Simulated Malfunction Injection
• Data Logging
5.2 Run/Freeze
The progress of an exercise can be suspended at any point during the
course of a
simulation exercise utilising the ‘FREEZE’ Command. When FREEZE is
selected:-
• The exercise is frozen at the point it reached in the simulation
• The exercise clock stops
• All Instrument readings and indicators retain their current status and
any further trainee
control inputs are ignored.
FREEZE enables the exercise to be interrupted, perhaps for an instructor
intervention while
offering advice to trainees.
This suspended animation state is maintained until simulation ‘RUN’ is
executed. At this
point the simulation continues from the point when freeze was selected.
5.2.1 Initial Conditions (Snapshot) Selection
Initial Conditions Sets, or ‘SNAPSHOTS’ effectively act as exercise start
points whereby all
drilling and equipment parameters representing the status of the rig
and well at a
particular point in time are stored. DrillSIM-20 comes equipped with a
range of basic
SNAPSHOTS which enable effective simulation training to be conducted
immediately
following installation. Selecting a SNAPSHOT from the library
automatically prepares the
simulator for commencement of a specific exercise. SNAPSHOTS are
stored on computer
hard disk for ease of access.
5.2.2 Snapshot Generation
The snapshot generation facility provides for the possibility of creating
snapshots. Using
this facility an instructor is able to build up a library of Initial conditions
sets over a period
of time. The normal method of generating a snapshot would be to
modify certain
parameters from an existing snapshot and then to save it to computer
hard disk.
Alternatively, an instructor can generate a totally new initial condition
by methodically
working through a series of data entry pages included within the
instructor facility.
Another important advantage of this facility is the ability to store
particular situations at
any point during the course of an exercise. These situations can then be
recalled for post
exercise analysis or training reinforcement.
5.2.3 Time Rate Control
This facility allows an exercise to progress at rates faster, or slower
than real time. For
instance, during the course of a well kill using the wait and weight
method the instructor
may choose to increase the time rate while gas is circulated out
following the successful
completion of pumping kill mud to the bit. This would reduce the
training time without
compromising training fidelity.
Alternatively, simulation response times can be slowed down using this
facility to assist
trainees in their operation of rig controls during complex activities.
When their
familiarisation and confidence improves the exercise can be re-run in
real time.
5.2.4 Simulated Malfunction Injection
DrillSIM-20 is equipped with an extensive range of simulated fault and
malfunction
situations. These can be used to enhance, and test, the ability of
trainees thereby adding
to their confidence and capacity for dealing appropriately with live rig
problems.
5.2.5 Data Logging
In addition to the on-line chart plotting facilities provided, DrillSIM-20 is
equipped with an
on-line data logging facility whereby an instructor can choose a range of
simulator
parameters to be saved to a computer file. These files can also be saved
onto diskette and
input directly into spreadsheet analysis packages in an off-line mode.
The results may
then be made available for inclusion in trainee performance reports.
5.3 Control and Display Facilities
Powered by a Pentium laptop, refresh times and screen changes are
very fast providing a
smooth visual picture of events being simulated. Where there is a
requirement for
numerical values to be entered, a large calculator style keypad appears
on the. Correction
facilities are provided on the keypad in case of input errors.
Control and display facilities provided for the Instructor include:-
• Start-up Display Screen
• Configuration Menu Display Screen
• Rig Type Selection Display Screen
• BOP Configuration Menu Display Screen
• Well-bore Geometry Menu Display Screen
• Mud System Menu Display Screen
• Rig Equipment Menu Display Screen
• Run-time Menu Display Screen
• Malfunctions Menu Display Screen
• Snapshot Utilities Control Screen
• Units and Conversion Control Screen
• Simulation Control Command Screens
• Malfunctions Control Command Screens
• Process Monitoring Screens
• Trainee Performance Monitoring Screen
• Simulator Hardware Diagnostics Screens
The following pages provide typical display examples
5.3.1 Start-up Display
The following screen is initiated at start-up. From here all other
simulator controls and
operations can be initiated.
5.3.2 Configuration Menu Display Screen
There are 6 main menu options activated from the configuration menu:
The Exercise Configuration Menu is used when configuring new well
snapshots. This is
achieved by loading an existing well snapshot with similar parameters
to those desired,
e.g.: a sub-sea or surface well. From this point a new well can be
configured by stepping
through the Exercise Configuration Menu. Once configuration is
complete the Snapshot
Utilities Menu can be used to save the new well snapshot.
5.3.3 Rig Type Selection Display Screen
Selecting the Rig Type button, the Instructor can choose the type of rig
for the exercise.
Land, Floater, Jack-up or Work-over options can be selected from this
screen.
5.3.4 BOP Configuration Menu Display Screen
The BOP configuration screen enables BOP and diverter options to be
selected.
Further screens allow the following to be set:-
• Flow Nipple or Riser Inside Diameter
• Flow Line to Ground Level or Seabed
• RKB to Seabed
• Sea Depth
• Choke Line Inside Diameter
• RKB to Bit Depth
• Choke Line Friction Factor
5.3.5 Well-bore Geometry Menu Display Screen
Further sub-screen menus are initiated by selection of the above icons.
5.3.6 Mud System Menu Display Screen
Further sub-menus allow the parameters from each of the highlighted
sub-systems to be
set or altered:-
5.3.7 Rig Equipment Menu Display Screen
Further sub-menus allow detailed configuration of the above equipment
sets.
5.3.8 Run-time Menu Display Screen
The speed of the simulator can be set to Real Time or a multiplier.
5.3.9 Malfunction Menu Display Screens
A series of dedicated Simulated Malfunctions Screens access a wide
range of equipment
and well problems which may be imposed upon a training exercise.
5.3.10 Snapshot Utilities Control Screen
The Instructor can setup and save snapshots.
5.3.11 Units and Conversions Control Screen
The Units and Conversions function provides Instructor with maximum
flexibility in
assigning engineering units to his display.

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