Digital double of the drilling rig

Digital double of the drilling rig

Last week, we finished an interesting project – a digital duplicate of the URALMASH BU 5000/320EUK-Я drilling rig, which is designed for drilling deep and ultra-deep wells for oil and gas, with a conditional drilling depth of 5,000 meters.

This is the drill we are talking about. There will be many letters, but for those who do not like to read, I will immediately provide a video with several topics:

And right away an example of a mathematical model of rock destruction:

Now briefly the goals and tasks of creating such a simulator. Let’s start with the problem. Again, import substitution and existing restrictions. Today, drill training simulators are presented in most foreign (USA, England) companies. In addition, these drilling simulators are based on foreign drilling rigs, foreign rules (scenarios), “their” equipment layout schemes, do not take into account “our” weather conditions, only drillers are trained (and driller’s assistants, mechanics, craftsmen also work on the drilling rig ) and many other professions) etc.

Thus, a decision was made to create a domestic analogue of foreign simulators with extended functionality.

The BO 5000/320EUK-Y machine tool was taken as a basis, including mathematical models and 3D objects of the following equipment:

  • Drilling pump UNBT-950A

  • UV-320MA swivel

  • Talova system 5×6

  • Tower VMA-45-320

  • Rotor R-700

  • Winch LBU-37-1100

  • Kronblok – UKBA-6-400

  • Hook block – UTBK-5-320

  • Talev block-UTBA-5-320

  • Winch: electric motor 4PS-450-1000-UHL2

  • Drilling pump: electric motor 4PS-450-1000-UHL2

  • Circulation system CS5000ER (Vibrating screen, Sitohydrocyclone separator, Sand separator, Sludge separator, Centrifuge, Degasser, Hydromixer, Cooking tank, Drain tank, Fence tank, Riser)

  • Upper drive TD-350-HT (Bentec)

  • The driller’s remote control

  • Pipe wrenches, etc.

The underground part is represented by mathematical and 3D objects of the following equipment and objects:

  • Well

  • Drill pipe

  • Heavy drill pipes (HBT)

  • Thick-walled drill pipes (THB)

  • Conductive drill pipes

  • A destructive tool

  • Displacement engines

  • Bypass (overflow) valve

  • Translator

  • Sludge metal catcher (SMU)

  • Check valves

  • Mechanism of distortion

  • Calibrators and centralizers

  • Stabilizers

  • Extenders

  • Yass

  • Rotary deflectors

  • Downhole telemetry systems (MWD), logging systems while drilling (LWD) and rotary guided systems (RUS)

As a result, we were able to fully reproduce the entire 3D and mathematical model of the rig using analytical formulas, the Lattice Boltzmann Equation Method (LBM) and the non-parametric function recovery method.

In addition, the following was implemented:

  • Software and hardware implementation with an exact copy of the control of the driller’s cabin (workplace of the student – driller) + laptops (workplaces of students – drillers’ assistants) + laptop (workplace of the instructor) + server.

  • Software and hardware implementation with an exact copy of the control of the driller’s cabin based on the virtual reality (VR) formation system (workplace of the student – the driller) + laptops with the virtual reality (VR) formation system (workplaces of students – assistant drillers) + laptop (workplace of the instructor )

The result was such a distributed simulator, completely domestic and about domestic equipment, the functionality of which made it possible to implement:

  • Acquiring practical skills of safe work during the construction of oil and gas wells.

  • Training and acquisition of practical skills for the prevention, localization and elimination of oil and gas leaks and open fountains during the construction of oil and gas wells.

  • Continuous and periodic control and testing of the level of knowledge and skills of technological process management and localization of emergency situations.

  • Improving the quality of training of workers and engineering and technical workers engaged in technological process management and equipment operation.

  • Reducing the probability of emergency situations arising as a result of the manifestation of the human factor.

Scenarios:

Basic simulator scenarios:

  1. Study of the design of the drilling rig

  2. Study of the design of the well and the drill string

  3. Lowering operations

  4. Replacement of pistons/bushings on the pump

  5. Troubleshooting and replacement of pump valves

  6. Passing (drilling) with the upper drive

  7. Lowering the casing and cementing

  8. Safety rules (detection of violations during drilling)

  9. Safety rules (detection of violations during work at height)

  10. Safety rules (detection of violations during lifting operations)

Additional scenarios:

  1. Closing the well

  2. Damping by the drill method

  3. Silencing by volume method

  4. Filling out the suppression letter

Personnel actions during PLAS execution:

  • Check at the beginning of the work shift

  • GNVP during drilling (flushing) of the well

  • GNVP at SPO

  • GNVP during the descent of the casing string

  • GNVP in the absence of drill (casing) pipes in the well and the FFR

  • GNVP, outdoor fountain

  • Silence after GNVP

Additional scenarios – execution of typical operations:

  • Drilling (drilling) is rotary

  • Drilling (drilling) rotary + downhole motor (VZD)

  • Bit replacement and drill string arrangement (wear determination, replacement)

  • Well flushing

  • Repair/fishing works

  • High-rise construction works

Additional scenarios – for driller assistants and mechanics:

  • Replacement of pistons/bushings on the pump

  • Detection of malfunctions and changing of meshes in vibroscreens

  • Fault detection and replacement of piso/mud separator elements

  • Replacement of the rope

  • Current maintenance and repair of the BU system

Additional scenarios for geophysical works:

In this way, we managed to create a drilling simulator that completely replaces imported analogues, that has greater adequacy and universality of the mathematical model, more accurate and realistic 3D/VR, and most importantly – that imitates domestic drilling equipment.

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