Drillsim 20 Manual

Compact Portable Drilling & Well Control Simulator
Operator’s Manual
2007
Drilling Systems (UK) Ltd

Hurn View House, 5 Aviation Park West, Bournemouth International Airport, Dorset, BH23 6EW, United Kingdom
Tel: +44(0) 1202 582255 Fax: +44 (0) 1202 582288
Email: info@drillingsystems.com Web: www.drillingsystems.com
Working to Support Industry Standards

Introduction 1.i
1. INTRODUCTION....................................................................................................................................1.1
1.1 GENERAL INFORMATION.......................................................................................................................................................1.1
1.2 DRILLSIM OVERVIEW...........................................................................................................................................................1.1
1.2.1 Computer Equipment...................................................................................................................1.1
1.2.2 Simulation Control.......................................................................................................................1.2
1.2.3 Diagnostic Software.....................................................................................................................1.4
1.2.4 DrillSIM-5000 Standard Equipment............................................................................................1.4
1.2.5 DrillSIM-5000 Optional Equipment............................................................................................1.4
1.2.6 DrillSIM-500 Standard Equipment..............................................................................................1.4
1.2.7 DrillSIM-500 Optional Equipment..............................................................................................1.5
1.2.8 DrillSIM-50 Standard Equipment................................................................................................1.5
1.2.9 DrillSIM 20 Standard Equipment................................................................................................1.5
1.2.10 DrillSIM-5 Standard Equipment..................................................................................................1.6
1.3 OPERATIONAL CAPABILITY.................................................................................................................................................1.7
1.3.1 Normal Operation........................................................................................................................1.7
1.3.2 Operational Effects......................................................................................................................1.8
1.3.3 Operational Malfunctions............................................................................................................1.8
1.4 USING THE TOUCH SCREEN..................................................................................................................................................1.9
DrillSIM Operators Manual

© Drilling Systems Ltd
Introduction 1.1
1. INTRODUCTION
1.1 General Information

This DrillSIM Reference Manual provides a definitive guide to the facilities of the
DrillSIM range of simulators. Where differences appear between the simulator models,
refer to the section reference for your model. Chapters 2-5 on the simulator start-up
and the instructor interface are designed to get the system up and running by providing
the basic operational skills necessary to accomplish the set-up of exercises and
operation of the simulator. Please take the time to read these chapters thoroughly and
use them as a reference. The Drilling Systems engineer conducting your initial
operational training programme will use the manual as a guide throughout his lectures
and demonstrations.
1.2 DrillSIM Overview

In the configuration delivered to your training centre, the DrillSIM simulator comes
equipped with a range of simulated consoles, equipment and manifolds closely
resembling those found on a modern drilling rig floor.
The consoles are manufactured using controls and instrumentation resembling those
used in operating field consoles. Realism is further enhanced by the use of digitally
reproduced sound effects, which are fully synchronised, with the various operational
activities of the simulator. A high resolution Colour Graphics Monitor provides the
trainee with a real time graphic representation of the movement of the Hoisting and
Rotary System equipment and other rig floor operations. The graphics are interactive
with the various Driller's controls and simulated rig equipment. A separate touch
screen Student Station has also been provided to allow the student to accomplish other
tasks that are not found on the drill floor, e.g. changing the Mud Weight.
1.2.1 Computer Equipment
Pre – 1996 models use a DEC MicroVAX 3100 as the simulator computer whereas the
current configuration of the DrillSIM-5000 utilises a DEC AlphaStation computer.
IBM PC compatibles (COMPAQ) are used for the Student station, graphics generation
and the instructor station. The DrillSIM-500 and 50 simulators employ a range of high
performance desktop and laptop PCs. Drilling Systems has selected these systems due
to service reliability and performance stability.
The DrillSIM system computer employs a mathematical model. The model simulates
the operation of rig equipment and downhole characteristics encountered in "real
world" situations. When the system is powered up the model is loaded from the hard
disk following login, in the case of the Rig Floor simulator that utilises a MicroVAX
or AlphaStation. For the DrillSIM-500 and 50, the model is automatically loaded into
the flash processor.

© Drilling Systems Ltd
Signals initiated by the Trainee through interaction with various controls and switches
are fed to the Simulator Computer via an Input/Output Interface System. The Interface
System converts these signals so that they are meaningful to the Computer in order the
appropriate calculations can be carried out to predict the response of the process. The
resulting output is fed back via the Interface System to drive gauges, digital displays,
the graphics displays and the Sound Effects System to provide a realistic
representation to the Trainee's activities.
1.2.2 Simulation Control
The Instructor is able to control the simulator and monitor the Trainee’s performance
through all phases of an exercise.
The DrillSIM simulation software is a fully integrated modular package that is

designed to interact with the Trainees actions. The simulator software allows the
Trainee to observe the consequences of his actions just as they would occur in the
field. Several base-line exercises are supplied with the system, these include:
 Top Drive with Surface BOP
 Top Drive with Subsea BOP
 Kelly with Surface BOP
 Kelly with Subsea BOP
 Work-over
 Cementing
 Top Drive with Motion Compensator and Sub-sea BOP
 Kelly with Motion Compensator and Sub-sea BOP
These exercises should be used as reference points for starting or configuring new
exercises.
The set of initial conditions (well snapshots) provided with the DrillSIM simulator
provide all the necessary parameters to commence a wide variety of training exercises.
Having selected the desired well-snapshot or initial condition set, no further input is
required. No pre-programming is necessary. This leaves the Instructor free to monitor
Trainee performance. The Instructor can create new well snapshots at any time for use
in subsequent Trainee exercises.
No restrictions are placed on either Trainee or Instructor thereby allowing the Trainee
to select the desired response to a given situation or condition. The fully interactive
DrillSIM software model is unique in that neither a Trainee nor Instructor has to act in
any pre-defined sequence. Operational events such as stuck pipe or loss of circulation
occur as a result of Trainee action or pre-configured conditions of the wellbore
geology, thus allowing the Instructor to enforce particular operational drilling
problems for group training purposes.
In addition, the Instructor can change parameters of the exercise and introduce
simulated malfunction situations into the simulation exercise. Malfunctions such as
equipment failure or downhole problems can be pre-configured in the initial well
snapshot or changed during the simulation exercise. These malfunctions will then
interact with the software model to produce the appropriate effects on the simulation
instrumentation.
Repetition of the exercise will assist the Trainees in retaining the knowledge gained
throughout the simulation exercises. By placing the Trainees in simulated potentially
dangerous situations the Instructor has the opportunity to evaluate Trainee competence
when they are under pressure, this type of training develops the logical thought
process of the Trainee and builds confidence and troubleshooting skills to handle
similar situations in the field.
1.2.3 Diagnostic Software
The DrillSIM internal diagnostic software enables the Instructor to perform a full
range of tests of the various controls, gauges, lamps and switches on all the consoles.
Two versions of the diagnostic are available with MicroVAX/AlphaStation based
systems and one on the PC based systems.
1.2.4 DrillSIM-5000 Standard Equipment

The following lists the typical equipment and consoles that comprise the minimum
configuration of the DrillSIM-5000.
1) Drilling Gauges Console
2) Drilling Controls Console
3) Surface Blowout Preventer Control Console
4) Remote Choke Control Console
5) Standpipe Manifold
6) Choke Manifold
7) Colour Graphics Monitor for surface and down-hole displays
8) Student and Mud Station Colour Graphics monitor with Touch Screen
9) Session Plotter for recording drilling and well control data
10) Instructor Station, comprising a PC, Colour Monitor and Software
11) Sound System with sixteen digitally recorded, playback sounds
1.2.5 DrillSIM-5000 Optional Equipment

The following optional items are available and may be added to the standard system.
All have been developed and are installed at various sites around the world.
1. Subsea Blowout Preventer Control Console
2. Subsea Diverter Control Console
3. Surface Diverter Control Console
4. Drill String Compensator Control Console
5. Top Drive System
6. Workover Land Manifold
7. Well Services B.O.P.
8. Full Size Well Head & Production Tree
9. Cement Head
10. Cement Pumping Console
11. Workover Mimic Panel with Workover Manifold and Well Head and Production
Tree.
12. Rogalands VR Software.

1) Drilling Controls Console & Gauges Console
2) Surface and Subsea Blowout Preventer & Diverter
3) Standpipe and Choke Manifolds
4) Workover Console
5) Choke Console
6) Kelly and Top Drive
7) Touch Screen Student and Graphics Station
8) Desktop PC
9) Colour Printer
10) Touch Screen Instructor Station
1.2.7 DrillSIM-500 Optional Equipment

1) Coiled Tubing Console
2) Wire Line Console
3) DST Console
4) VR Software
1) Drilling Controls Console & Gauges Console

2) BOP Console with Subsea and Surface plug-in modules.
3) Standpipe and Choke Manifolds
4) Top Drive & Kelly System
5) Choke Panel
7) Laptop PC
8) Colour Printer
9) UPS
1.2.9 DrillSIM 20 Standard Equipment
1) Choke Panel
2) Pump controls Panel
3) Laptop PC
5) Colour Printer
6) UPS
1) Virtual Choke Panel

2) Virtual Drawworks controls Panel
3) Virtual Surface or Subsea BOP Panel
4) Virtual Manifolds Panel
5) Software on CD
6) Instructors & Student Manuals
There is no actual hardware supplied with the DrillSIM-5, as it is a PC based version

of the Drilling & Well Control software.
1.3 Operational Capability
1.3.1 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 50,000 ft. During use of the Simulator, basic and advanced training can be
given in:
1) Well Planning
2) Drilling Equipment Sizing and Performance
3) Hoisting System Operational Control
4) Rotating System Operational Control
5) Circulating System Operational Control
6) Blowout Prevention System Operational Control
7) Mud Treatment and Control
8) Drilling Practices
9) Tripping Practices
10) Running and Cementing Casing
11) Downhole Drilling and Equipment Problems
12) Pressure Testing
13) Blowout Prevention
14) Well Control
15) Downhole Well Control and Equipment Problems
16) Stripping Operations
17) Crew Supervision
And with additional options
1) Cementing Operations
2) Motion Compensator Operations
3) Work Over Operations
1.3.2 Operational Effects
During the course of an exercise, depending on the conditions selected, the Trainee
experiences combinations of the following effects:
1) Bit Wear.
2) Bit Bearing Wear.
3) Kicks from High Pressure Permeable Formations.
4) Pipe Surge and Swab.
5) Kicks while Tripping.
6) Multiple Kicks.
7) Lost Circulation.
8) Formation Fracture.
9) Underground Blowout.
10) Mud System Changes.
11) Motor Overload.
12) Pump Over Pressure.
1.3.3 Operational Malfunctions

In addition to the Operational Effects, the Instructor can introduce numerous
conditional malfunctions which fall into the following categories:
 Downhole
1) Bit
2) Lost Circulation
3) Stuck Pipe
4) Pipe Twist-off and Washout
5) Tight Hole
 Rig Equipment
1. Pumps
2. Hoisting
3. Rotary
4. Subsea BOP
5. Surface BOP
6. Choke
1.4 Using the Touch Screen
The Instructor Station and Mud Control Station may use a touch screen for data input.
A touch screen is a device that enables people to interact with computers in a simple,
natural way by touching the screen.
Point at the touch screen with one finger extended, and keep other fingers away from
the touch screen. Touch the screen slowly and firmly. If another finger besides your
working finger touches the screen this will cause a sudden jump of the cursor to a spot
halfway between the two touch points.
The simulator touch screens operate in “Lift-off Mode”. The initial touch locates the
cursor on the screen. You can move your finger around the screen to reposition the
cursor if desired. When you lift your finger off the screen a “Single Click” occurs at
that location. This allows a button to be selected by a single touch down and lift off.
Note: A touch screen should not be powered off unless the computer associated with
that touch screen is also powered off. Control of the computer from the touch screen
will stop if the touch screen is powered off. To re-establish control both the touch
screen AND computer will need to be restarted.
Power Up & Power Down Procedures a
Revision History
Revision Date Revised By Details
Manual updated to reflect changes made to the
October 2003 B. March
simulator.
Addition of the SimStartUP application for starting
September 2007 E. Ramsay and shutting down the new PC-based models.

© 2007 Drilling Systems Ltd
Power Up & Power Down Procedures i
Table of Contents
2. POWER UP & POWER DOWN PROCEDURES.............................................................1

2.1 INTRODUCTION...................................................................................................................................... 1
2.2 DRILLSIM-5000 (SERIAL NUMBER 5000-042 OR BEFORE).................................................1
2.2.1 Powering up the MicroVAX or AlphaStation.....................................................2
2.2.2 Powering up the Simulator Consoles.............................................................2
2.2.3 Powering up the Simulator Peripherals..........................................................2
2.2.4 Student Station Touch Screen......................................................................3
2.2.5 Logging Into the System Computer Maintenance Terminal................................3
2.2.6 Logging In To the Simulator.........................................................................3
2.2.7 Loading A Snapshot on the Instructor Station.................................................3
2.2.8 Power Down Sequence................................................................................3
2.2.9 Recovery From a Power Failure....................................................................4
2.3 DRILLSIM-5000 (SERIAL NUMBER 5000-043 OR LATER)...................................................5
2.3.1 Powering up the Simulator Consoles.............................................................5
2.3.2 Powering up the Simulator Peripherals..........................................................5
2.3.3 Student Station Touch Screen......................................................................5
2.3.4 Initialising the DrillSIM Simulation Software...................................................5
2.3.5 The Instructor Interface..............................................................................6
2.3.6 Loading A Snapshot on the Instructor Station.................................................7
2.3.7 Power Down Sequence................................................................................7
2.4 DRILLSIM-500....................................................................................................9
2.4.1 Power Up Procedures..................................................................................9
2.4.2 The Instructor Interface............................................................................10
2.4.3 Loading A Snapshot..................................................................................10
2.4.4 Power Down Sequence..............................................................................10
2.5 DRILLSIM-50 AND DRILLSIM-20.............................................................................13
2.5.1 Power Up Procedures................................................................................13
2.5.2 Logging In To the Simulator.......................................................................13
2.5.3 Loading A Snapshot..................................................................................13
2.5.4 Power Down Procedures............................................................................13
2.6 DRILLSIM-5......................................................................................................14
2.6.1 From the ‘START’ menu.............................................................................14
2.6.2 From the Desktop.....................................................................................14
2.6.3 Logging In...............................................................................................14
2.6.4 Shut Down Sequence................................................................................14

Power Up & Power Down Procedures 1
2. POWER UP & POWER DOWN PROCEDURES
2.1 Introduction
This chapter describes the procedure for two types of Power Up/Down procedures -
COLD START & COLD STOP, where the simulator is started for the first-time or is re-
started after a total shutdown of the entire system including all UPS-maintained
systems and shut down to the same level and SESSION START/SESSION STOP.
COLD START
 Switching On the simulator and Loading the Software.
 Switching the System Off completely (COLD STOP).
 Recovering from a Power Failure.
2.2 DrillSIM-5000 (Serial Number 5000-042 or before)
For the full sized simulators, always take a quick walk around the simulator to make
sure nobody is performing any electrical repairs on the equipment. Check that the
main breakers are switched on at the simulator; these may have been switched off if
maintenance work has been carried out on the simulator, or company policy dictates.
For the full sized simulators it is important that the MicroVAX or AlphaStation
computer be powered up prior to any other equipment. This will ensure that the
MicroVAX or AlphaStation to PC communication is set up properly during the start up
procedure. Once the simulation computer (the MicroVAX or AlphaStation depending
upon the age of the simulator) has completed its start-up, the other peripherals and
consoles can be powered up.
WARNING:
If the Graphics, Student station and Instructor PC computers are powered up before
the MicroVAX or AlphaStation Computer, the VAX or AlphaStation to PC
communication link may not function properly.

2.2.1 Powering up the MicroVAX or AlphaStation
 Switch on the VT 510 Terminal by setting the Power On/Off switch to ON located
on the lower right corner of the terminal. After about 30 seconds a message
"Selftest OK" will appear on the screen showing the unit has warmed up.
Depress the Return key. A flashing square cursor will appear at the top left of
the following page with a message 1(001,001) Printer: None at the bottom of
the page.
 If the terminal characteristics have been altered, it may be necessary to reset
it. This is achieved by pressing the SETUP key F3 on the keyboard.
 To power up the MicroVAX or AlphaStation set the ON/OFF switch to "1" (from
the front, the switch is located at the left rear of the computer) and check that
the green lamp on the front is illuminated. When the power switch is activated
a beep should be heard.
 Shortly thereafter the serial number of the MicroVAX or AlphaStation processor
will be displayed on the VT 510 terminal. Initially a memory check is conducted
followed by the MicroVAX or AlphaStation boot up procedure, which will take 3-
5 minutes. When the flashing cursor is sitting at the line indicating Charged CPU
Time: hit the RETURN key. The message Welcome to MicroVAX or AlphaStation
VMS V5.5-2 followed by Username: The VAX or Alpha is now ready to be logged
into.
CAUTION: EXTREME CARE MUST BE TAKEN TO AVOID DEPRESSING ANY OTHER

KEYS WHILE IN SETUP MODE.
2.2.2 Powering up the Simulator Consoles
 Check the MAINS supply is on.

 Ensure that MicroVAX or AlphaStation Computer is fully booted up.
 On the side of the Drilling Gauges Console, switch the three main breakers to
the ON position commencing with the one on the far right first. This will power
up all the simulator consoles and the computer stations running the graphics and
the student station terminals.
2.2.3 Powering up the Simulator Peripherals

When the switch for the outstation computers is turned on at the side of the Drilling
Gauges console, the student station and graphics computers will automatically
come on.
2.2.4 Student Station Touch Screen
Switch on the Student Station Touch Screen by setting the Power On/Off switch to
ON. The switch is located on the lower right front of the unit. Note: This terminal
should already be on unless shut down for maintenance or some other
reason.
2.2.5 Logging Into the System Computer Maintenance Terminal

Following boot up of the MicroVAX or AlphaStation a login prompt will appear on the
instructor's terminal:
>Username: INSTRUCTOR
>Password: INSTRUCTOR
Once you have logged into the MicroVAX or AlphaStation you need to select option ‘2’
to Re-Initialise the system. Parts of the system may not function correctly if you do
not Re-Initialise the system each time you power up the simulator.
This sequence starts various programs, which communicate with the simulator and
PC’s. It is not necessary to utilise the VAX or Alpha terminal after you have logged
in. All interactions should take place on the Simulator hardware and Instructor or
Student Station terminals
2.2.6 Logging In To the Simulator

After the initial DrillSIM-5000 Banner is displayed, a login window will appear. There
are five instructor logins pre-set, INSTRUCTOR1 through INSTRUCTOR5. The
password for all is DrillSIM. You may use UPPER or lower case to enter the login and
password. These defaults can be changed, however in the interests of security please
contact Drilling Systems Ltd., Customer Support Dept. Tel: +44 (0)1202 582255
2.2.7 Loading A Snapshot on the Instructor Station
 When the main menu appears select the button displaying the CAMERA icon.
This will bring up a new window with a listing of the snapshots available to the
instructor.
 Use the mouse to select which snapshot you want to load.
 Select the LOAD command.
 The exercise will then be loaded and be placed in a FROZEN condition.
 The simulator is now ready to accept Instructor input prior to going to putting
the simulator into RUN.
2.2.8 Power Down Sequence

If the simulator is running on a daily basis it is recommended to leave the MicroVAX
or AlphaStation powered up. Should there be a danger of severe electrical storms
then the system computer should be shut down if not tied into an UPS. The
Simulation System should be powered down in the following sequence from the
Instructor terminal:
 Select the FREEZE icon from the Instructor interface menu bar.
 If you wish to save the current conditions you are working with use the
CAMERA icon on the instructor interface to save the snapshot.
 Select EXIT from the File menu on the instructor interface.
 The Instructor Interface computer is now return back to Windows.
 Exit from Windows.
At the VAX or Alpha or Alpha Station

 Use the EXIT Command to get out of Simulation mode by typing EXIT at the >
prompt followed by hitting the <RETURN> key. A message WARNING
Command terminates simulation use END key to abort. (The END key is 8 key
on the numeric keypad on the right of the keyboard.) To proceed with the log
out hit the <RETURN> key a second time.
 Prior to powering down the MicroVAX or AlphaStation log back into the system
as “SHUTDOWN”. At the password prompt type SHUTDOWN. The MicroVAX or
AlphaStation now systematically shuts down the operating system and parks the
hard disk in preparation for power down. Continue to power down all the other
equipment and peripherals before powering down the MicroVAX or AlphaStation.
This will give the MicroVAX or AlphaStation sufficient time to go through its
shutdown procedure.
 Power down the Instructor Touch Screen and PC first if not tied directly into
the OutStation Computer circuit.
 On the left side of the Drilling Gauges console turn off the switch for
the OutStation Computers and Terminals.
 On the left side of the Drilling Gauges console turn off switch for the
Drilling Controls and Drilling Gauges.
 On the left side of the Drilling Gauges console turn off the switch for the
Subsea BOP Console, Diverter, Surface BOP and Swaco.
 Switch off the Drilling Recorder printer if not tied into the main circuit for the
out station computers.
 Switch off the Data Logger printer if not tied into the main circuit for the
out station computers.
 Switch off the MicroVAX or AlphaStation Computer.
 Switch off the VT terminal.
2.2.9 Recovery From a Power Failure

In the event of a Power Failure, switch off the system. On restoration of power
supplies, power up the system and reload the Software as detailed in Section 2.2.
2.3 DrillSIM-5000 (Serial Number 5000-043 or later)
For the full sized simulators, always take a quick walk around the simulator to make
sure nobody is performing any electrical repairs on the equipment. Check that the
main breakers are switched on at the simulator; these may have been switched off if
maintenance work has been carried out on the simulator, or company policy dictates.
2.3.1 Powering up the Simulator Consoles
 Check the MAINS supply is on.

 On the side of the Drilling Gauges Console, switch the three main breakers to
the ON position commencing with the one on the far right first. This will power
up all the simulator consoles and the computer stations running the graphics and
the student station terminals.
2.3.2 Powering up the Simulator Peripherals

When the switch for the outstation computers is turned on at the side of the Drilling
Gauges console, the student station and graphics computers will automatically
come on.
2.3.3 Student Station Touch Screen

Note: This terminal should already be on unless shut down for maintenance
or some other reason.
 Switch on the Student Station Touch Screen by setting the Power On/Off
switch to ON.
2.3.4 Initialising the DrillSIM Simulation Software

 If not already switched on, switch on the Instructor PC
Note : The Student and Graphics displays should already be booted up following
turning the outstations switch on. These should display a white screen with the
Drilling Systems Company logo.
After carrying out various manufacturer diagnostics the Instructor computer will
boot and present a screen similar to one below:
You will now undertake a two stage process, the first is to connect to each computer,
then to run the applications.
 In the Simulation Selection window, select the DrillSIM-5000 option using the
left mouse button and then click on the Connect button.
The system will then attempt to connect to all the different components that make
up the DrillSIM solution.
 If ticks are displayed in ALL the Targets, then all the components have
been connected and by clicking on the Run button, the DrillSIM system will
be launched.
After a few seconds, each PC will display it’s relevant application (ie Instructor
Station, Student Station, Graphics, Sound)
2.3.5 The Instructor Interface

Having completed the SimStartup process, highlighted above, after the initial
DrillSIM Banner is displayed, a login window will appear. There are five individual
instructor logins pre-set, INSTRUCTOR1 through INSTRUCTOR5. The password for
all is DrillSIM. You may use UPPER or lower case to enter the login and password.
These defaults can be changed, however in the interests of security please contact
Drilling Systems Ltd., Customer Support Dept. Tel: +44 (0)1202 582255.
2.3.6 Loading A Snapshot on the Instructor Station
instructor.
 The simulator is now ready to accept Instructor input prior to going to putting
the simulator into RUN.

The Simulation System should be powered down in the following sequence:
 Select EXIT from the File menu on the Instructor Interface.
If you want shutdown all computers and power down the simulator consoles, select
the top option. If you want to just exit the Instructor Station (but leave the Student
and Graphics still running), then select the bottom option.
 Select the appropriate option to return back to SimStartup Screen
 Select the Shutdown option with the mouse, then press Connect.
The system will confirm which targets will be shutdown

 Select Run to confirm the shutdown.
If a complete shutdown has been performed (ie not just exiting the Instructor
Station), then all the computers will be shutdown completely.
If you just exiting the Instructor Station, then only this one PC / Notebook will
shutdown.
 Power off the Simulator
 Power off any additional hardware (ie the Printer and / or UPS)
Note : If you have shutdown the whole simulator, you will need to power-off the
panels (using the power switch on the remote choke).
2.4 DrillSIM-500
2.4.1 Power Up Procedures
 Ensure the components of the simulator are correctly connected.

 Switch on the UPS
 Switch on the Simulator by using the switch on the rear of the Choke
Panel. When the switch is in the on position it will glow amber.
The Digital Displays will initially say “hello” and then either fill with “......” or
“88888”. Then after a delay of approximately 45 seconds the simulator will initialise.
 Switch on the three computers (PCs or notebooks) (Instructor, Student and
Graphics) and the Printer. After carrying out various manufacturer diagnostics
the Instructor computer will boot and present the following menu:
You will now undertake a two stage process, the first is to connect to each computer,
then to run the applications.
 In the Simulation Selection window, select the DrillSIM-500 option using the
left mouse button and then click on the Connect button.
The system will then attempt to connect to all the different components that make
up the DrillSIM-500.
 If ticks are displayed in ALL the Targets, then all the components have been
connected and by clicking on the Run button, the DrillSIM-500 system will
be launched.
After a few seconds, each PC will display it’s relevant application (ie Instructor
Station, Student Station and Graphics)
2.4.2 The Instructor Interface

Having completed the SimStartup process, highlighted above, after the initial
DrillSIM-500 Banner is displayed, a login window will appear. There are five
individual instructor logins pre-set, INSTRUCTOR1 through INSTRUCTOR5. The
password. These defaults can be changed, however in the interests of security
please contact Drilling Systems Ltd., Customer Support Dept. Tel: +44 (0)1202
582255.
2.4.3 Loading A Snapshot
instructor.
 The simulator is now ready to run.

The Simulation System should be powered down in the following sequence:
 Select EXIT from the File menu on the Instructor Interface.
If you want shutdown all computers and power down the simulator consoles, select
the top option. If you want to just exit the Instructor Station (but leave the Student
and Graphics still running), then select the bottom option.
 Select the appropriate option to return back to SimStartup Screen
 Select the Shutdown option with the mouse, then press Connect.
The system will confirm which targets will be shutdown
 Select Run to confirm the shutdown.
If a complete shutdown has been performed (ie not just exiting the Instructor
Station), then all the computers will be shutdown completely.
If you just exiting the Instructor Station, then only this one PC / Notebook will
shutdown.
 Power off the Simulator
 Power off any additional hardware (ie the Printer and / or UPS)
Note : If you have shutdown the whole simulator, you will need to power-off the
panels (using the power switch on the remote choke).
2.5 DrillSIM-50 and DrillSIM-20
2.5.1 Power Up Procedures

 Ensure the components of the simulator are correctly connected as in
the diagram.
 Switch on the UPS by pressing the green button.
 Switch on the Simulator by using the switch on the rear of the Choke Panel.
When the switch is in the on position it will glow amber. The Digital Displays will
initially fill with 8’s. Then after a delay of approximately 45 seconds the
simulator will initialise. During this period you may hear noises as the sound
system initialises and the dials on the analogue dials spin before going to their
initial settings. The digital dials will also take on new values.
 Switch on the Laptop Computer and the Printer. After carrying out various
manufacturer diagnostics the computer will boot and present the following
menu:
 Start with Laptop mode with LCD Touch Screen
 DrillSIM Utility Programs
Enter a choice… (1)

 Select the default option - 1 - by pressing the Enter Key and the computer
will install the Windows interface and initialise the touch screen.
 Using the mouse, place the cursor on the DrillSIM50/20 icon and select it.
The software will load and the simulator will be ready to use.
2.5.2 Logging In To the Simulator

 After the initial DrillSIM-50/20 Banner is displayed, a login window will appear.
There are five individual instructor logins pre-set, INSTRUCTOR1 through
INSTRUCTOR5. The password for all is DrillSIM. You may use UPPER or lower
case to enter the login and password. These defaults can be changed, however
in the interests of security please contact Drilling Systems Ltd., Customer
Support Dept. Tel: +44 (0)1202 582255.
2.5.3 Loading A Snapshot
instructor.
 The simulator is now ready to run.
2.5.4 Power Down Procedures
 Using the mouse highlight the File Menu on the top of the screen and a drop
down menu will appear. Highlight and select “Exit DrillSIM-50/20”. The
computer will go back to the standard Windows 3.1 interface. Switch off the
Computer and printer.
 Switch off the Simulator by using the Power Switch on the back of the
Choke Panel.
 Power off the UPS.
2.6 DrillSIM-5
2.6.1 From the ‘START’ menu
The DrillSIM-5 Installation program will install into a program group ‘Drilling Systems
Applications’ from the START menu button on your Windows Desktop.
 Select the ‘DrillSIM-5 Student’ from the menu, this will then run the DrillSIM-5.
2.6.2 From the Desktop
The DrillSIM-5 installation program will automatically create a shortcut

on the desktop for you. You can double click the DrillSIM-5 shortcut
from the desktop to launch the DrillSIM-5-student package.
2.6.3 Logging In
After the initial DrillSIM 20 Banner is displayed, a login window will appear. There are
five individual instructor logins pre-set, INSTRUCTOR1 through INSTRUCTOR5. The
password. These defaults can be changed, however in the interests of security please
contact Drilling Systems Ltd., Customer Support Dept. Tel: +44 (0)1202 582255.
2.6.4 Shut Down Sequence

The Simulation System should be powered down in the following sequence: -
 Select EXIT from the File menu on the
instructor interface.
 The Instructor Interface computer is now return back to Windows.

Controls and Instrumentation (DrillSIM-20)
Table of Contents
3. CONTROLS AND INSTRUMENTATION.....................................................................3.1
3.1 DRILLING CONTROLS CONSOLE............................................................................................................. 3.2
3.2 REMOTE CHOKE CONTROL CONSOLE......................................................................................................3.4
3.3 SURFACE BOP CONTROL CONSOLE.......................................................................................................3.7
3.4 SUBSEA BOP CONTROL CONSOLE...................................................................................................... 3.10
3.5 MUD PUMP & TANK LINE UP...............................................................................................................3.13
3.6 TRIP TANK & STRIP TANK ALIGNMENT................................................................................................3.15
3.7 DRILLING & TRIPPING DATA DISPLAY................................................................................................. 3.16
3.8 SURFACE GRAPHICS SCREEN.............................................................................................................. 3.17
3.9 STANDPIPE AND CHOKE MANIFOLD......................................................................................................3.20
3.10 DOWNHOLE GRAPHICS........................................................................................................................3.23
3.11 DRILLING RECORDER..........................................................................................................................3.24
3.12 WORKOVER EQUIPMENT......................................................................................................................3.26
3.13 DIVERTER CONTROL CONSOLE............................................................................................................ 3.26
Revision History
Version Date Revision Details Editor
1.0 January 1998 Initial Version of Manual ITL
2.0 October 2003 Re-written to match revisions of software BEM
3.0 September 2004 Updated to include DrillSIM-20 screens EMR
4.0 Sept 17th 2004 Updated to include new equipment (Mk4) photos EMR
5.0 July 2005 New Logo EMR
5.01 15th October 2008 The adding / removing stands or singles button needs CJB/EMR
to pressed for 2 seconds before it operates
File Location:
S:\Product Manuals\DrillSIM\Operators Manual\English\chapter 3_20_English_v5.01.doc
DrillSIM Operator’s Manual

Controls and Instrumentation : DrillSIM-20 3.1
3. CONTROLS AND INSTRUMENTATION

3.1 Drilling Controls Console
This function is provided by the DrillSIM software rather than by a series of physical
controls.
3.1.1 Mud Pump 1 Speed Control

Control of Mud Pump 1 Speed is by means of a control knob which turns through 240
degrees. The speed control enables control in the range 0 to 200 SPM. The instructor,
using the instructor station software, can determine the maximum pump speed
allowed in the simulation.
3.1.2 Mud Pump 2 Speed Control

Control of Mud Pump 2 Speed is by means of a control knob which turns through 240
degrees. The knob enables control in the range 0 to 200 SPM. The instructor can
determine the maximum pump speed at the instructor station.
3.1.3 Mud Pump SPM Display

A 6-digit numeric display provides a visual indication of the speed of either Mud
Pump 1 or 2 or any combination thereof. Selection of the Mud Pump for display is
achieved by use of push button selector switches. The accuracy of the displayed
reading is +/- 1 stroke per minute (SPM).
3.1.4 Mud Pump Total Strokes Displays

One five-digit display indicates the total number of strokes pumped by each Mud
Pump. The total number of strokes pumped during drilling or tripping can be
displayed by selecting the associated push buttons for the desired pumps. If more
than one pump is running, the display accumulates the strokes generated by each
pump. A blue push button switch is available to reset the total strokes display to
zero.
Allows the user to control the mud system, including pumps and pits.
Displays the Surface Graphics screen.
Allows the student to configure the Trip and Strip Tanks.
Displays the Down Hole Graphics screen.
Displays the Standpipe and Choke Manifolds
Displays the Remote Choke screen.
Displays the Drilling & Tripping Data screens
Displays the BOP Control screen.
Displays the Chart Recorder option.

3.2 Remote Choke Control Console
3.2.1 Drill Pipe Pressure Gauge

A 6,000-psi (420 BAR) pressure gauge is provided for the Driller to monitor the
Standpipe Pressure.
3.2.2 Casing Pressure Gauge

A 6,000-psi (420 BAR) pressure gauge is provided for the Driller to monitor the
Casing Pressure.
3.2.3 Remote Choke Control

A 3-position lever operated switch controls the selected remote choke, the centre
position holding the choke at the current setting. The choke setting can be anywhere
from fully open to fully closed.
3.2.4 Kill Line Pressure

A digital read out showing the kill line pressure.
3.2.5 Remote Choke Position Indicator
The selected Remote choke Position is displayed on an electrically driven gauge with
240° full-scale deflection. A scale dial, calibrated with 20 graduations from fully
open to fully closed, is fitted to the gauge. The position of the choke is normally
closed.
With a Swaco choke the choke does not begin to open until the actuator has rotated
17°. This amount of rotation is modelled and therefore the choke will not open the
needle is past two graduations.
3.2.6 Hydraulic Regulator Control

A rotary control actuated 1-turn potentiometer controls the rate at which the
selected Remote Choke responds to the Remote Choke Position Control. The range of
control is variable from fast to slow. A recommended speed to set the opening and
closing of the choke to is 20 - 25 seconds from fully closed to fully open.
3.2.7 Mud Pump SPM Display

A 6-digit numeric display provides a visual indication of the speed of either Mud
Pump 1 or 2 or any combination thereof. Selection of the Mud Pump for display is
achieved by use of push button selector switches. The accuracy of the displayed
reading is +/- 1 stroke per minute (SPM).
3.2.8 Mud Pump Total Strokes Displays

One five-digit display indicates the total number of strokes pumped by each Mud
Pump. The total number of strokes pumped during drilling or tripping can be
displayed by selecting the associated push buttons for the desired pumps. If more
than one pump is running the display accumulates the strokes generated by each
pump. A blue push button switch is available to reset the total strokes display to
zero.
3.2.9 Mud Pump Strokes Display Select Push Buttons

Selection of the Mud Pump for display is achieved by use of push-button selector
switches. If more than one pump is selected the SPM and total strokes displays will
show the accumulated amounts generated by the respective pumps.
3.2.10 Remote Choke Screen
This screen allows the user to change the settings of the Remote Choke
(modelled on the industry standard Swaco design).
The Remote Choke screen allows the user to vary the aperture of the Remote Choke
manifold for use in a well control situation. The choke position is controlled using the
large lever in the centre of the screen – to open or close the choke, simply click
upon the appropriate arrow. The speed at which the choke will change position is
determined by the hydraulic regulator. This screen also allows the user to set the
mud pumps running and provides a range of well control data along the bottom of
the screen.
3.3 Surface BOP Control Console
This screen allows the user to control the BOP stack (either a standard
surface BOP or a Subsea BOP, depending upon how the exercise has
been configured).
Please note that this is a software only control.
3.3.1 Accumulator Pressure Display

Accumulator Pressure is displayed on either an electrically driven 5-digit data display
or an analogue gauge.
3.3.2 Manifold Pressure Display

Manifold Pressure is displayed on either an electrically driven 5-digit data display or
an analogue gauge.
3.3.3 Rig Air Pressure Display

Rig Air Pressure is displayed on either an electrically driven 5-digit data display or an
analogue gauge.
3.3.4 Annular Pressure Display

Annular Pressure is displayed on either an electrically driven 5-digit data display or
an analogue gauge.
3.3.5 Push & Hold To Operate
A latching touch push-button switch controls the power supply to the Surface BOP
Control Console pilot controls. When operating any BOP or valve control, the Push to
Operate button must be pressed first.
3.3.6 Annular Pressure Regulator

Two touch push buttons Increase and Decrease the Hydraulic Operating Pressure to
the Annular Preventer. Activating the “PUSH TO OPERATE” button then the
appropriate push-button in causes a corresponding pressure change.
3.3.7 Manifold Pressure Regulator

Two touch push buttons Increase and Decrease the Hydraulic Operating Pressure to
the rams and fail-safe valves. Activating the “PUSH TO OPERATE” button and the
appropriate push-button in causes a corresponding pressure change.
3.3.8 Annular Preventer Control

The Annular Preventer is Opened and Closed using an illuminated momentary
touch push-button. When the Preventer has reached the Open or closed position
then the appropriate button will change colour to confirm the status.
3.3.9 Upper Pipe Rams

The Upper Pipe Rams are Opened and Closed using an illuminated touch
momentary push-button. When the ram has reached the open or closed position
then the appropriate button will change colour to confirm the status.
3.3.10 Blind Rams

The Blind Rams are Opened and Closed using an illuminated momentary touch push-
button. When the ram has reached the Open or closed position then the appropriate
button will change colour to confirm the status.
3.3.11 Kill Line Control

An illuminated momentary push-button switch is used to Open and Close the Upper
Kill Line Valve. When the valve has reached the Open or closed position then the
appropriate button will change colour to confirm the status.
3.3.12 Choke Line Control
An illuminated momentary push-button switch is used to Open and Close the Upper
Choke Line Valve from the Middle Pipe Ram to the Choke Manifold. When the valve
has reached the Open or closed position then the appropriate button will change
colour to confirm the status.
3.3.13 Lower Pipe Rams

The Lower Pipe Rams are Opened and Closed using an illuminated momentary
touch push-button. When the ram has reached the Open or closed position then the
appropriate button will change colour to confirm the status.
3.3.14 Flow Totalizer

The flow totalizer displays the amount of hydraulic fluid (in gallons) flowing to the
activated Preventer or valve when the appropriate control is activated.
3.3.15 Flow Meter Reset

This push-button is activated to reset the flow meter to zero. The flow meter should
be reset to zero each time a new control is activated.
3.3.16 Pump Running

This lamp is illuminated when the accumulator pressure reaches 2700psi (186 BAR)
and the accumulator pump is engaged.
3.4 Subsea BOP Control Console
This screen allows the user to control the BOP stack (either a standard
surface BOP or a Subsea BOP, depending upon how the exercise has
been configured).
3.4.1 Accumulator Pressure Gauge

Accumulator Pressure is displayed on either an electrically driven 5-digit data display.
3.4.2 Rig Air Pressure Gauge

Rig Air Pressure is displayed on either an electrically driven gauge 5-digit data
display.
3.4.3 Annular Regulator Readback Pressure Gauge

Annular Regulator Readback Pressure is displayed on either an electrically driven 5-
digit. The Annular Readback Pressure Gauge will lag the Annular Regulator Pilot
Pressure gauge when adjusting the regulator pressure.
3.4.4 Manifold Regulator Readback Pressure Gauge

Manifold Regulator Readback Pressure is displayed on either an electrically driven 5-
digit data display. This gauge will lag the manifold regulator pilot pressure gauge
when the pressure regulator is adjusted.
3.4.5 Annular Pressure Regulator
Two pushbutton switches Increase and Decrease the Hydraulic Operating Pressure to
the Annular Preventer.
3.4.6 Manifold Pressure Regulator

Two push-button switches Increase and Decrease the Hydraulic Operating Pressure to
the rams and fail-safe valves.
3.4.7 Push to Operate Control

The PUSH TO OPERATE button is provided as a safety device to assist in preventing
accidental operation of any control. All other controls on the SSBOP control console
must be activated in series with this control to enable operation.
3.4.8 Annular Control

Three illuminating touch push buttons, coloured green, orange and red, respectively
Open Block and Close the Lower Annular Preventer. The appropriate push-button
illuminates to indicate the status of the Upper Annular. These controls must be
operated in conjunction with the PUSH TO OPERATE button. If the BLOCK switch is
activated the BLOCK lamp should illuminate and the last function operated will
remain illuminated. To deactivate the BLOCK function, activate the OPEN or CLOSE
function.
3.4.9 Kill Line Control

Two sets of illuminating touch push buttons Open, Block and Close the Inner and
Outer Upper Kill Line valves. The appropriate push buttons illuminate to indicate the
current status of the valves, red for Open, Orange for Block and green for Closed. If
the BLOCK switch is activated the BLOCK lamp should illuminate and the last
function operated will remain illuminated. To deactivate the BLOCK function, activate
the OPEN or CLOSE function.
3.4.10 Upper Choke Line Control

Outer Upper Kill Line valves. The appropriate push buttons illuminate to indicate the
3.4.11 Lower Choke Line Control

Outer Lower Kill Line valves. The appropriate push buttons illuminate to indicate the
3.4.12 Ram Controls

Four groups of three illuminating touch push-buttons Open, Close and Block the
Shear, Upper, Middle and Lower Pipe Rams. Shearing pipe requires 3000-psi (210
BAR) hydraulic operating pressure on the shear rams. The appropriate push-button
in each group illuminates to indicate the status of the related rams, green for Open,
orange for Blocked and red for Closed. If the BLOCK switch is activated the
BLOCK lamp should illuminate and the last function operated will remain
illuminated. To deactivate the BLOCK function, activate the OPEN or CLOSE
function.
3.4.13 Flow Meter

A four-digit flow meter displays the Hydraulic Flow in the range 000.0 to 999.9
gallons or litres. An associated push-button switch resets the flow to 000.0.
3.5 Mud Pump & Tank Line Up
This screen provides the user with a range of information about the Mud
Pumps and the Mud Pits.
Make Water Valves

Transfer Valve
3.5.1 Mud Pump 1

This button links to a screen which gives details of the properties of Mud Pump 1,
namely the Output per stroke and the Relief Valve Status. If the Standpipe Pressure
exceeds that of the Relief Valve then the Relief Valve (commonly known as the Pop-
off valve) will activate, the valve can be reset using the button labelled “Reset
Relief Valve”. To exit the properties screen, press the button marked “Previous”.
3.5.2 Mud Pump 2

This button links to a screen which gives details of the properties of Mud Pump 2,
namely the Output per stroke and the Relief Valve Status. If the Standpipe Pressure
exceeds that of the Relief Valve then the Relief Valve (commonly known as the Pop-
off valve) will activate, the valve can be reset using the button labelled “Reset
Relief Valve”. To exit the properties screen, press the button marked “Previous”.
3.5.3 Active Pit

The Active Mud Pit screen allows the user to enter the Volume of mud in the pit and
the Mud Weight, the rest of the values (PV, YP etc) are calculated by the simulator.
If you wish to change any of the data, simply click on the desired button and a
calculator style data entry screen will appear. As the well is drilled, the data on this
screen will change (for instance, the settled solids will increase as drilled cuttings
pass through the solid control equipment and into the active tank), so it I important
that you pay close attention to the mud properties. There is an option labelled as
“Auto Density Control” which will automatically maintain the current mud weight.
The button labelled “Dump” enables the user to empty and clean the pit.
3.5.4 Reserve Pit

The Active Mud Pit screen allows the user to enter the Volume of mud in the pit and
the Mud Weight, the rest of the values (PV, YP etc) are calculated by the simulator. If
you wish to change any of the data, simply click on the desired button and a
calculator style data entry screen will appear.
3.5.5 Transfer Valve

This valve is used to transfer mud from the Reserve Pit to the Active Pit. It cannot be
used to transfer in the opposite direction.
3.5.6 Make Water Valves

This collection of valves allows the user to transfer freshwater to the active pit. The
rate of the transfer can be set using the transfer rate button.
3.6 Trip Tank & Strip Tank Alignment
This screen allows the Student to change the alignment of the various
valves and controls associated with the Active Mud System. The valves can
be controlled by clicking on the desired option which will toggle the valve
status, for instance in the image below, the Trip Tank Fill valves are closed
– to open either valve, simply click on it and the caption will change to
“Open”.
Trip Tank Fill Valves
The gauges throughout the simulator will reflect the changes made to the mud
system, for instance, by filling the trip tank with 10m3 of drilling fluids, the active
system will see a corresponding loss.
3.7 Drilling & Tripping Data Display
This screen provides the user with an overview of the current data being
displayed. This screen is designed to offer a wide range of data and
information to the user in a clear and easily accessible format. The
information will be updated in real time and allows the user to maintain a
close watch on the drilling parameters.
 Total Depth  Bit Depth

 Hook Load  Casing Pressure
 Mud Pump 1 SPM  Mud Pump 2 SPM
 Torque  Rotary Table Speed (RPM)
 Weight on Bit  Rate of Penetration
 Mud Weight In  Mud Weight Out
 % Return Flow  Pit Gain / Loss
 Pit Volume  Kill Mud Volume
There is a similar screen which provides a range of data more closely associated
with Tripping operations, which can be accessed by using the “View Tripping Data”
button on the bottom left hand side of the screen.
3.8 Surface Graphics Screen
This icon will change the main screen to the Surface Graphics screen, which
allows the user to perform the operations normally associated with the drill
floor.
3.8.1 Pump Controls
Pressing either of the Pump Control buttons will cause this panel to appear. The
current Strokes per Minute will be displayed along with the following controls:
 Pump On/Off (toggles between states)
 Pump Speed (dial control)
3.8.2 Rotary / TDS Speed
Pressing the Rotary/TDS Speed button will cause this panel to appear. The current
Rotary Speed will be displayed along with the following controls:
 Rotary On/Off (toggles between states)
 Rotary Speed (dial control)
3.8.3 Hoist Up
This button will allow the student to raise the Travelling Block. To continue to raise
the block, you will need to press and hold this button.
3.8.4 Lower Down

This button will allow the student to lower the Travelling Block. To continue to lower
the block, you will need to press and hold this button.
3.8.5 Install IBOP

This will install and uninstall the IBOP and toggles between the options.
3.8.6 Slips
This will toggle the Slips in and out.
3.8.7 Add/Remove Stand

This will either add or remove a stand (3 joints of tubulars) depending upon the
position of the pipe e.g. if the stump is just above the drill floor, the simulator will
assume you wish to add a stand of drill pipe. This button must be pressed for 2
seconds.
3.8.8 Add/Remove Single

This will either add or remove a single joint of tubulars depending upon the position
of the pipe e.g. if the stump is just above the drill floor, the simulator will assume
you wish to add a joint of drill pipe. This button must be pressed for 2 seconds.
3.8.9 Connect / Disconnect Kelly (applicable in Kelly mode only)

If running a Kelly, an additional button appears to be able to connect or disconnect
the Kelly. This button must be pressed for 2 seconds.
3.8.10 Auto Driller

When the Auto Driller feature is activated, the current Weight on Bit will be
maintained until the next connection has to be made.
3.8.11 Show Trip/Strip
This button will change the format of the screen to that illustrated below, namely the
Return Flow & Pit Deviation gauges are replaced by the Trip Tank & Strip Tank
controls. The Alarm settings can be set by clicking upon the face of the gauge and
using this controls which appear.
3.8.12 Data Display Log

These charts are displayed along the right hand side of the screen and allow the
user to view a range of historical date as a graph. The user is able select which
parameter they wish to plot from the following list by simply clicking on the graph
itself:
 Drill Pipe Pressure
 Casing Pressure
 Mud Volume
 Pit Deviation
 Hookload
 Weight on Bit
 Trip Tank Volume
 Strip Tank Volume
 TDS Torque
 Rotary Torque
 ROP
 Return Flow
 Choke Position
 SPM
3.9 Standpipe and Choke Manifold
This screen allows the user to change the status of the manifold valves and
monitor the readings on the pressure gauges.
3.9.1 Mud Pump 1 Inlet Valve (SM2)

A 2-position switch allows the user to open and close the Inlet Valve from Mud Pump
1 and Mud Pump 3.
3.9.2 Cross Left Isolation Valve (SM6)

A 2-position switch allows the user to open and close the Standpipe Isolation Valve.
3.9.3 Choke Manifold Isolation Valve (SM3)

A 2-position switch allows the user to open and close the Choke Manifold Isolation
Valve.
3.9.4 Cross Centre Isolation Valve (SM7)

3.9.5 Kill Line Isolation Valve (SM4)

A 2-position switch allows the user to open and close the Kill Line Isolation Valve.
3.9.6 Cross Right Isolation Valve (SM8)
3.9.7 Mud Pump 2 Inlet Valve (SM5)

A 2-position switch allows the user to open and close the Inlet Valve from Mud Pump
2.
3.9.8 Standpipe 1 Rotary Hose Isolation Valve (SM9)

A 2-position switch allows the user to open and close the Rotary Hose Isolation Valve.
3.9.9 Bleed Off Line Isolation Valve (SM1)

A 2-position switch allows the user to open and close the Rotary Hose Isolation Valve.
3.9.10 Standpipe Pressure Gauge (TAP1 and TAP2)

Standpipe Pressure is displayed on the digital displays
3.9.11 Choke Line Valve (CM1)

A 2-position switch allows the user to open and close the Choke Line Valve.
3.9.12 Left Remote Choke Input Valve (CM5)

A 2-position switch allows the user to open and close the Left Remote Choke Input
Valve.
3.9.13 Left Remote Choke

An orange rectangle on the choke manifold represents the Left Remote Choke.
3.9.14 Left Remote Choke Output Valve (CM8)

A 2-position switch allows the user to open and close the Left Remote Choke Output
Valve.
3.9.15 Connection to Standpipe Manifold Valve (CM2)

A 2-position switch allows the user to open and close the valve coming from the
Choke Manifold outlet on the Standpipe Manifold. This connection enables pumping
down the choke line and reverse circulation.
3.9.16 Casing Pressure Gauge (TAP3 and TAP4)

Casing Pressure is displayed on the digital displays
3.9.17 Manifold Input Bypass Valve (CM6)

A 2-position switch allows the user to open and close the Manifold Bypass Valve.
3.9.18 Cross Connection Valve (CM4)

A 2-position switch allows the user to open and close the Upper Cross Connection
Valves.
3.9.19 Right Bypass line
A 2-position switch allows the user to open and close the Right Manual Choke Input
Valve.
3.9.20 Right Manual Choke Output Valve (CM10)

A 2-position switch allows the user to open and close the Right Manual Choke Output
Valve.
3.9.21 Kill Line Valve (CM3)

A 2-position switch allows the user to open and close the Kill Line Valve.
3.9.22 Manifold Bypass Output Valve (CM9)

A 2-position switch allows the user to open and close the Manifold Bypass Output
Valve.
3.9.23 Right Remote Choke Input Valve

A 2-position switch allows the user to open and close the Right Remote Choke Input
Valve.
The Remote choke position can be altered using

the Remote Choke screen. The Manual choke can
be altered by either clicking on the representation
of the manual choke or the caption beside it.
3.10 Downhole Graphics
This screen provides the user with an insight into the pressures and
conditions within the wellbore. Examples of this would be the presence of
zones of different density fluids (including kick fluids), formations and
phenomena (formation invasion, communication between formations etc)
3.11 Drilling Recorder
This screen provides the user with the facility to monitor a range of
drilling data. The charts are updated every second and display a
historic record of the chosen parameters.
The user can change the displayed parameters by double-clicking on the chart they
wish to change and selecting the new parameter they wish to display. The list of
parameters is as follows:
 TDS Torque  Hookload

 Drill Pipe Pressure  Choke Position
 Casing Pressure  Pit Deviation
 Return Flow  Trip Tank Volume
 ROP  Strip Tank Volume
 WOB  Total Mud Volume
 Total SPM 
3.11.1 Recorded Variables
A 6-channel recorder, specially modified for use with the Simulator, is provided to
produce a permanent record of drilling and well control operation variables. They are:
Default Drilling Parameters

 Hook Load.
 Rate of Penetration.
 Rotary RPM
 Rotary Torque.
 Pump Stroke Rate.
 Pump Pressure.
Default Well Control Parameters

 Drill Pipe Pressure.
 Casing Pressure
 Bottom Hole Pressure
 Pit Gain
 Shoe Pressure
An additional yellow formation pressure reference line is printed as a guideline to

monitoring bottom-hole pressure during well killing operations.
3.12 Workover Equipment
There is no workover option on the DrillSIM-20.
3.13 Diverter Control Console
The DrillSIM-20 does not have this option.

Instructor Control Station 4.i
Table of Contents
4. DRILLSIM INSTRUCTOR STATION........................................................................4.1

4.1 MAIN MENU....................................................................................................................................... 4.2
4.1.1 Ghosted Options......................................................................................4.2
4.1.2 Flashing Toolbar......................................................................................4.2
4.2 DRILLSIM-5 MAIN MENU..................................................................................................................4.3
4.2.1 User Selection.........................................................................................4.3
4.3 CONFIGURATION MENU.......................................................................................................................4.5
4.3.1 Rig Selection...........................................................................................4.6
4.3.2 Well-bore Geometry.................................................................................4.9
4.3.3 Tubulars...............................................................................................4.18
4.3.4 Formation Data – Change Geology............................................................4.32
4.3.5 Formation Data - Summary of Geology.....................................................4.43
4.3.6 Mud System..........................................................................................4.44
4.3.7 Rig Equipment.......................................................................................4.50
4.4 REAL TIME DATA DISPLAY................................................................................................................4.62
4.4.1 Drilling Data..........................................................................................4.63
4.4.2 Pump Data............................................................................................4.64
4.4.3 Mud Data..............................................................................................4.65
4.4.4 Well Control Data...................................................................................4.66
4.4.5 Operator Warnings.................................................................................4.67
4.4.6 Deviated Well Data.................................................................................4.68
4.5 RUNTIME INSTRUCTOR CONTROLS.................................................................................................... 4.69
4.6 SIMULATION SPEED..........................................................................................................................4.71
4.7 MALFUNCTIONS................................................................................................................................4.72
4.7.1 Rig Equipment.......................................................................................4.74
4.7.2 Downhole Malfunctions...........................................................................4.89
4.8 SNAPSHOT UTILITIES.....................................................................................................................4.101
4.9 GRAPHICS DISPLAY........................................................................................................................4.102
4.9.1 Tank Alignment....................................................................................4.102
4.9.2 Pumps & Mud......................................................................................4.102
4.9.3 Auto Driller..........................................................................................4.102
4.9.4 BOP Information..................................................................................4.102
4.9.5 Data Display Panel...............................................................................4.103
4.9.6 Data Display Graphs.............................................................................4.103
4.10 DOWN HOLE GRAPHICS................................................................................................................. 4.104
4.11 TRIP TANK OPTIONS...................................................................................................................... 4.105
4.12 MUD PUMP AND TANK LINE UP OPTIONS........................................................................................ 4.106
4.13 CHART RECORDER......................................................................................................................... 4.107
4.13.1 Plotting with the Chart Recorder.............................................................4.107
4.13.2 Using the Data Log...............................................................................4.108
4.13.3 Configuring & Using the Chart Recorder...................................................4.109
4.14 VARIABLE INSPECTION AND DIAGNOSTICS......................................................................................4.115
4.15 UNIT CONVERSIONS...................................................................................................................... 4.117
4.15.1 Change Unit Conversion Screens............................................................4.118
4.15.2 Unit Configuration Menu > Unit Overview................................................4.119
4.15.3 Unit Configuration Menu > Add / Modify Units..........................................4.120
4.15.4 Unit Configuration Menu > Create New Group...........................................4.121
4.16 MANIFOLD DISPLAY (DRILLSIM-5000 / DRILLSIM-500).............................................4.122
4.17 BOP INFORMATION....................................................................................................................... 4.123

Instructor Control Station 4iii
Revision History
Revision Date Revised By Details Section

Manual updated to reflect changes made to the
October 2003 B. March
simulator.
25/01/2005 G.Chen / ALW Updated note on Reservoir Fluid Density 4.3.4.4
26/01/2005 G.Chen / EMR Correct numbering structure All
File Location –
T:\Products Oil\Manuals\DrillSIM\Operators Manual\English\chapter 4_English_v4.doc

Instructor Control Station 4.1
4. DRILLSIM INSTRUCTOR STATION
After the initial DrillSIM Banner is displayed, a login window will appear. There are
five different instructor logins pre-set, INSTRUCTOR1 through to INSTRUCTOR5. The
password. These defaults can be changed, however in the interests of security
please contact Drilling Systems Ltd., Technical Support Dept. Tel: +44 (0) 1202
582255.

4.1 Main Menu
On the screen are two areas, which allow interaction with the mouse to select various
options. At the very top of the screen is the Menu. It lists five options: File,
Simulation, Configuration, Run Time and Display. Below that is the Toolbar with a
range of buttons, each is described below.
4.1.1 Ghosted Options

Please note that some buttons described in this manual may not be available on your
system or may appear ‘ghosted’. Reasons for this include that the option would
result in an inappropriate action, or an option was not purchased with your system.
Please contact Drilling System’s Customer Support if you have a query.
4.1.2 Flashing Toolbar

If the Toolbar flashes, an error has occurred – for details see Section 4.4.5.
4.2 DrillSIM-5 Main Menu
Selecting the drop

down display will
Shows the current display all the current
‘connected’ user and available DrillSIM-5
their status. users on the network.
4.2.1 User Selection

The DrillSIM-5 is designed to work across a network computer system that supports
the TCP/IP protocol. The instructor only needs to select a user from the list of
available connections to connect to them. Once connected all actions that are
performed on the Instructor station are sent to the connected station. This allows
the Instructor to connect a Student station and activate malfunctions, view the
current progress of that Student during a Well Control exercise etc.
Summary of Icons
The Freeze icon shows the current status of the simulator. Clicking on the
icon will toggle the status from Freeze to Run.
The camera icon provides quick access to the Snapshot Utilities, where exercises can be saved and
loaded.
The clock icon allows the user to set the speed of the simulator. The
speed can be set to real time or a multiplier value.
The Snapshot Configuration icon allows the Instructor to set up the exercise for the student. The
Instructor can set-up the Rig Type, the Well-bore Geometry, the Formation Data, the Mud
System and the Rig Equipment.
Displays the Runtime Menu
Runtime Instructor Controls Menu (DrillSIM-5000)

See Section 4.5
Malfunctions Menu
Displays the Surface Graphics screen by toggling graphics screen on/off.
Displays the Down Hole Graphics screen by toggling the graphics screen
on/off.
Allows configuration of the Trip and Strip Tanks
Allows the student to control the mud system, including pumps and pits.
Displays the Chart Recorder option, where the printer can be switched on
and off, and the mode of recording, Drilling or Well Control.
4.3 Configuration Menu
To configure an exercise, either select the Snapshot Config icon or

choose Exercise Configuration from the Configuration options on the
main menu.
The Exercise Configuration Menu is used when configuring new well snapshots or
altering existing ones. Start by loading an existing well snapshot with similar
parameters to those desired, e.g. a subsea or surface well. From this point, a new
well can be configured by stepping through the Exercise Configuration Menu. Step
through each sub-menu as described in the following pages, check each data value
displayed and adjust as appropriate. Once configuration is complete use the
Snapshot Utilities Menu to save the new well snapshot.
4.3.1 Rig Selection
Selecting the Rig Type button, the Instructor can choose the type of rig for the
exercise to be based on.
Select from Land, Floater, Jack-up or
Workover. Note that options with ghosted
text are not available on your simulator.
The currently selected rig will change and
the previously selected BOP will be
removed.
Select the Bop Equipment icon, to

determine which types of equipment can
be installed.
Clicking or touching the icons will

toggle them between Enabled and Disabled.
Based on the rig selected and whether the BOP equipment has been enabled or
disabled, the drawing of the currently selected rig displays all the equipment that has
been installed.
Flow Nipple or Riser Internal Diameter
On a land rig the flow nipple I.D. (internal diameter) is generally set to match the
I.D. of the BOP stack. If a 13 5/8” 5000 psi BOP stack is used the I.D. of the flow
nipple should be set to 13.625 inches. For simplicity sake the mathematical model
considers the BOPs to be the same I.D. as the flow nipple or riser. When setting the
I.D. for the marine riser a typical marine riser I.D. is 19.25 inches.
Caution:
Never set the Flow Nipple or Marine Riser I.D. less than the I.D. of the casing
Flow Line to Ground Level or Seabed
This button is used to set the height of the flow line from ground level or seabed.
Typical distances of the flow line from the rotary table are 5ft. (1.5 m) for a land rig
and 15 ft. (4.6 m) for a floater. The model fixes the sub height on a land rig to be
30ft. (9.14 m) therefore the Flowline to ground level setting would be 25ft. (7.6 m).
RKB to Seabed
This button is used to set the distance from the rotary table to the seabed for floating
vessel operations.
Sea Depth
This button is used to set the water depth. Air gap can be calculated by subtracting
this value from the value of RKB to Seabed. The model considers the gradient of the
seawater to be 0.445 psi/ft (10.07 kPa/m), (10.07 BAR/10m). Seawater
hydrostatics, formation pressures and reduced fracture gradients must be calculated
using this gradient.
Choke Line Internal Diameter
This button is used to set the I.D. (internal diameter) of the choke and kill lines. This
value is typically set to 3 in. (76.2 mm) for both land and floating vessel operations.
RKB to Bit Depth
This button is used to set the depth of the bit in the well. The mathematical
considers all drill string members to be 30ft. (9.14 m) long therefore when setting
the bit position it should be set in multiples of this length. If the bit depth is set to
hole depth the model will calculate the nearest bit position as a multiple of 30 ft.
(9.14 m) and place the bit in that position when the simulator is put into the run
mode.
Choke Line Friction Factor
To comply with IWCF requirements of 150 psi (1035 kPa), (10.4 Bar) minimum
choke line friction loss, this button can be used to adjust the model calculated
friction loss to the desired value. For example if the choke line friction loss measured
in 525 ft (160 m) water is only 50 psi (345 kPa) with a 10 ppg (1.2 S.G.) mud, the
Choke Line Friction Factor can be set to 3 or 4 to bring the choke line friction loss up
over 150 psi.
4.3.2 Well-bore Geometry
Use the Well-bore Geometry menu to configure the casing and liner and well profile.
The perforations option is to be used during a Workover or DST operation.
4.3.2.1 Casing
Casing Outside Diameter
This button is used to set the outside diameter of the casing in the hole. Casing data
can be acquired from a standard engineering handbook such as the IFP Drilling Data
Handbook. When selecting casing for the well make sure the planned bit size will fit
inside the casing.
Casing Inside Diameter
This button is used to set the inside diameter of the casing in the hole. Casing data
inside the casing.
Casing Weight
This button is used to set the weight of the casing in the hole. Casing data can be
acquired from a standard engineering handbook such as the IFP Drilling Data
Handbook.
Collapse Pressure
This button is used to set the Collapse Pressure of the casing in the hole. Casing data
Handbook
Tensile Strength
This button is used to set the Tensile Strength of the casing in the hole. Casing data
can be acquired from a standard engineering handbook such as the IFP Drilling
Data Handbook
Depth of Set Casing
This button is used to set the Measured Depth of the casing in the hole. True
Vertical Depth of the set casing can be calculated using standard directional well
planning calculation methods found in Section J of the Green Book (IFP Drilling Data
Handbook).
4.3.2.2 Liner
Liner Outside Diameter
This button is used to set the outside diameter of the liner in the hole. Casing
and liner data can be acquired from a standard engineering handbook such as
the IFP Drilling Data Handbook.
Liner Inside Diameter
This button is used to set the inside diameter of the liner in the hole. Casing and liner
data can be from a standard engineering handbook such as the IFP Drilling Data
inside the liner.
Liner Weight
This button is used to set the weight of the liner in the hole. Casing and liner data
Handbook.
Depth of Set Liner
This button is used to set the Measured Depth of the liner in the hole. True Vertical
Depth of the set liner can be calculated using standard directional well planning
calculation methods found in Section J of the Green Book (IFP Drilling Data
Handbook).
4.3.2.3 Hole Data
Select the hole data menu to build the desired well profile and to cross check shoe
depths, hole depth and hole size.
The simulation software will look to see what parameters have been entered. If you
are changing from a deviated hole to a straight hole, be sure to enter zeros for all of
the deviated parameters.
Straight Hole Profile
Total Depth
Total depth is set using the measured depth button. The model will calculate true
vertical depth of the well once the simulator is put into run mode.
The previously entered data for the Casing shoe and the Liner shoe hole size will be
brought forward and can be changed.
Build and Hold Profile
Kick Off Depth
The selection of both the kick-off point and the build-up rate depend on many
factors including the hole pattern selected, the casing programme, the mud
programme, the required horizontal displacement and the maximum tolerable
inclination. The choice of kick-off point may be influenced by the need to steer the
well path away from existing wells.
Build Rate
Build up rates are usually inn the range 1.5° /100 ft MD to 4.0° / 100 ft MD for
normal directional wells. The maximum permissible dogleg severity must be
considered when choosing the appropriate rate.
Build Angle (Tangent Angle)
This angle can be calculated from the build up rate and length of the build up
section. Experience over the years has been that directional control problems are
aggravated when the tangent inclination is less than 15°. This is because there is a
greater tendency for bit walk to occur. To summarise, most run-of-the-mill
directional wells are still planned with inclinations in the range of 15° - 60° wherever
possible. If wells are drilled at inclinations up to 80°, the area that can be covered
from a single platform is approximately 8 times that covered if the maximum
inclination of the wells is limited to 60°. However, inclination angles over 65° may
result in excessive torque and drag on the drill string and present hole cleaning,
logging, casing, cementing and production problems. Tangent angles in the simulator
are limited to 90°.
True Vertical Depth
The model will calculate true vertical depth of the well once the simulator is put into
the run mode.
S-Type Profile
Kick Off Depth
The selection of both the kick-off point and the build-up rate depend on many
factors including the hole pattern selected, the casing programme, the mud
programme, the required horizontal displacement and the maximum tolerable
inclination. Choice of kick-off point may be severely limited by the requirement to
keep the well path at a safe distance from existing wells. The shallower the KOP and
the higher the build-up rate used, the lower the maximum inclination.
Build Rate
Build up rates are usually inn the range 1.5° /100 ft MD to 4.0° / 100 ft MD for
normal directional wells. The maximum permissible dogleg severity must be
considered when choosing the appropriate rate.
Build Angle (Tangent Angle)
This angle can be calculated from the build up rate and length of the build up
section. Experience over the years has been that directional control problems are
aggravated when the tangent inclination is less than 15°. This is because there is a
greater tendency for bit walk to occur. To summarise, most run-of-the-mill
directional wells are still planned with inclinations in the range of 15° - 60° wherever
possible. If wells are drilled at inclinations up to 80°, the area that can be covered
from a single platform is approximately 8 times that covered if the maximum
inclination of the wells is limited to 60°. However, inclination angles over 65° may
result in excessive torque and drag on the drill string and present hole cleaning,
logging, casing, cementing and production problems. Tangent angles in the simulator
are limited to 90°.
Tangent Length
The length of the tangent is simply the Along Hole Length of the section.
Drop Off Rate
On S-type wells, the drop off is selected mainly with regard to ease of running
casing and avoidance of completion and production problems. It is much less critical
with regard to drilling because there is less tension in the drill pipe run through this
deeper dogleg and less time will be spent rotating below the dogleg.
Drop Angle
Drop angle is calculated from the drop rate and the length of the drop off section.
4.3.2.4 Perforations (Workover Options)
Selecting either the Depth of Perforations or Length of Perforations, will result in

a pop-up calculator appearing to allow data input. The button marked “Casing
Perforated”, toggles between Yes and NO options.
Depth of Perforations
This is the measured depth from the surface that the casing can be perforated.
Length of Perforations
This sets the length of the section that is to be perforated.
Casing Perforated
To actuate the perforations, ensure that this toggle switch is set to ‘YES’.
4.3.3 Tubulars
This screen allows the system to be configured for:

 Drillstring – Normal Drilling and Well Control exercises
 Tubing – Workover Operations
 Casing String – Running of Casing and Cementing.
The current selection is highlighted in yellow.

4.3.3.1 Drill String Set-up
Initial Length Run In
This is the initial set depth of the drill pipe from the top of the drill pipe, not RKB.
E.g. if the pipe is connected to the Hook, then its from the hook down. Once the
simulator is put in to run the depth is rounded to the nearest 30ft.
Drillpipe
This selection will present the Upper Drill Pipe selection menu (see section 4.3.12 for
details).
Heavy Weight
This selection will present the Heavy Weight Drill Pipe menu. The number of joints of
Heavy Weight Drill Pipe currently in the BHA is displayed, (see section 4.3.13 for
details).
Collars
This selection will present the Drill Collars selection menu (see section 4.3.14 for
details). The number of currently selected Drill Collars in the BHA is displayed.
Float In
Selecting this button will toggle between Fitted and Not Fitted. The Fitted action
places a float in the drill collar just above the bit. The float prevents reverse flow of
fluids up the drill string and is a useful well control tool during tripping operations. If
a kick is taken with a float in the string the float must be pumped open in order to
acquire a shut-in drill pipe pressure.
Bit
Selecting this button will present the Bit Data menu (see section 4.3.15 for details).
Drillpipe
Upper Drill Pipe Outside Diameter
This button is used to set the outside diameter of the upper drill pipe in the hole. Drill
pipe data can be acquired from API RP7G or the IFP Drilling Data Handbook.
Upper Drill Pipe Inside Diameter
This button is used to set the inside diameter of the upper drill pipe in the hole. Drill
pipe data can be acquired from API RP7G or the IFP Drilling Data Handbook.
Upper Drill Pipe Weight
This button is used to set the weight of the upper drill pipe in the hole. If the
parameters for new drill pipe are entered then the approximate weight including tool
joints should be entered here. If Premium Class drill pipe is used then enter only the
nominal weight of the drill pipe. Drill pipe data can be acquired from API RP7G or
the IFP Drilling Data Handbook.
Upper Drill Pipe Tensile Strength
This button is used to set the tensile strength of the upper drill pipe in the hole. The
model fails the drill pipe at the set tensile strength. Tensile failure of the drill string
occurs just under the rotary table. Drill pipe tensile data can be acquired from API
RP7G or the IFP Drilling Data Handbook.
Upper Drill Pipe Maximum Torque
This button is used to set the torsional strength of the upper drill pipe in the hole.
The model fails the drill pipe at the set torsional strength and results in torsional
failure of the drill string to occur just under the rotary table. Drill pipe torsional data
can be acquired from API RP7G or the IFP Drilling Data Handbook.
Cross Sectional Area of the Upper Drill Pipe
This button is used to set the cross sectional area of the upper drill pipe. Cross
sectional area can be calculated or acquired from API RP7G or the IFP Drilling Data
Handbook.
Number of Joints
This button is used to set the total number of joints of drill pipe available to the
student for the exercise. The button does not set the number of joints of drill pipe in
the hole. If the student runs out of drill pipe an operator error message will be
displayed on the maintenance terminal and on the instructor station.
Stands Racked
This will set the number of stands in the pipe rack (as displayed on the surface
graphics screen).
Heavy Weight Drillpipe
Heavy Weight Drill Pipe Outside Diameter
This button is used to set the outside diameter of the upper drill pipe in the hole.
Heavy weight drill pipe data can be acquired from API RP7G or the IFP Drilling Data
Handbook.
Heavy Weight Drill Pipe Inside Diameter
This button is used to set the inside diameter of the heavy weight drill pipe in the
hole. Heavy weight drill pipe data can be acquired from API RP7G or the IFP Drilling
Data Handbook.
Heavy Weight Drill Pipe Weight
This button is used to set the weight of the heavy weight drill pipe in the hole. Heavy
weight drill pipe data can be acquired from API RP7G or the IFP Drilling Data
Handbook.
Heavy Weight Drill Pipe Tensile Strength
This button is used to set the tensile strength of the heavy weight drill pipe in the
hole. Heavy weight drill pipe tensile data can be acquired from API RP7G or the IFP
Drilling Data Handbook.
Number of Joints
This button is used to set the number of joints of heavy weight drill pipe in the BHA.
Drill Collars
Drill Collar Outside Diameter
This button is used to set the outside diameter of the drill collars in the hole. It is
important to set the drill collar size less than the hole size to prevent an operator
from occurring. Drill collar data can be acquired from API RP7G or the IFP
Drill Collar Inside Diameter
This button is used to set the inside diameter of the drill collars in the hole. Drill
collar data can be acquired from API RP7G or the IFP Drilling Data Handbook.
Drill Collar Weight
This button is used to set the weight of the drill collars in the hole. Drill collar data
Number of Joints
This button is used to set the total number of joints of drill collars in the BHA.
Bit Data
IADC Bit Code
This button is used to select the IADC bit code for the bit in the well. A selection of
seven bit types is available to the instructor. These bit types are:
 1,1,1  1,1,6  1,3,4  2,1,1
 2,1,4  5,1,7  7,1,7
Bit Size
This button is used to select the bit size. A pop-up keypad will display to allow entry
of the bit size.
Bit Age
This button is used to set the age of the bit. Maximum bit age is set in the model at
50 hours. Upon reaching 50 hours of life ROP is reduced to zero and the bit is
considered to have failed.
Nozzles Sizes
As standard, bits are supplied with 3 nozzles, except in certain cases, where there
will be four. If you have selected a bit with 4 nozzles and only three nozzles are
required the fourth nozzle can be blanked with a zero. Nozzles sizes are measured in
32nd of an inch or equivalent units depending on unit system selected. Nozzle sizes
can be changed during the course of the exercise if the instructor wishes to create a
situation whereby gradual plugging takes place.
Bearing Type
This button is used to select the bearing type for the bit selected. Three bearing
types are available to the instructor:
 Unsealed
 Sealed
 Journal
4.3.3.2 Tubing Set-up (Workover and Drill Stem Testing)
Initial Length Run In
Initial Depth of the tubing from the well-head
Top Drive or Kelly
Either Top Drive or Kelly
Tubing
A Button that actuates the tubing selection menu
Downhole Equipment
A Button that actuates the equipment selection menu.

Tubing
Tubing Outside Diameter
This button is used to set the outside diameter of the tubing in the hole. Tubing data
Tubing Inside Diameter
This button is used to set the inside diameter of the tubing in the hole. Tubing data
Tubing Weight
This button is used to set the weight of the tubing in the hole. If Premium Class
tubing is used then enter only the nominal weight of the tubing. Tubing data can be
acquired from API RP7G or the IFP Drilling Data Handbook.
Tubing Tensile Strength
This button is used to set the tensile strength of the tubing in the hole. The model
fails the tubing at the set tensile strength. Tensile failure of the tubing occurs just
under the rotary table. Tubing tensile data can be acquired from API RP7G or the
IFP Drilling Data Handbook.
Tubing Maximum Torque
This button is used to set the torsional strength of the tubing in the hole. The model
fails the tubing at the set torsional strength and results in torsional failure of the
tubing to occur just under the rotary table. Tubing torsional data can be acquired
from API RP7G or the IFP Drilling Data Handbook.
Cross Sectional Area of the Tubing
This button is used to set the cross sectional area of the tubing. Cross sectional area
can be calculated or acquired from API RP7G or the IFP Drilling Data Handbook.
Number of Joints
This button is used to set the total number of joints of tubing available to the student
for the exercise. The button does not set the number of joints of tubing in the hole. If
the student runs out of tubing, an operator error message will be displayed on the
maintenance terminal and on the instructor station.
Downhole Equipment
Height of Packer
This will be shown on the Down Hole graphics.
Height of Tubing Plug
The tubing plug is a tool that will close and prevent any communication between
the tubing and the annulus. This can be installed and removed by the student.
Will be shown on Downhole graphics.
Height of Sliding Sleeve
The sliding sleeve is a circulation port that can provide communication between
the tubing to the annulus. This is controlled by the student. Will be shown on
down-hole graphics.
4.3.3.3 Casing String Set-up
Initial Length Run-In
The depth that the casing will be initially run to.
Casing
Button to actuate Casing configuration menu. See Section 0
Float Collar
The depth that the casing will be initially run to.
Casing Shoe
A casing shoe is always selected.

Casing
Outside Diameter
This button is used to set the outside diameter of the run casing. Casing data can be
acquired from a Cementing Tables Handbook.
Inside Diameter
This button is used to set the inside diameter of the run casing. Casing data can be
acquired from a Cementing Tables Handbook.
Weight
This button is used to set the weight per 40ft. length of run casing. Casing data may
be obtained from a Cementing Tables Handbook.
4.3.4 Formation Data – Change Geology
By selecting the Change Geology button, the instructor can
configure up to 10 formations, by setting the depth,
formation pressure gradient, permeability, rock strength,
formation fluid type and the abrasion factor.
Loss Zone
The current formation selection parameters are also displayed.
Reservoir
The current reservoir formation is displayed. Selecting this button will allow the user
to configure the reservoir
4.3.4.1 Formations
Selecting each of the formations, the Instructor can assign the various parameters as
shown.
Depth at Top of Formation
Cannot be altered for Formation 1.
Formation Fluid
Can be set to either of the following: Gas, Oil or Water.
Abrasion Factor
This will control the speed at which the bit will age and eventually wear out. This
factor has a value range from 1 to 10.
Permeability
This is the rate at which the formation fluids (see above) will migrate into the well
bore.
Formation Pressure Gradients
Typically Drillers will calculate formation pressure gradients always referencing RKB
or ground level. In planning an exercise for the simulator the instructor can use this
Driller’s gradient to calculate the pressures desired at the top of each formation in
the exercise. The gradient that is required for the simulator is the gradient applied
to the particular formation only. The gradient is calculated by dividing the pressure
within the formation by its respective thickness. It is not surprising that the gradient
might be 500 psi/ft or more in a transition. The following is an example of the
calculations necessary.
The top of formation 1 is always 30 ft for a land well and RKB to Seabed for an
offshore well.
Simulator
Depth Driller’s Pressure at
Pressure
Formation Formation Gradient Formation
Gradient
Top (Ft) (Psi/ft) Top (Psi)
(Psi/ft)
1 30 14.7 0.465
2 5030 0.465 2339 0.525
3 6030 0.475 2864 0.546
4 7030 0.485 3410 0.565
5 8030 0.495 3975 0.450
6 8040 0.500 4020 121.2
7 8050 0.650 5232 0.660
8 8150 0.650 5298 0.741
9 9150 0.660 6039 1.066
10 10150 0.700 7105 0.784
Simulator Pressure Gradient (Formation 1)
= (Formation 2 Top Pressure - Formation 1 Top Pressure) / (Formation 2 Top -

Formation 1 Top)
= (2339 psi - 14.7 psi) / (5030 ft - 30 ft)
= 2324.3 psi / 5000 ft
= 0.465 psi/ft

Formation 2 Top)
= (2864 psi - 2339 psi) / (6030 ft - 5030 ft)
= 525 psi / 1000 ft
= 0.525 psi/ft

Formation 3 Top)
= (3410 psi - 2864 psi) / (7030 ft - 6030 ft)
= 546 psi / 1000 ft
= 0.546 psi/ft

Formation 4 Top)
= (3975 psi - 3410 psi) / (8030 ft - 7030 ft)
= 565 psi / 1000 ft
= 0.565 psi/ft

Formation 5 Top)
= (4020 psi - 3975 psi) / (8040 ft - 8030 ft)
= 45 psi / 10 ft
= 0.45 psi/ft

Formation 6 Top)
= (5232 psi - 4020 psi) / (8050 ft - 8040 ft)
= 1212 psi / 10 ft
= 121.2 psi/ft

Formation 7 Top)
= (5298 psi - 5232 psi) / (8150 ft - 8050 ft)
= 660 psi / 100 ft
= 0.66 psi/ft

Formation 8 Top)
= (6039 psi - 5298 psi) / (9150 ft - 8150 ft)
= 741 psi / 1000 ft
= 0.741 psi/ft

Formation 9 Top)
= (7105 psi - 6039 psi) / (10150 ft - 9150 ft)
= 741 psi / 1000 ft
= 1.066 psi/ft

Formation 9 Top)
= (21600 psi - 7105 psi) / (30,000 ft - 10,150 ft)
= 14,495 psi / 19,850 ft
= 0.730 psi/ft
4.3.4.2 Casing Shoe Leak Off.
Leak Off Gradient
This is the pressure gradient that will be used to determine the point at which
the leak-off begins (at the casing shoe).
Rupture Gradient
This is the pressure gradient from RKB at which fracture of the shoe will occur.
Propagation Gradient
The new leak off pressure gradient following fracture. Following fracture pressures
above the propagation pressure will result in a more severe loss than before fracture.
Fracture Inhibit
Both leak off and fractures can be prevented by setting Fracture Inhibit to “On/Off”.
4.3.4.3 Loss Zone
Select button 2 to 10 set the current Loss Zone Formation Number
Loss Zone Parameters.
Partial Loss Gradient
This is the pressure gradient from RKB at which loss will first occur.
Total Loss Gradient

The pressure gradient from RKB at which rupture of the loss zone will occur and total
losses will be experienced.
Propagation Gradient
This figure represents the loss gradient following rupture. Following rupture pressures
above the propagation gradient will result in a more severe loss than before rupture.
Loss Inhibit
Setting Loss Inhibit to “Yes/No” can prevent both fluid loss and rupture at the loss
zone.
4.3.4.4 Reservoir
Select buttons 2 to 10 to set the current Reservoir Formation Number
Reservoir Parameters
Geothermal Gradient
This is the temperature gradient from RKB for all formations.
Reservoir Pressure Gradient
Is displayed for reference only and cannot be changed directly. It will be calculated
from the formation pressure gradients when the simulator is put into run.
Annulus Migration Rate

This figure is the speed at which gas bubbles will rise through mud in the annulus.
Drillpipe Migration Rate
This figure is the speed at which gas bubbles will rise through mud in the Drillpipe.
Bull Head Differential Pressure
The over pressure required to force annulus fluids into the kick zone formation.
Kick Inhibit
Setting Kick Inhibit to “On” can prevent influx flow from the reservoir.
Secondary Kick Inhibit
This option can be used to force the influx fluids to form a single bubble (if “On”
option has been selected), otherwise, secondary kicks will occur.
Change Fluid Gradients
The Change Fluid Gradients option enables the Instructor to change the oil, water
and gas gradients.
Reservoir Fluid Densities
These are the densities of the well fluids that will be released during a kick.
The densities of the formation / kick fluids can be modified by simply clicking
on the desired choice and entering the new value.
Note
The water and oil density must be greater than 30 lbs/cuft (4.01 ppg), and the gas
density must be lower than 30 lbs/cuft (4.01 ppg). There is also a lower gas density
minimum value. The DrillSIM flow model will calculate the minimum value of the gas
density based on the reservoir formation depth and pressure. If the user sets the
gas density to an unrealistic lower value, the flow model will automatically overwrite
by the minimum value.
4.3.5 Formation Data - Summary of Geology
A quick reference summary of the parameters for each
of the ten formations is available by selecting the
summary icon.
The L / R columns indicates which zone contains the Loss Zone, and which contains
the Reservoir. Clicking on Form Depth, Strength, Ab. Fact, Perm and Gradient result
in a keypad appearing allowing the value to be changed as shown below. Clicking
on the column labelled “Fluids” will permit the selection of Oil, Gas or Water.
4.3.6 Mud System
Active System
This button allows the Instructor to configure the mud system for the Active Tank.
Reserve System
This button allows the Instructor to configure the mud system for the Reserve Tank.
Solids Control
This button allows the Instructor to configure the mud system for Solids Control
Initial Mud Conditions
This button allows the Instructor to configure the default mud system for the Well
Bore, the Active System and the Surface Pipework.
4.3.6.1 Active System
Plastic Viscosity and Yield Point
These Values will be calculated as a function of the mud weight when the simulator is
put into run. The Instructor cannot control these figures directly.
Mud Weight
This button is used to set the density of mud in the Active Mud Pit. Note that
densities of less than 10 lb./cu ft (4 lb./gal, 0.48 SG) are assumed to be gas.
Pit Capacity
This button is used to set the capacity of the Active Mud Pit.
 600 Reading
This button allows the Instructor to determine the θ 600 properties of the mud.
 300 Reading
This button allows the Instructor to determine the θ 300 properties of the mud.
Pit Contents
This button is used to set the volume of mud present in the Active Mud Pit.
Settled Solids
This button will set the volume of settled solids in the Active Mud Pit.
Water Flow Rate
This button sets the flow rate for make up water into the Active System. The make
up water is switched on and off from the Mud Control Station.
4.3.6.2 Reserve System
Plastic Viscosity and Yield Point
These values will be calculated as a function of the mud weight when the simulator is
put into run.
Pit Capacity
This button is used to set the capacity of the Reserve Mud Pit.
Pit Contents
This button is used to set the volume of mud contained in the Reserve Mud Pit.
Mud Weight
This button is used to set the mud density in the Reserve Mud Pit. Note that densities
of less than 10 lb./cu ft (4 lb./gal, 0.48 SG) are assumed to be gas.
4.3.6.3 Solids Control
Return Line Max Flow
This buttons sets the return line flow rate at which the % flow gauge on the Drilling
Gauges Console will show 100%.
Solids Control Efficiency
This button sets the combined efficiency for the solids control equipment (Shale
Shaker, Desander, Desilter and Centrifuge). A value of 85% will result in 85% of the
solids in the return mud being removed and 15% being passed to the mud pits.
% Solids
This button sets the percentage value of solids entering the tanks that will settle out
4.3.6.4 Initial Mud Conditions
These controls are used to set the mud density in all tanks to the Initial Mud
Density. This will also ensure that the drillstring, annulus and riser are completely
full of mud at the Initial Mud density.
Select the desired mud density then press the Reset button. The mud density will be
reset when the simulator is put into run.
Plastic Velocity
The initial PV value can be entered. This will then be used as the default Start Point
for calculating the PV value once the simulator is put into run.
Yield Point
The initial YP value can be entered. This will then be used as the default Start Point
for calculating the YP value once the simulator is put into run.
Surface Pipe Volume
The surface pipe volume is the volume in the surface lines from the pits to the top of
the drill pipe/tubing.
4.3.7 Rig Equipment
Selecting these buttons lead you to screens that provide the facilities to make your
Rig Equipment selection. See Sections 4.3.7.1 through 4.3.7.7 for details of the
options available.
If the Motion Compensator is not available then the button will be ghosted out.
4.3.7.1 Surface BOP
This screen allows the Instructor to enter the desired

settings for the Surface BOP stack. Clicking either of
the buttons will cause a calculator style input screen
to appear, allowing the instructor to enter the new
value.
Note: Setting any of these values to zero will enable the RAM PREVENTER to be
opened/closed immediately.
4.3.7.2 Subsea BOP
This screen allows the Instructor to enter the desired

settings for the Surface BOP stack. Clicking either of
the buttons will cause a calculator style input screen
to appear, allowing the instructor to enter the new
value.
Note: Setting any of these values to zero will enable the RAM PREVENTER to be
opened/closed immediately.
4.3.7.3 Accumulators
This allows the Instructor to modify the values & settings associated with the various
Accumulators (Surface, Diverter & Subsea). To access these settings, click on the
desired option.
Surface Accumulator
Total Accumulator Volume
This allows the Instructor to determine the total capacity of the Accumulator.
Pump In Pressure
This sets the pressure at which the pump will kick in.
Pump Out Pressure
This sets the pressure at which the pump will stop.
Low Acc Pressure
This figure is used to determine the threshold for the Low Accumulator Pressure
alarm.
Maximum Oil Volume
This represents the maximum amount of oil allowed in the accumulators.
Pump Output
This determines the rate at which the accumulator pump will function.
Precharge Pressure
This will determine the Precharge pressure for the accumulators.
Actuator Flow Rate
This determines the maximum flow rate through the actuator.

Subsea Accumulator Sizing (Page 1 of 2)
This allows the Instructor to determine the total capacity of the Accumulator.
Pump In Pressure
Pump Out Pressure
Low Acc Pressure
This figure is used to determine the threshold for the Low Accumulator Pressure
alarm.
Maximum Oil Volume
This represents the maximum amount of oil allowed in the accumulators.
Pump Output
This determines the rate at which the accumulator pump will function.
Precharge Pressure
This will determine the Precharge pressure for the accumulators.
Actuator Flow Rate

Subsea Accumulator Sizing (Page 1 of 2)
This screen allows the Instructor to determine the initial conditions for a wide range
of data which as soon as the simulator is put into “Run”, will be modified (for
instance, Rig Air Pressure”) by the mathematical model. The data on this screen is
designed to be used as a starting point for the data which will be used throughout
the exercise.
Diverter Accumulator
This allows the Instructor to determine the total capacity of the Diverter
Accumulator.
Pump In Pressure
Pump Out Pressure
Actuator Flow Rate
Precharge Pressure
This will determine the Precharge pressure for the Diverter Accumulator.
Pump Output
This determines the rate at which the Diverter Accumulator pump will function.
4.3.7.4 Pumps
The number of pumps

available is dependent
on the simulator
configuration.
Pump Type
Toggles the selection between Duplex and Triplex.
Liner Diameter, Stroke Length & Rod Diameter
These buttons allow the Instructor to determine the volume which will be displaced
per stroke.
Efficiency
The standard value for efficiency should be entered here (each company has their
own standard figure for pump efficiency, but a value of 95 to 97% is
recommended).
Pump Output
The Output for each pump will be calculated as soon as the simulator put into “Run”.
Maximum Stroke Rate
The minimum value for this figure is 100. Please consult the documentation
associated with the chosen pump type and style.
Relief Valve Setting
This is the value at which the Relief Valve (commonly known as the Pop-Off valve)
will operate to prevent damage to the pump.
Relief Valve Status
This allows the instructor to determine the state of the Relief Valve at the beginning
of the exercise.
4.3.7.5 Power System
This screen enables the Instructor to configure or modify the Power Generation
system on board the simulated rig. When selecting the buttons requiring numerical
input, a pop-up keypad will appear to allow input of replacement values.
4.3.7.6 Hoisting System
This screen allows the Instructor to configure and modify the Hoisting System on
board the simulated rig. When selecting the buttons requiring numerical input, a
pop- up keypad will appear to allow input of replacement values.
4.3.7.7 Drill String Compensator (DrillSIM-5000)
This screen allows the Instructor to determine the options and settings relating to the
Motion Compensator. When selecting the buttons requiring numerical input a pop-up
keypad will appear to allow input of replacement values. This screen can only be
accessed if the simulator has been supplied with the Motion Compensator option.
4.4 Real Time Data Display
To view the runtime pages, select the Runtime Icon, or select the
Runtime Data Menu option from the Runtime option on the Main Menu.
The following sections provide details of these options.

4.4.1 Drilling Data
This screen allows the Instructor to view a range of data related to drilling
operations. This screen cannot be used to modify this data.
4.4.2 Pump Data
This screen allows the Instructor to view a range of data related to the Mud Pumps.
This screen cannot be used to modify this data, to do this, please consult section
4.3.43
4.4.3 Mud Data
This screen allows the Instructor to view a range of data related to the Mud Pumps.
This screen cannot be used to modify this data.
4.4.4 Well Control Data
These screens will provide the Instructor with a wide range of well control data
relating to the current state of the simulator. This data will be updated in real.
4.4.5 Operator Warnings
This screen is used to alert the Instructor to the incorrect operation of a piece or
pieces of rig equipment (for instance, abusing the gears on the Drawworks). As soon
as the incident occurs, the main menu toolbar will begin to flash. Upon entering this
screen, any alarms that have been triggered will display the word “ACTIVE” with the
text coloured red. Once the student has been made aware of the problem, the alarm
can be acknowledged by pressing the appropriate button. If the problem reoccurs
then the alarm will be triggered again.
4.4.6 Deviated Well Data
This screen allows the Instructor to view a range of data related to the current well,
with an emphasis upon the directional drilling aspects. This screen cannot be used to
modify this data.
4.5 Runtime Instructor Controls
The Runtime Instructor Controls enables the Instructor to set the

Graphics monitor to display either surface or Downhole graphics..
Selecting the Surface View icon toggles to the Downhole View options below.
Rig Heave and Cementing Head are options and may be ghosted or not appear on
your system.
The Rig Heave options are available to those simulators with the Drill String
Compensator Option.
The Cement Head options are available to those simulators with the Cement Head
Software installed.
4.6 Simulation Speed
To change the speed of the simulator, click on the clock icon, or select
Simulation Speed from the Simulation option on the Main Menu..
The speed of the simulator can be set

to Real Time or a multiplied value.
4.7 Malfunctions
To select the Malfunctions menu, select Malfunctions from the Runtime

Menu, accessed from the Main Menu.
The malfunctions are grouped into 3 main categories, presented in sections 4.7.1 to
4.7.2:
 Rig Equipment Malfunctions – these include malfunctions with the Rig Pumps, Hoisting, Rotary,
Surface BOP/ Subsea BOP, Swaco Choke, Rig Equipment (e.g. rig electricity & water supply
failures), Gauge malfunctions and damage to the Solids Control equipment.
 Downhole Malfunctions – These include malfunctions or damage to the Drill Bit and Washouts &
twist offs in the drill string, but also includes hole cleaning problems, lost circulation, tight hole
problems and stuck pipe problems.
 Pipe Handling Malfunctions (Only available on DrillSIM-6000 simulators)
Upon selecting a malfunction, a small screen will appear giving the instructor the
option to either clear a malfunction, activate a malfunction (immediate) or to delay
the malfunction for a set period (this period can be measured in either seconds,
pump strokes or volume (bbls) and can be determined by the Instructor.) This
screen is presented below:
4.7.1 Rig Equipment
This screen enables the Instructor to select from a wide variety of malfunctions
which can affect the equipment and facilities on board the simulated rig as well as
purposely making the gauges throughout the simulator malfunction, become
innacurate or even not work at all.
The Instructor has full discretion with regard to introducing malfunctions into the
simualtion exercise and can tailor each exercise to allow the students to exerience
the difficulties presented by each of the problems represented by the malfunctions
in the safety of the classroom environment.
4.7.1.1 Pump Malfunctions
This screen allows the Instrctor to do the following to all of the rig pumps and the
cement pump:
 Power Failure (Complete breakdown)
 Blow Pop-offs (Relief Valves)
 Change / Reduce the efficiency of the pump
4.7.1.2 Hoisting Malfunctions
This screen enables the Instructor to simulate malfunctions effecting the Hoisting
system, specifically, the Drawworks. The Instructor can induce the following
problems into the exercise:
 Drawworks Motor Failure
 Travelling Block seizure
 Drawworks clutch Failure (Stuck in either the Engaged or Disehgaged positions)
 String Drag (entered as a percentage)
4.7.1.3 Rotary Malfunctions
This screen enables the Instructor to introduce malfunctions relating to the Rotary
System (Top Drive, Rotary Table etc). The list of malfunctions comprises of the
following:
 Load Torque Increase
 Drive Motor Failure
 Drive Motor Limit overide
 Torque Fluctuation (Percentage range)
 Gauge Fluctuation (Percentage range)
4.7.1.4 Surface BOP Malfunctions
This screen details the malfunctions available for the Surface BOP stack. The options
available are as follows:
 Annular Preventer – Failure  Annular Preventer – Leak
 Upper Pipe Ram – Failure  Upper Pipe Ram – Leak
 Blind Pipe Ram – Failure  Blind Pipe Ram – Leak
 Middle Pipe Ram – Failure  Middle Pipe Ram – Leak
 Lower Pipe Ram – Failure  Lower Pipe Ram – Leak
 Accumulator Pump Failure

4.7.1.5 Subsea BOP/ Diverter Malfunctions
This screen details the malfunctions available for the Subsea BOP stack. The options
available are as follows:
 Leak in Subsea Blue Pod (See section 4.7.1.5.1)
 Leak in Subsea Yellow Pod (See section 4.7.1.5.2)
 Accumulator Pump Failure
 Low BOP Accumulator Fluid
 Annular Preventer - Upper Actuator Failure
 Annular Preventer - Lower Actuator Failure
 Shear Ram Actuator Failure
 Pipe Ram - Upper Actuator Failure
 Pipe Ram - Middle Actuator Failure
 Pipe Ram - Lower Actuator Failure
 Diverter Low Antifreeze
 Low Diverter Accumulator Fluid
Leak in Subsea Blue Pod
This screen details the malfunctions available for the Subsea BOP Blue Pod. The
options available are as follows:
 Pod Leak  Vent Line Leak
 Ram Line Leak

Leak in Subsea Yellow Pod
This screen details the malfunctions available for the Subsea BOP Yellow Pod. The
options available are as follows:
 Pod Leak  Vent Line Leak
 Ram Line Leak

4.7.1.6 Choke Malfunctions
This screen allows the Instructor to select what type of malfunction they wish to
introduce. At this stage, you will not need to specify which choke is going to
malfunction. By simply selecting the desired type of malfunction, the Instructor will
be presented with one of the three screens presented below in options 4.7.1.6.1 to
4.7.1.6.3
Choke Washout Malfunctions
This screen allows the Instructor to introduce malfunctions into the Manual and
Remote chokes, specifically by introducing washouts into the choke plate. The
options are detailed below:
 Left Hand - Remote choke washout
 Right Hand - Remote choke washout
 Left Hand – Manual choke washout (This option is not available on all simulators)
 Right Hand - Manual choke washout
 Choke washout Rate
 Max size of Choke Washout
Seized Choke / Choke Failure Malfunctions
This screen enables the Instructor to introduce failure malfunctions to both the
Manual and Remote Chokes. The options are as follows:
 Left Hand – Remote Choke Seizure
 Right Hand – Remote Choke Seizure
 Left Hand – Remote Choke failure (fail in the closed position)
 Right Hand – Remote Choke failure (fail in the closed position)
 Left Hand – Manual Choke Seizure (Not available on all simulators)
 Left Hand – Manual Choke failure (fail in the closed position) (Not available on all simulators)
 Right Hand – Manual Choke Seizure
 Right Hand – Manual Choke failure (fail in the closed position)
Choke Plugged Malfunctions
This screen allows the Instructor to simulate the effect of the chokes becoming
plugged. The options available are as follows:
 Left Hand Remote Choke Plugged

 Right Hand Remote Choke Plugged
– Immediate effect
 Right Hand Manual Choke Plugged

 Workover Manifold – Manual Manifold
Choke Plugged Immediate effect
 Workover Manifold – Remote

 Workover Manifold – Fixed Manifold Choke
Manifold Choke Plugged – Immediate
Plugged
effect
 Rate at which Choke will become Plugged  Max size of Choke (when) Plugged
(measured in the chosen system of units
e.g. inches or cm)
4.7.1.7 Equipment Malfunctions
This screen allows the Instructor to introduce the following malfunctions to the Rig
Equipment:
 Rig Alarm Failure  Rig Water Supply Failure
 Rig Air Supply Failure  Rig Electrical Supply Failure

4.7.1.8 Gauges Malfunctions
This screen allows the Instructor to introduce a range of malfunctions to a selection

of gauges throughout the simulator, namely:
 Remote Choke
 Manifolds
 Drilling Gauges (2 screens)
Once a gauge has been selected, the instructor should enter a value for the Gauge
Calibration Factor, which will determine the level of error on the gauge.
4.7.1.9 Shaker & Solids Malfunctions
This screen allows the Instructor to introduce malfunctions and damage to the Solids
Control equipment onboard the simulated rig. The options are as follows:
 Shale Shaker Blocked Grid (Screens have been blinded)
 Shale Shaker Hole in Grid (Torn screen)
 Desander Failure
 Desilter Failure
 Centrifuge Failure
4.7.2 Downhole Malfunctions
This screen allows the Instructor to set up and initiate malfunctions within the drill
string and the annulus, collectively grouped together as “downhole” malfunctions.
4.7.2.1 Bit Malfunctions
This screen allows the instructor to either wash-out or plug any of the nozzles on the
drill bit as well as being able to set the amount of wear accumulated on the teeth &
bearings of the bit (this information should be added in accordance with IADC dull
bit grading guidelines). The Instructor can also cause the bit itself to washout (e.g.
around the weld)or become balled up.
4.7.2.2 Lost circulation
This screen enables the instructor to induce lost circulation conditions and set the
percentage of losses, which will develop.
4.7.2.3 Pipe Washout & Twist-off
This screen enables the Instructor to initiate a washout in the drill pipe and to cause the drill
string to part (twist off).
4.7.2.4 Hole Cleaning
The DrillSIM-5000 Deviated Hole Cleaning and Stuck Pipe Model embodies the results
of the following BP paper:
Yuejin, L., Bern, P.A., Chambers, B.D. and Kellingray, D.S., B.P. Exploration. Simple
Charts To Determine Hole Cleaning Requirements in Deviated Wells.
In: IADC/SPE Drilling Conference, Dallas, Texas, 15-18 February 1994. p499-505.
Ref: IADC/SPE 27486
Following the procedure described in the paper, you can calculate the
minimum circulation rate required to clean the hole effectively for any deviated-well
snapshots that you have set up, using a given rate of penetration. The driller must
then circulate above this minimum rate in order to keep the hole clean. As shown in
the paper, drilling ahead faster will require a higher circulation rate.
To use the stuck pipe model in an exercise, you must,

 Set up a well profile with deviation angle greater than 25 degrees. (The Hole Cleaning Model is
only valid for deviated wells.)
 Enable the model using the Cuttings Build-up button.
The model will now be active, and you should begin to see the effects of under-
circulating.
If the Driller circulates too slowly while drilling ahead, then cuttings will start to build
up in the annulus (this will be shown by the blue bar on the "Cuttings Build Up
Indicator", which measures the average length and height of the cuttings beds). As
the length of the blue bar increases, the pump pressure, rotary torque, and string
drag will also increase in proportion due to the cuttings beds now building up around
the string.
You will also notice on the Cuttings Build Up Indicator, a red line marked "Threshold",
and a label indicating a "Sticking Region". When the blue bar reaches this line and
enters the "Sticking Region", the hole has become tight, rotary torque oscillations will
begin to occur, and the BHA may now become stuck in the cuttings beds. On the
next trip out of the well, the driller will experience a "stuck point" after tripping a
few feet off bottom. The string will be stuck at the BHA, over-pull will increase, and
rotary stall, if rotating, will be experienced.
The severity of the sticking will depend on how far the blue bar on the Cuttings
Build- Up Indicator has extended over the Threshold, into the Sticking Region. For
less severe sticking the driller can either pull through the stuck point, or set down on
the stuck point to come free again. Successful freeing of the pipe will be seen on the
WOB meter as a sudden return to normal string weight.
For more severe sticking, the driller will not be able to pull through the stuck point
without parting the string. In this case the only option will be to slack off in order
to free the pipe. However, the amount of slack-off required will depend on how
much overpull was allowed to occur on pulling into the stuck point. The greater the
overpull, the more tightly the BHA will be wedged into the cuttings, and the greater
the slack-off required to free the pipe.
Once a stuck point has been experienced, several courses of remedial action can be
taken: the first of these being to increase the rate of circulation and circulate
"bottoms up". However, if the minimum circulating rate calculated from the BP paper
cannot be achieved without blowing the mud pump safety valves, then no hole
cleaning will occur (the blue bar on the Cuttings Indicator will not decrease in
length). In this situation, hole cleaning can only be achieved by rotating the string
and/or working the string, whilst circulating.
Simply increasing the rotary speed whilst circulating will increase the effectiveness
of hole cleaning, since the rotating string will disturb the cuttings beds and also
impart a rotational velocity to the circulating mud, tending to drive it into the
cuttings beds.
Upwards and downwards movement of the pipe will also break up the cuttings beds.
However, this carries the additional risk of getting stuck. In the DrillSIM-5000
model, cuttings beds begin a few feet behind the BHA, and pulling the BHA into the
cuttings without back-reaming will always result in sticking of a greater or lesser
severity (depending on how far over the Threshold the Cuttings Indicator has
extended). In order to extend the distance through which the string can be safely
worked, the driller should back-ream when pulling the BHA through the cuttings bed.
This will move the start of the cuttings bed back up the hole, since the rotating BHA
will immediately disperse any cuttings it touches. The driller may now safely work
the pipe up to the point where he has back-reamed without getting stuck. The hole
will remain "tight", however, until all the cuttings further up the hole have been
circulated out.
Note that tripping too fast while back-reaming through cuttings will also result in
sticking.
The rate at which the cuttings will build-up and disperse can be varied using the
Rate Of Cuttings Build-Up control. This is simply linked to a time multiplier, and will
artificially increase the rate at which cuttings build up, when under-circulating, or
decrease, when cleaning the hole. Typically, the rate can be increased when the
student is under-circulating and the instructor wishes to arrive at the Sticking Region
more quickly. When the Cuttings Build-Up Indicator reaches the Sticking Region, the
rate control can be set back to normal while the student deals with the stuck pipe
problem. Switching the whole simulator into a fast rate will have a similar effect on
cuttings build-up/decrease.
Please note that disabling the stuck pipe model using the Cuttings Enable button will
reset the model and cause any built-up cuttings to disappear.
4.7.2.5 Tight Hole
This malfunction screen allows the Instructor to introduce tight hole sections into the
well bore and associated phenomena such as keyseats, differential sticking and
sloughing problems. This screen is also used to determine the depth at which the
student will encounter these problems, for instance, the instructor can set the depth
at which a keyseat will develop, the thickness of the keyseat and the amount of
overpull the student will have to exert to free themselves from the situation.
4.7.2.6 Stuck Pipe & Jarring
This facility is only available as an optional extra, if you wish to upgrade your
simulator to include this option, please contact Drilling Systems by any of
the following means:
Telephone Fax E Mail
+44 (0) 1202 582255 +44 (0) 1202 582288 info@drillingsystems.com
Input Parameters
Two type jars are modelled on DrillSIM Jarring options – Hydraulic and Mechanical
Jars. Hydraulic jars use a hydraulic fluid to delay the firing of the jar until the driller
can apply the appropriate overpull / setdown force to the string to give an impact.
The time delay is provided by hydraulic fluid being forced through a small port or
series of jets. This process is called ‘metering’ or ‘tripping’. Hydraulic jar firing
delay is dependent on the applied overpull / setdown forces and time.
Mechanical jars have a preset load that has to be overcome before the jar can fire.
Consequently mechanical jars are sensitive only to applied load and not to time. The
hydraulic jar model was developed, based on Weir-Houston’s Hydra-Jar. The basic jar
parameters used on DrillSIM model are entered from the following screen.
Clicking the button marked “Set Defaults” will automatically set the jar parameters to
replicate those of Weir Houston Hydra Jar (OD = 8 inches).
Pipe Stuck Malfunctions
The pipe stuck malfunction can be activated from following screen
on Malfunctions/Down Hole / Stuck Pipe & Jarring in Instructor
Station.
There are five type malfunctions:

 Restricted Up. The drillstring can go down, but NOT up.
 Restricted Down. The drillstring can pull out, but NOT run in.
 Stuck. No drillstring movement both up and down.
 Stuck Rotationally. No drillstring and rotation movement. Once the rotary drive motor
developed torque is greater than the Rotational Release Force (set in this screen), the drill pipe
will rotate with increased torque.
 Packed Off. Apart for no drillstring movement, there is also a fluid flow restriction on the
annulus. 100% packed off means no fluid can pass through the annulus, 0% packed off means
there is no restriction on fluid flow through the annulus. The percentage of packed off will be
gradually decreased if there is any fluid flow in annular. If we continue to circulate the fluid in
annulus, the string will eventually become unstuck once the percentage of packed off is zero.
To active the stuck pipe malfunction, we must select at least one of above five stuck
conditions. Then click the Stuck Pipe Activation or set a value of Upon/After Bit
Depth to initiate the stuck pipe malfunction.
The other input data from this screen are: (1) Stuck Point Depth; (2) Packed Off %
only for Packed Off malfunction; (3) Rotational Release Force only for stuck
rotationally malfunction; (4) Up and Down Release Forces by click the up/down
button.
Once the jar is fired and the jar impact blow force is greater than the up release
force for fire jar up, or the down release force for fire jar down, all above 5 type
stuck areas /restrictions will be cancelled and reset to normal conditions.
If we click the Stretch Data button, the following screen will be displayed.
The stretch is calculated based on a combination of the amount of overpull, the drill
pipe length above the stuck point and the drill pipe weight. Please note that zero
stretch is assumed for hevi-wate drill pipe and drill collars.
Jar Force Calculations
Jar pump open force
Jar pump open force is calculated from the pressure difference between the external
(annulus) & internal (drill string) pressures, and the jar pump open area (jar wash
pipe area). The effect of pump open force on jarring could be considerable. It acts
to:
 Assist firing the jar up
 Assists cocking the jar down
 Opposes firing the jar down
 Opposes cocking the jar up
Please note that the pump open force is zero for a mechanical jar. Consequently the
pump open force will increase with increasing circulation rate.
Maximum hookload to cock the jar down for fire up
Maximum hookload to cock the jar down is calculated using the following
parameters:
 Hookload when the drill pipe is moved down (before the pipe became stuck).
 Drillstring weight below the jar
 Jar friction (set at the jar configuration screen)
 Pump open force (this should be set to zero when not circulating or when the string is not
packed off).
Minimum hookload to fire jar up

It is dependent upon the following parameters:
 Hookload when the drill pipe was pulled out (before the pipe is stuck)
 Jar up trip friction (set by the instructor on Jar Configuration screen)
packed off).
Minimum hookload to cock the jar up for fire down
This value is calculated from the following parameters:

 Hookload when the drill pipe pull out before the pipe is stuck
 Jar friction, set at the jar configuration screen
packed off).
Maximum hookload to fire jar down
The maximum hookload top fire jar down is dependent upon the following factors:
 Hookload when the drill pipe is moved down before the pipe is stuck
 Jar down trip friction, set by the instructor on Jar Configuration screen
packed off).
Impact jar blow

The impact jar blow is calculated from the amplification factor and the working load
of the jar. (Jar working load is the applied overpull/setdown force at jar for hydraulic
jar and is fixed for mechanical jar. The jar working load for mechanical jar is the
maximum working load set on the jar configuration screen.)
Guidelines for Firing Jar
Fire Jar Up
If the jar is in the “Fully Open” position when the drill string becomes stuck, the
student will have to reduce the hookload to level of the “maximum hookload required
to cock the jar down” (determined above). If the hookload drops to below the level
of the “maximum hookload to fire down”, the jar will switch from the short cycle to
the long cycle. Once this has occurred, the student should pull the drill string out of
the hole to increase the overpull, once the hookload is greater than the level
indicated as “minimum hookload to fire jar down”, the jar will begin to trip. The
tripping (delay) time to fire is dependent on the applied overpull at jar and the
position of the jar in its cycle.
If the jar is in the closed position when the pipe is stuck, we can directly apply the
overpull to the jar to fire the jar upwards.
Please note there is no time delay for the mechanical jar.
Fire Jar Down
If jar is in open position when pipe is stuck, we can directly slack off the weight on
the jar to fire the jar downwards.
If the jar is in closed position, we have to apply overpull at least to “Minimum
hookload to cock the jar up”. The jar position will change from short cycle to long
cycle once the hookload is greater than the “minimum hookload to fire jar up”. The
next step is to slack off the weight on the jar. The jar will start tripping down once
the hookload is less than the “maximum hookload to fire jar down”. Again the
tripping time is dependent on the applied set-down force on jar and the jar position
in its cycle.
Again there is no time delay for mechanical jar.

4.8 Snapshot Utilities
To load and save snapshots, click on the camera icon, or select the
appropriate option from the File option on the Main Menu.
Use the Snapshot Management page to load, save or delete well snapshots.
To load an existing snapshot, select the required snap name and select Load.
To save and update an existing snap, select the file name and select "Save".
To save a snap under a new name, choose the Save As option, enter a snap name
(up to 8 characters excluding the file extension name e.g. .SNP), enter a brief
description and press OK.
Deleting a snapshot can be performed by selecting the appropriate snapshot from the
list and then selecting the Delete option. A confirmation box is displayed alerting the
user about the deletion.
The Set Directory option enables the user to

access different drives or folders on the PC.
4.9 Graphics Display
On the portable range of DrillSIM simulators (e.g. DrillSIM-500, 50, 20

etc), this screen allows the user to visualise the operations being
conducted on the Drill-floor.
4.9.1 Tank Alignment

This option will change the screen currently displayed to the Trip Tank alignment
screen (see section 4.11 of this manual for details).
4.9.2 Pumps & Mud

This button will serve to change the current screen to the Mud Pump & Tank Line up
screen (see section 4.12 of this manual for details).
4.9.3 Auto Driller

This button is used to activate and deactivate the Auto Driller feature of the
simulator. When this option has been selected, the automatic driller will maintain the
current Weight on Bit (WOB), until either the position of the driller’s brake is
adjusted or the Drawworks is activated, for further information, see section 5.8 of
this manual for details).
4.9.4 BOP Information

This button will serve to change the current screen to the BOP Information screen
(see section 4.18 for details).
4.9.5 Data Display Panel
This panel contains a range of real time drilling data, listed below:
 Weight on Bit  Surface RPM
 Surface Torque  Pump Pressure
 ROP  Bit Depth
 True Vertical Depth  Measured Depth
4.9.6 Data Display Graphs

There are 2 separate graphs displayed to provide the driller with a historical record of
the data, for instance the Drill-pipe pressure, this is allow the user to identify data
trends more easily.
4.10 Down Hole Graphics
This screen allows the user to visualise the progress being made
during the drilling of the well but more importantly, this screen will
display the progress of any influxes as they progress up the annulus.
4.11 Trip Tank Options
the return from the Mud/Gas separator will flow into the Trip Tank, otherwise it will be sent to the Active System
NOTE: On the DrillSIM-5000 the Strip Tank is optional

4.12 Mud Pump and Tank Line Up Options
Reserve and Active Buttons
Clicking on the Reserve or Active System button will display the current
properties.
4.13 Chart Recorder
Click on the Chart Recorder icon, or on the Chart Recorder option

on the “Display” menu to bring up the screen shown below. This
screen controls the plotting and data logging functions of the
DrillSIM Instructor Facility.
Drilling parameters can be logged in two ways while an exercise is running. Firstly,
through use of the Chart Recorder (i.e., the colour dot-matrix printer which
emulates a pen recorder), and secondly through a data log file.
4.13.1 Plotting with the Chart Recorder

The Chart Recorder can plot data in two standard formats and two customisable
formats, selectable by clicking on the “Chart Type” display. The formats are,
1. Default Drilling Ahead: 6 columns, with one parameter traced in each

column; the parameters being Hook Load, Rate of Penetration, Rotary Speed,
Rotary Torque, Total SPM, and Pump Pressure.
2. Default Well Control: 2 columns, with the left-hand column displaying

choke position, and the right-hand column displaying Shoe Pressure,
Bottom Hole Pressure, Casing Pressure, Pit Gain, Total SPM, Drillpipe
Pressure, and Kick Zone Pressure, all overlaid.
3. Custom Drilling Ahead: 6 columns, with user-selectable parameters traced

in each.
4. Custom Well Control: 2 columns with user-selectable parameters traced
in each.
See the section on Chart Recorder Configuration for more information on setting up
the customisable formats.
The Chart Recorder can also plot parameters against time or total strokes pumped.
This is selected by clicking on the “Time” or “Strokes” options under “X-Axis Units”.
The current selection is indicated by a black dot. When plotting against time, the
chart output will show elapsed time in minutes down the left-hand side.
To start Chart Recording, first ensure that the printer is plugged in and loaded with
paper. Select the type of chart you require, select the type of x-axis you require,
then click on the large Chart Recorder icon in the centre of the screen. The status
message will change to say, “Plotting”, and the printer will start to print.
4.13.2 Using the Data Log

A more extensive set of parameters is continuously sent to an internal file, called the
data. While the simulation is running, drilling parameters are written to the data log
every 5 seconds (of simulation time). At the end of the exercise, the contents of the
data log can be saved to a text file for analysis with a graphing or spreadsheet
package.
To save the data log, click on the “Save Data” button < you will be prompted for a
file name and directory.
The “Log Size” display shows how many observations have been recorded in the data
log. You can clear the data log, and reset the elapsed time and total strokes pumped
for the current exercise by clicking on the “Reset To Zero” button.
The data log is also cleared whenever you load a new snapshot, or when you click on
the “Reset to Zero” button.
Do not forget to save the data log before loading a new snapshot or resetting to zero.
4.13.3 Configuring & Using the Chart Recorder
On the main menu bar - go to the Configuration menu and select the Chart Recorder
option.
The Chart Configuration screen will appear which will allow you to create and modify
different types of chart.
Select Column A - the current option should be Hookload (Drilling Defaults or Choke
Position) as illustrated in the frame labeled Column A
Select the current option and press the button marked "Remove", this should clear
the box.
Under the heading of "Plottable Parameters", there is a list of variables that can be
used for plotting.
 Select the variable ROP and press the "Add" button.
 You should now check that in the “Column A” box, the ROP variable has appeared.
 If you wish to change the colour of the graph line, select the desired colour from the drop down
list. The options are as follows: Black, Green, Red, Cyan, Yellow, Magenta and Blue.
 You can also change the scaling of the plot using the boxes below. This can be accomplished by
simply entering the new values into the spaces provided.
Repeat as necessary.
When satisfied, type the name of the new plot which you have just created into the
box labelled “Chart Type” and then press the button marked “SAVE” and the chart
settings will be saved under the name you entered earlier. A message box will
appear to confirm that the settings have been saved correctly. At any time, you can
modify your charts by selecting the desired chart from the “Chart Type” box and
following the steps outlined above.
Now go to the Exercise Session Plotter screen and select the chart type drop
down menu, the option “Manual1” should be present. Select this option, this will
ensure that your chart will feature all of the parameters and scaling that you
determined earlier.
Press the button marked "New Log File" and use the "New" button to create a new
log file, for this example, call it “Test” and save it to “My Documents” or any other
folder you wish to create.
The Log File Details screen should reappear with the log file name box now listing the
file location and name - C:\My Documents\test1.dsl
You can now enter the details of the log file (course name etc).
To finish, press Exit. This will save the details you have just entered as part of the
log file and allow you to return to this point in future.
The Exercise Session Plotter screen should now reappear, with the file name
(test1.dsl) listed where it says "File:" (beneath the Start/Stop Log File button). The
Start / Stop Log File button will automatically switch to the “Stop Log File” state as
soon as a log file has either been saved or loaded. This screen also allows you to
determine the scale units which will be used in the exercise – either Time (mins) or
Pump Strokes.
When the log file size has reached a value of 14, the chart is large enough to print.
 To print the chart, press the Stop Log File button (which will immediately change to "Start Log
File")
 You can now display the chart by pressing the Status button.
The changes you made to the plot configuration are now visible, if you search
through the list of plotted parameters, Section A will contain the ROP plot. You can
obtain a particular value from a chosen point in time by selecting the desired
parameter (in the case illustrate above, ROP) and clicking on the button labeled with
a “+” sign, this will display a large green target which you can position by simply
clicking n the portion of the line you are interested in – the values will be displayed
on the boxes labeled “Pin-point”.
You are able to magnify any portion of the graph by clicking on the button with a
picture of a magnifying glass on it. This will change the chart display by presenting a
large green box across the plot. You can move the borders of this box to focus on
whichever time period you wish to monitor – in this example, the time between 0.50
minutes (30 seconds) and 1.00 minute.
When you have selected the chosen period of time, press the button marked “OK”
and the plot will be rescaled to match the criteria. In the diagram above, you will
see that the scale runs from 0.00 to 1.50 minutes and the selected area runs from
0.50 to 1.00 minutes. The image below illustrates the newly rescaled graph.
4.14 Variable Inspection and Diagnostics
This facility can be reached from the following menu path:
1 2 3 4 5
6 7 8 9 10 11
1 The title of the current page of information. The title can be changed by
clicking on the title bar, which will then allow the user to type in a new
description.
2 Clicking on any of these buttons will allow the user to enter either a page
number or a variable name. Entering a page number will display the page
title. Clicking the Goto option will display that page. On entering a
variable name, the system will pull through a description of the variable,
the current value and the units. An Invalid Variable Name message
appears if the variable is not located.
3 The second column of buttons either displays < Goto > or the value of
the variable. If the Goto text is displayed, clicking on the button will go to
that page number. If a value is displayed, clicking the button will allow
the user to change the current value.
4 Displays the units of the variable.
5 Displays the description of the page or the variable.
6 Displays the previous page of information.
7 Shows the current page number
8 Moves to the next page.
9 Allows the user to go direct to a known page number.
10 Moves to Page 1, the Main Index Page
11 This will clear all of the entries for this page number.
4.15 Unit Conversions
The Units & Conversions function allows the Instructor Station to customize any
displayed data in any units or form that the user requires.
Every quantity or value displayed in the Instructor Station is obtained from the
complex series of mathematical processes, the final value of which is represented by
a variable, which has a unique identification code or name. The value of this variable
is calculated in a standard format, but before it is displayed, the Instructor Station
can convert the value into whichever units are required, according to a
Mathematically calculated conversion factor. For instance, if a value is calculated in
inches, it can be converted simultaneously and the same value displayed in
centimetres.
In the Unit Conversion screens, variables are grouped according to where they are
displayed, i.e. on a screen by screen basis, so that if the same variable appears in
more that one place, it can either be can be changed throughout the simulator or
displayed differently on (or if so wished) on an individual screen.
In addition to this, the whole set of conversion factors used throughout the
Instructor Station can be instantly changed for an alternative set e.g. switch from
Imperial units to Metric.
4.15.1 Change Unit Conversion Screens
This screen enables the Instructor to change how an individual variable is displayed
on a particular screen, for instance on the Bit Data screen, the Bit Age can be
represented in any form of time units e.g. Hours or Days. This will not affect how this
same value will be presented on other screens. Once selected, a variety about the
chosen variable will be displayed, giving details of the current units used and the
current way in which the displayed value is calculated.
This screen also allows the user to select how many decimal places are to be
displayed; this is achieved by simply choosing the correct option from a drop down
list. In doing this, the Instructor Station will take the chosen standard unit and only
display conversion units that are relevant to it e.g. it is not possible to convert a
volume (such as bbls) to a non-volumetric unit e.g. temperature or distance
To save time, rapid changes between distinct groups of units (e.g. Metric to
Imperial), can be made by selecting a different “Current Group Code”, this is
achieved by right-clicking on the chosen variable will bring up a menu, allowing the
user to select from a variety of standard groups e.g. S.I. (Systeme Internationale)
Units or Field Units. For information on how to create a group, see Chapter 4.14.4
If an entry has been accidentally deleted, then it can easily be re-installed by visiting
the screen to which the entry belonged. E.g. to replace the Bit Age entry, simply
access the Bit Data screen. This will replace the entry in the original position as if
nothing had happened.
4.15.2 Unit Configuration Menu > Unit Overview
This screen enables the user to change all uses of a particular unit throughout the
entire simulator at one time, e.g. change all volumes measured in barrels to the
equivalent volumes in m3.
By doing this, it is possible to very quickly customize an exercise for a particular

course of group of trainees without having to change the existing snap-shots. This
can also be used to change the display format for a unit that is already being used
throughout the simulator, e.g. set the number of decimal places.
4.15.3 Unit Configuration Menu > Add / Modify Units
This screen enables the user to create a new unit or to change how a unit already
existing within the Drillsim simulator is displayed.
To add a unit, the user has to choose which one of the standard unit used to
calculate the variable is to be converted. For example, to create a new unit to
measure flow rate, select Barrels / Minute from the “Convert From” list. Having done
this, simply choose how this unit should be calculated from the menu bars, e.g. to
calculate the same value in Barrels per day, select Barrels from the “Numerator”
panel and “Days” form the “Denominator” panel. The Instructor Station will
determine the correct conversion formula and use it automatically (without the user
having to type the formula in manually).
To name the new variable, enter the chosen name into the “Unit Name” box and click
on the “Add Unit” button. This screen can also be used to delete units that have been
created but are now surplus to requirements. The new unit can then be used within
the Drillsim simulator as normal.
4.15.4 Unit Configuration Menu > Create New Group
This enables the user to create a new Group of units to suit the training
requirements of a particular group or purpose, e.g. to match company standards.
This can be especially useful if the simulator is being used to train students from a
variety of backgrounds or nationalities, for instance, switch between Imperial and
Metric units or between European & American standard units. The simulator comes
provided with “Groups” designed to cover “Field Units” & “S.I. Units” pre-installed, as
well as the “Default” simulator options.
4.16 Manifold Display (DrillSIM-5000 / DrillSIM-500)
This screen allows the Instructor to monitor the status of the various valves and
chokes attached to the Standpipe Manifold and Choke Manifold. As the student(s)
change the status of the valves, the screen will change accordingly.
This screen can also be used when setting up an exercise (i.e. correctly aligning the
valves and positioning the chokes)
Student Control Station i
5. STUDENT STATION (DRILLSIM-5000 & DRILLSIM-500).......................................5.1

5.1 JARRING / WEIGHT ON BIT INDICATOR............................................................................................... 5.2
5.2 MUD ALIGNMENT................................................................................................................................ 5.3
5.2.1 Cement Pump (also Mud Pumps 1,2 & 3)........................................................5.4
5.2.2 Cement Slurry.............................................................................................5.5
5.2.3 Active Pit....................................................................................................5.6
5.2.4 Reserve Mud System....................................................................................5.8
5.2.5 Make Water................................................................................................5.9
5.3 TRIP TANK ALIGNMENT.....................................................................................................................5.10
5.4 CEMENT HEAD..................................................................................................................................5.12
5.5 DSC APV SYSTEM.......................................................................................................................... 5.13
5.6 WORKOVER...................................................................................................................................... 5.14
5.7 DATA DISPLAY................................................................................................................................. 5.15
5.7.1 Plot Using Drilling Parameters......................................................................5.15
5.7.2 Plot Using Well Control Parameters...............................................................5.15
5.7.3 Update Frequency......................................................................................5.15
5.8 SUBSEA BOP...................................................................................................5.16
5.9 AUTO DRILLER................................................................................................................................. 5.17
5.10 UNITS & CONVERSIONS................................................................................................................... 5.18

Student Control Station 5.1
5. STUDENT STATION (DRILLSIM-5000 & DRILLSIM-500)
The Student Control Station is designed to complement any control or display features
that are not provided by hardware on the simulator. The station is controlled via a
menu system and a touchscreen monitor.
The options listed on this screen may not necessarily reflect the options available with
your simulator configuration – those options not available with your simulator will be
disabled and the icon will appear to have been “greyed out”.

5.1 Jarring / Weight on Bit Indicator
This screen allows the Student to perform Jarring operations (where this feature has
been installed). The screen allows the student to rotate the outer scale in either a
clockwise or anti-clockwise direction to assist with setting the overpulls required to
cock the jars.
5.2 Mud Alignment
The Mud Alignment screen allows the user to maintain and modify the mud system
during the course of the exercise. This screen also enables resetting of the pop-off
valves, selecting different types of cement slurry and the making, mixing and dumping
of drilling fluids, as explained in the sections presented below.
5.2.1 Cement Pump (also Mud Pumps 1,2 & 3)
5.2.1.1 Output per Stroke

This is the output per stroke from the selected pump (the efficiency factor of the pump
has been used to calculate this figure).
5.2.1.2 Relief Valve Status

This panel will display the current state of the relief valve (also known as Pop-off
valves) for the selected pump. The Instructor determines the pressure at which the
relief valve will operate.
5.2.1.3 Reset Relief Valve

If the Relief valve has been activated (i.e. Blown), the student is able to reset the valve
status by simply clicking this button. If the pressure is still too high or the cause of the
problem is still present then the relief valve will not reset until the problem has been
resolved.
5.2.2 Cement Slurry
5.2.2.1 Chemical Type

These buttons allow the user to select which type of material is to be pumped. The
options are as follows:
 Prewash  Spacer
 Lead  Tail
5.2.2.2 Weight
This option allows the user to set the desired weight of the cement slurry.
5.2.2.3 Plastic Viscosity

This option allows the user to set the desired Plastic Viscosity of the cement slurry.
5.2.2.4 Yield Point

This option allows the user to set the desired Yield Point of the cement slurry.
5.2.3 Active Pit
Displays the properties of the active pit. The current mud weight is displayed on the
button for easy reference.
5.2.3.1 Tank Size

This is the total volume of the Active Pit.
5.2.3.2 Total Contents

This is the volume of fluids and solids in the Active pit.
5.2.3.3 Mud Volume

This is the total volume of drilling fluids in the Active Pit. N.B. This does not include
the amount of drilled or settles solids. The student can change this figure at any time.
5.2.3.4 Settled Solids

This is the volume of settled solids in the Active Pit.
5.2.3.5 Mud Weight

This displays the current mud weight in the Active Pit. The student can change this
figure at any time.
5.2.3.6 PV
This is the current Plastic Viscosity of the drilling fluids in the Active Tank.
5.2.3.7 YP
This is the current Yield Point of the drilling fluids in the Active Tank.
5.2.3.8 Auto Density Control

Activating this option will cause the current mud weight in the active tank to be
maintained regardless of the condition of the mud returning from the well.
5.2.3.9 Dump
Will prompt the user to empty the active mud system, the volume of fluids in the tank
including the settled solids will be set to zero.
5.2.3.10 Numeric Data Entry

When selecting buttons which require numeric input, a pop-up calculator style panel
appears. Selecting the button marked “Enter” will update the simulator with the
displayed values. Selecting the button marked “Cancel” will not update the displayed
value to the simulator.
5.2.4 Reserve Mud System
This screen allows the user to review a range of data regarding the Reserve Mud
System – Tank size, Plastic Viscosity, Yield Point
5.2.4.1 Tank Size

This is the total volume of the Reserve Pit
5.2.4.2 Total Contents

This button allows the user to change the current volume of mud in the Reserve Pit.
5.2.4.3 Mud Weight

This button allows the user to change the current mud weight in the Reserve Pit.
5.2.4.4 PV
This is the current Plastic Viscosity of the drilling fluids in the Reserve Tank.
5.2.4.5 YP
This is the current Yield Point of the drilling fluids in the Reserve Tank.
5.2.5 Make Water
The large button in the centre of the “Add Water” screen is used to set the rate at which fresh
water will be added to the active system.
This button will, providing that the valve down stream is open, fill the active system with
water at the flow rate entered.
5.3 Trip Tank Alignment
This screen allows the user to change the alignment of the various valves required to
make use of the Trip Tank and Strip Tank. To change the state of any of the valves
then simply click on the desired valve, the valve will be shown to spin for
approximately one second after which the state will have changed (e.g. from open to
closed). The Open state is shown by the centre of the valve turning green (see example
below).
Closed Valve Open Valve
Mud gas separator is the inlet from the Poorboy degasser on the choke manifold. If the
valve downstream is closed, then the output from the Mud Gas Separator will go into
the active system.
If a message like this appears, then the user has selected a valve, which actually has a
physical (hardware) switch on the drilling gauges panel. The message denotes that to
operate the function selected, the Push Button on the Drilling Gauges Panel will have
to be used instead.
5.4 Cement Head
This option is only available if your Drillsim 5000 is fitted with the optional Cement
Head. This option is not available with other simulators in the Drillsim range of
products.
If the cement head option has been activated, the user is able to:
 Load the solid plug.
 Load the reputable plug.
 Unload the plugs.
 Open/Close the discharge valves.
 Launch the plugs using the hand wheel valves.
Note: The instructor is able to reverse the plugs.

5.5 DSC APV System
This option is only available if your Drillsim 5000 is fitted with the optional Drill
String Motion Compensator. This option is not available with other simulators in the
Drillsim range of products.
This screen allows the user to monitor the pressure levels in the Accumulator bottles
and switch the individual bottles between being on-line and off-line.
5.6 Workover
This option is only available if your simulator is equipped with the Workover option
(Drillsim 5000 & 500 only).
The following equipment can be operated:
 Packer
 Well Head/BOP
 Tubing Plug
 Sliding Sleeve
 Production Choke – To Manifold – To Production
The buttons will show the current status by changing to yellow when the function is
activated.
5.7 Data Display
This screen allows the user to monitor the data collected whilst drilling the well.
The data is presented in two different charts: current and history. The Current chart
displays data from the last minute whereas the history chart will display data collected
since the start of the exercise.
5.7.1 Plot Using Drilling Parameters

This button will change the categories of data being collected to a pre-configured list
of parameters designed for use whilst drilling ahead.
5.7.2 Plot Using Well Control Parameters

This button will change the categories of data being collected to a pre-configured list
of parameters designed for use in a well control situation.
5.7.3 Update Frequency

This scroll bar allows the user to change the frequency in which data is collected. The
range is from 1 second to 30 seconds.
5.8 Subsea BOP
This option is only available is your simulator is equipped with the Subsea BOP
console.
5.9 Auto Driller
When this option has been selected, the automatic driller will maintain the current
Weight on Bit (WOB), until either the position of the driller’s brake is adjusted or the
Drawworks is activated.
5.10 Units & Conversions
This button allows the user to switch between different systems of units and to modify
the individual units used throughout the simulator. Pressing this button will produce
the following screen:
The units presented on the individual screens (numbered 1 to 15) are displayed along
with the unit used by the mathematical model. The user can enter any conversion
value, unit name and display format they wish. If the user wishes to switch between
complete unit systems (for instance, between API field units and SI units), this can be
achieved by simply clicking the button labelled “Unit Group”. Any changes made to
the units and conversions will occur immediately and all measurements throughout the
student station will be changed to correspond with the new system. It is recommended
that any new conversion factors are taken from industry standard sources (all
conversion factors provided upon installation are taken from the seventh edition of the
“Drilling Data Handbook”, published by the Institut Français du Pétrole Publications,
ISBN 2-7108-0756-4).
Graphics Station 6.i
6. GRAPHICS STATION............................................................................................6.1
6.1 COLOUR GRAPHICS PRESENTATION (DRILLSIM-5000).....................................................6.1
6.1.1 General Description.....................................................................................6.1
6.1.2 Display Components (DrillSIM-5000)..............................................................6.1
6.2 COLOUR GRAPHICS PRESENTATION (DRILLSIM-500, 50).................................................6.3
6.2.1 General Description.....................................................................................6.3
6.2.2 Display Components (DrillSIM-500, 50)..........................................................6.3
6.2.3 Display Components (DrillSIM-20).................................................................6.4
6.2.4 Graphics System.........................................................................................6.5

Graphics Station 6.1
6. GRAPHICS STATION
6.1 Colour Graphics Presentation (DrillSIM-5000)
6.1.1 General Description

The Hoisting System is shown by graphic representation on a 21-inch Colour Monitor.
The monitor displays an animated picture of the major static and dynamic components
of a typical drilling rig floor, viewed through a window. Control of the components
represented on the monitor is accomplished from the pipe handling controls on the
Drilling Controls Console. Operation of dynamic component controls causes a
corresponding animated response to be displayed on the monitor.
6.1.2 Display Components (DrillSIM-5000)

The static and dynamic elements represented on the Colour Monitor are as follows:
Static:
 Top of the Rig  Cement Head
 Rat Hole  BOP – Subsea / Surface
 Mouse Hole  Manifolds – Choke and Standpipe
 Drill Floor  Workover Wellhead plus Tree
 Outline of Rotary  Workover Manifold
 Pipe Stand Fingerboard  Drawworks
Dynamic:
 Motion Compensator  Single Tubular Item – see list
below
 Travelling Block  Pipe Moving in BOP
 Drilling Line  Slips
 Links and Elevators  Rotary Motion
 Kelly  Kelly Mark
 Valves on Various Manifolds  Stand (made up of 3 tubular items

– see list below)
 Rams Showing Open/Close in

BOP

Tubular Items:
 Drill Pipe  Tubing
 Heavy Drill Pipe  Drill Bit
 Collars  Packer
 Casing and Liners  Casing Shoe

6.2 Colour Graphics Presentation (DrillSIM-500, 50)
6.2.1 General Description

The Hoisting System is shown by graphic representation on a Touch Screen. The
monitor displays an animated picture of the static and dynamic components of a typical
drilling rig floor, viewed through a window. Control of the components represented on
the monitor is accomplished from the pipe handling controls on the Drilling Controls
Panel. Operation of dynamic component controls causes a corresponding animated
response to be displayed on the monitor
6.2.2 Display Components (DrillSIM-500, 50)

The static and dynamic elements represented on the Touch Screen are as follows:
Static:
 Rat Hole  Mouse Hole
 Drill Floor  Outline of Rotary
Dynamic:
 Travelling Block  Drilling Line
 Link and Elevators  Kelly/Top Drive
 Single Tubular Item – see list  Stand (Made up of three tubular

below items – see list below)
 Slips
Tubular Items:
 Drill Pipe  Heavy Weight Drill Pipe
 Collars  Casing and Liners
 Tubing  Drill Bit
 Packer  Casing Shoe

6.2.3 Display Components (DrillSIM-20)
The static and dynamic elements represented on the Touch Screen are as follows:
Static:
 Rat Hole  Mouse Hole
 Drill Floor  Outline of Rotary
Dynamic:
 Travelling Block  Drilling Line
 Kelly/Top Drive  Slips
 Stand (Made up of three tubular  Single Tubular Item – See list

items – see list below) below
Tubular Items:
 Drill Pipe  Heavy Weight Drill Pipe
 Drill Collars  Tubing
 Drill Bit
6.2.4 Graphics System
Graphically represented dynamic components respond to control manipulation in the
following ways:
Orthogonal Movement (DrillSIM-5000, 500)
Travelling Block, Kelly, Single Drill Pipes and Stand, all move either up, down, left or
right. Left and right movement of the Travelling Block is limited to one of four pre-set
positions, which correspond to:
 Rat Hole
 Rotary Table
 Mouse Hole
 Monkey Board
Slips (DrillSIM-5000)
Slips In/Out are displayed in one of two positions, either engaged in the Rotary Table,
or on the rig floor to the left of the table when disengaged. The setting and removal of
the slips is carried out with the foot control or the push button on the Drilling Controls
panel.
Slips (DrillSIM-500, 50,20)
Slips In/Out are displayed in one of two positions, either engaged in the Rotary Table,
or on the rig floor to the left of the table when disengaged. The setting and removal of
the slips is carried out with set/remove slips control.
Top Drive Links (DrillSIM-5000, 500)
Top drive links are displayed in three positions, at the rotary table, over the Mousehole
or at the monkey board racking position. On the DrillSIM-5000, the link tilt position
is controlled with the Link Tilt button on the top drive control panel. On the DrillSIM-
500 a pushbutton is provided on the Drillers Panel.
Top Drive Links (DrillSIM-50,20)
A button is provided to Add Stand / Remove Stand.
Inside BOP (DrillSIM-500,50,20)
The status of the inside BOP is displayed on the graphics screen.
Rotary Motion (DrillSIM-5000)
A vertical line moving horizontally within the graphics outline of the table represents
rotary motion of the Rotary Table or Top Drive. Left to right movement of the line
indicates forward rotation and right to left movement indicates reverse rotation.
Rotary Motion (DrillSIM-500, 50)
A static line of arrows moving in the direction of travel represents rotary motion of the
Rotary Table or Top Drive.
Sound Effects System 7.i
7. SOUND EFFECTS SYSTEM..................................................................................................................7.1

7.1 SOUNDS PRODUCED..........................................................................................................................................................7.1
7.2 GENERAL DESCRIPTION..................................................................................................................................................7.1
7.3 SOUND SYSTEM VOLUME CONTROL..........................................................................................................................7.1

Sound Effects System 7.1
7. SOUND EFFECTS SYSTEM
7.1 Sounds Produced

The sound effects generated by the system are classified into three types as follows:
Continuous during simulation:

 Diesel Generator Noise (DrillSIM-5000).
Continuous in response to student action:
 Drawworks Motor
 Drawworks Cooling Motor Fan
 Brake Screech
 Fluid & Gas Through the Choke
 Drilling Line Spooling Out
 Rotary Table
 Mud Pump Operation
Instantaneous in response to specific action by student:

 Air Control Operations
 Swaco Choke Operation
 Accumulator Pump Operation
 Slip In and Out
 Elevators Latch
7.2 General Description

Sounds generated from the equipment on typical drilling rig floor are digitally
reproduced to enhance the realism of simulation. The sounds produced are interactive
with student actions and vary in synchronism with operational changes. They are
emitted from one or more strategically positioned speakers on the DrillSIM-5000 and
from internal speakers on the DrillSIM-500 and 50. On the DrillSIM-20 the laptops on
board speakers are used.
7.3 Sound System Volume Control

The Instructor can set the volume of the sound effects by dragging down the menu
item Simulation and selecting Volume. A sliding control provides volume adjustment.
This volume setting is passed each time a snap is loaded.
With the DrillSIM-20, the overall volume is controlled via the Windows task bar
volume control or the laptops master volume control.

Scope of Simulation 8.i
8. SCOPE OF SIMULATION.......................................................................................8.1
8.1 INTRODUCTION...................................................................................................................................8.1
8.2 INSTRUCTOR FACILITIES.................................................................................8.2
8.3 CIRCULATING SYSTEM........................................................................................................................ 8.3
8.3.1 Mud Control Window....................................................................................8.3
8.3.2 Mud Tanks.................................................................................................8.4
8.3.3 Drilling Fluid...............................................................................................8.8
8.3.4 Mud Pumps and Cement Pump......................................................................8.9
8.3.5 Standpipe Manifold......................................................................................8.9
8.4 ROTARY SYSTEM.............................................................................................................................. 8.10
8.4.1 Drilling Equipment.....................................................................................8.10
8.5 DRAWWORKS SYSTEM...................................................................................................................... 8.12
8.5.1 Driller's Window Graphics...........................................................................8.12
8.5.2 Drilling Controls.........................................................................................8.13
8.6 BLOWOUT PREVENTION AND WELL CONTROL SYSTEM........................................8.15
8.6.1 Choke Manifold..........................................................................................8.15
8.6.2 Surface BOP Control Console.......................................................................8.16
8.6.3 Drill String Valves......................................................................................8.17
8.6.4 Subsea BOP Control Console.......................................................................8.17
8.6.5 Subsea Diverter System.............................................................................8.18
8.7 EQUIPMENT AND OPERATIONAL MALFUNCTIONS...............................................8.19
8.7.1 Hoisting System Malfunctions......................................................................8.19
8.7.2 Power System Malfunctions.........................................................................8.19
8.7.3 Rig Instrumentation Malfunctions.................................................................8.19
8.7.4 Fluid Handling System................................................................................8.20
8.7.5 Air Supply Malfunction................................................................................8.20
8.7.6 BOP and Well Control Equipment Malfunctions...............................................8.20
8.8 DOWNHOLE EFFECTS........................................................................................................................8.22
8.8.1 Geology...................................................................................................8.22
8.8.2 Leak-off Testing........................................................................................8.23
8.8.3 Bottom Hole Effects...................................................................................8.24
8.8.4 Downhole Malfunctions...............................................................................8.24
8.8.5 Downhole Mechanics..................................................................................8.25
8.8.6 Annular Malfunctions..................................................................................8.25
8.8.7 Torque and Drag Malfunctions.....................................................................8.25
8.8.8 Fluid Flow and Pressure Loss.......................................................................8.26
8.9 WELL CONTROL............................................................................................................................... 8.28
8.9.1 Causes of Kicks.........................................................................................8.28
8.9.2 Types of Kicks...........................................................................................8.32
8.9.3 Condition Dependent Kick...........................................................................8.33
8.9.4 Multiple Kicks............................................................................................8.33
8.9.5 Kick Influx Density.....................................................................................8.34
8.9.6 Influx Flow Rate........................................................................................8.34
8.9.7 Reservoir Drawdown and Stabilisation..........................................................8.34
8.9.8 Gas Expansion..........................................................................................8.35
8.9.9 Gas Migration............................................................................................8.35
8.9.10 Underground Blowout.............................................................................8.36
8.9.11 Dynamic Pressures During Well Control.....................................................8.37
8.9.12 Kicks While Drilling Surface Hole..............................................................8.38
8.9.13 Kicks While Drilling.................................................................................8.38
8.9.14 Kicks While Tripping...............................................................................8.39
8.9.15 Stripping..............................................................................................8.40
8.9.16 Kicks While Out of the Hole.....................................................................8.41
8.9.17 Kicks While Running Casing and Liners......................................................8.41
8.9.18 Driller's Method of Well Control................................................................8.41
8.9.19 Wait and Weight Method of Well Control....................................................8.42
8.9.20 Bullheading...........................................................................................8.42
8.9.21 Volumetric Method of Well Control............................................................8.43
8.9.22 Concurrent Method of Well Control...........................................................8.43
8.9.23 Low Choke Method of Well Control............................................................8.44
8.10 CEMENTING......................................................................................................................................8.45
8.10.1 Cement Head........................................................................................8.45

Scope of Simulation 8.ii
8.10.2 Cement Pump Console Option (DrillSIM-5000)...........................................8.46

8.11 WORKOVER INTRODUCTION..............................................................................................................8.47

Scope of Simulation 8.1
8. SCOPE OF SIMULATION
8.1 Introduction
The mathematical models within the DrillSIM range of products 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 pre-defined characteristics. The DrillSIM
provides user-friendly interface 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 the following simulator components:

 Instructor Facilities
 Circulating System
 Rotary System
 Hoisting System
 Blow-out Prevention and Well Control System
 Rig Instrumentation and Auxiliary Systems
 Equipment and Operational Malfunctions
 Downhole Effects
 Well Control
 Workover
 Cementing
The DrillSIM 's simulated processes and equipment are modelled on those encountered
on a typical drilling rig in the field. Equipment malfunctions and process problems are
detailed and explained.

8.2 Instructor Facilities
The instructor interface provides the instructor with an easy to use interface. This
allows the instructor to easily create new simulation exercises, control the exercise,
monitor trainee performance and to save & retrieve exercise snapshots at any time.
The menu bar systems allow the user to manoeuvre around the system with ease. The
instructor interface includes:
 Simulation Control Screens
 Speed Controls
 Snapshot (Exercise) Configuration
 Real-Time Data Screens
 Malfunction Control Screens
 Simulator Diagnostics Screens
See Section 4 of this manual for a complete overview of the instructor interface.
8.3 Circulating System
The DrillSIM simulator models the behaviour of a number of components within the
circulating system (such as Shale Shakers etc) and provides a wide range of flexibility
in system design and the fluid properties bith for the student (through the Student
Station) and the Instructor (through the Instructor Station). See section5 of this manual
for a more comprehensive overview of the facilities available.
8.3.1 Mud Control Window

The Student Station features a facility called the Mud Control Window which allows
the student control over the operations and parameters for the mud system and the
auxiliary rig equipment including the following:
 Density of the mud in the Reserve  Capacity of the Reserve Tank

Tank
 Volume of mud contained in the  Density of the mud in the Active Tank
Reserve Tank
 Capacity of the Active Tank  Volume of mud in the Active Tank
 Dump the entire contents of the Mud  Make-up Water outlet to Active Mud
Tank Tank
 Activating the Automatic Density
Control
Opening and closing the following valves;
 Cement Tank outlet to Cement  Reserve Tank outlet to Cement

Pump. Pump.
 Reserve Tank outlet to Active  Reserve Tank outlet to Mud
Mud Tank. Pumps.
 Active Tank outlet to Mud Pumps  Riser Valve
 Riser to Trip Tank Valve  Riser to Shaker Valve
 Mud Gas Separation Tank outlet  Trip Tank Outlet to Strip Tank
to Trip Tank
Opening the Reserve Mud Tank Outlet valve will connect the Reserve Pit to the Active
Pit – this will serve to equalise the volume of mud across the pits and to standardise
the mud properties (density, viscosity etc).
Using the Mud Control Window, the trainee can monitor the following properties:
 Properties of the Active Mud Tank (tank volume, tank contents and mud
density, plastic viscosity and yield point).
Properties of the Reserve Mud Tank (tank volume, tank capacity and mud
density, plastic viscosity and yield point).
 Pump output and relief valve status of all mud pumps and the ability to re-set
the relief valves.
NOTE: Tank contents include the volume of accumulated solids from drill cuttings.
8.3.2 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 circulating fluid and cement.
An insight into the effect of accumulated drill cuttings and their removal is included.
The surface mud tank equipment includes the following:
 Active Mud Tank

 Solids Control Equipment
 Reserve Mud Tank
 Trip Tank
 Strip Tank
 Degasser Tank
 Cement Tank
8.3.2.1 Active Mud Tank

Density, plastic viscosity and yield point are the only properties of mud or cement,
which are catered for in the tank systems.
The contents of the active tank are defined by a volume of mud available for
circulation and the volume of settled solids created by an accumulation of drilled
cuttings which have not been 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 drilled cuttings returned to the active tank depends upon the efficiency
of the solids control equipment. This value ranges from 0 to 100% of drilled cuttings
which will be removed at surface. The Instructor should define the percentage of
solids which will settle in the pits once the mud has passed through the Solids Control
equipment – this value is represented as a percentage. The material which settles out
will accumulate in the pit until removed by cleaning. The remainder of the solids
which have not been removed by the Solids Control equipment and have not settled
out will remain in suspended in the drilling fluids held in the tank. The presence of the
suspended solids will alter the density of the drilling fluid (it is assumed that cuttings
will be of a constant density).
The volumes of solids and both volume and density of mud is updated dynamically
depending upon the total volume of flow both into and out of the tank. Flows to and
from the tank are comprised of the following:
 Return line mud flow-rate.
 Return mud flow-rate from the Mud Gas Separation Tank.
 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 Mud System Control
Terminal, the physical simulator controls 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.
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.
The Instructor can also trigger alarm malfunctions.
Solids Control Equipment
The following Solids Removal Equipment is simulated:
 Shale Shaker.
 Desander.
 Desilter.
 Centrifuge.
The efficiency of the overall solids removal is determined as a percentage value, which
is dependent on the removal efficiencies of its components. The malfunction and
failure of the individual components of the solids control system can be initiated by the
Instructor at any time. The Instructor is also able to modify the effectiveness of the
solids control equipment at any time.
During simulation, the mass balance of the system is maintained and operational losses
and additions are taken into account. Changes in mud density by the addition of
cuttings affect the hydrostatic head, circulating pressures and downhole circulation
flow characteristics. Pressure and volume changes caused by the influx of gas, oil or
salt water from simulated downhole permeable formations also affect the system.
8.3.2.2 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 Student Station, or through the
Instructor’s touch screen commands is able to change both properties prior to, or
during the course of an exercise.
Flow out of the reserve tank is either direct to the circulating system via the pumps or
to the active tank. Flow between the active and reserve tanks depends upon the
heights of liquid in both due to a U-tube effect. A flow-rate to the active tank results
in an instant change in the density of the active tank mud.
The reserve tank can be sized small enough to use as a slug tank to mix and pump
weighted pills down the drill pipe prior to trips or to displace anti-stick fluids in the
case of stuck pipe.
8.3.2.3 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 is fixed at 300 gallons per minute. When the well is full, the pump
will circulate fluid across the well back into the trip tank.
If the flowline 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 trainees can make-up, pump out or utilise
the tank contents, as required, from the Drilling Gauges Console where the following
facilities are provided:
 Tank level Indicator (0 to 50 Bbls).
 Outlet Valve, Open/Close Pushbuttons.
 Fill Valve, Open/Close Pushbuttons.
 Trip Tank Pump, ON/OFF Pushbuttons.
8.3.2.4 Strip Tank
During stripping operations, the volume of mud equivalent to the wet displacement of
the pipe being stripped is drained from the trip tank into the strip tank. This small 10
bbl tank provides an accurate measuring device to monitor stripping volumes. The
increase in volume of mud caused by gas expansion remains in the trip tank.
The contents of the strip tank are the dynamic resultant of flows into and out of the
tank due to:
 Fill flow from the trip tank
 Pump flow out of the strip tank
 Dump flow when the strip tank is drained to the disposal tank
Fill flow rate is fixed when the fill valve from the trip tank 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 strip tank.
Pump flow rate is fixed at 300 gallons per minute. When the strip tank is full, the
pump will move the fluid across into the active mud tank.
8.3.2.5 Degasser Tank

Flow out of the choke manifold is either directed to the active system via the Mud Gas
Separation tank or directed to the trip tank in case of stripping operations. The
appropriate valves can be aligned on the Student Station touch screen. When the trip
tank is full, the mud can either be dumped or pumped back to the active system.
Returned cuttings circulated through the choke manifold are ignored and effectively
lost from the simulation.
8.3.2.6 Cement Tank

The volume and dimensions of the cement tank are assumed to be infinite. A supply of
cement is assumed to be readily available to the cement pump inlet. The Instructor can
set the cement density at any time.
8.3.3 Drilling Fluid
The DrillSIM simulator allows the students to exerience handling a typical drilling
fluid without going into the intricacies of mud engineering. The drilling fluid features
the following parameters:
 Mud Density  Yield Point
 Plastic Viscosity  Consistency Factor
 Compressibility
The 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 Student Station
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 modelled inside the drill string during
normal circulation. While compressing mud by pumping, the resulting pressures are a
function of the following; the volume of the closed section of the flow network, the
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.
8.3.3.1 Density Tracking

Effects of fluid density on circulating pressure losses and downhole hydrostatic head
pressures provide basic training in surface equipment limitations and well control
techniques. The density of fluid, whether it is circulating mud 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 fifty 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, dependent on the flow rates and geometry of each section of the
network.
All of the “slugs” of drilling fluid in the drill string will be passed to the annulus only
through the bit nozzles. Any changes in muid density or volume density due to a
washout in the drill pipe or due to a twist-off are not modelled in this simulator. Any
influxes experienced will automatically change the density of the mud as they pass
through the annulus.
During tripping operations, which are defined by the removal of one or more stands
from the drill string, all mud in the annulus will take on the density of that contained in
the active tank, this is in effect the result of assuming that a complete circulation has
been completed prior to commencement of tripping and that the mud has been properly
conditioned.
8.3.4 Mud Pumps and Cement Pump

The mud pumps and cement pumps are positive displacement units. Three mud pumps
and one cement pump are provided and controlled from the Drilling Controls Console.
The Instructor can select pump characteristics: pump type (duplex or triplex); liner
capacity (volume displaced per stroke); length of stroke; efficiency and pop-off valve
setting. The pumps are electrically driven from SCR controllers with speed-demand
controls. The driller sets the desired pump setting using the demand control and will be
able to see the corresponding changes to the rate of SPM on the pump gauges.
The resulting Standpipe 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
control knob will need to be varied to achieve a given SPM according to the pressure
delivered. Similarly, if the resistance of the circuit changes, the speed of the pump
will change accordingly to the efficiency of its speed regulation. The quality of
regulation in terms of the magnitude of SPM variation with pressure can be set by the
Instructor. This facility provides training in controlling pump speed during changing
flow conditions, for instance in a well control incident. Mud and cement pump relief
valves can be reset by the trainee using the Student Station control terminal
commands. Relief valves cannot be reset unless the pump speed controllers are
completely off.
8.3.5 Standpipe Manifold

The Standpipe Manifold is designed to provide maximum flexibility with any
simulated exercise and is arranged so that:
 Any Mud Pump can be lined up with the standpipes, choke manifold or kill
line.
 The Cement Pump can be lined up with the standpipes, choke manifold, kill
line or optional Cementing Head for cementing operations.
 The Standpipe Manifold can be connected directly to the Choke Manifold.
 The Standpipe Manifold can be isolated from the Standpipe.
The Standpipe Manifold is fitted with a number of manually operated valves and two
pressure gauges which indicate the manifold pressure.
8.4 Rotary System
The simulated Rotary System comprises a Rotary Table driven by a DC motor via a
transmission system. Indication of Rotary Table performance is represented on the
Colour Graphics Monitor.
Control of the Rotary Table is achieved from the Drilling Controls Console. The
appropriate sound effects are simulated and the rotary table responds in a realistic
manner. The torque available is a function of motor speed, gear ratio and direction of
rotation and is limited by the motor rating and efficiency of transmission systems.
Torque demanded is the sum of bit torque, drill string torque and acceleration torque.
These factors are determined by the characteristics of the simulated drill string and
bottom hole effects. A rotary torque limit control on the Drilling Controls Console
enables the driller to set a rotary drive trip when the torque demand exceeds the set
level. Rotary RPM and torque gauges are provided on the Drilling Gauges Console
for the Driller's observation.
8.4.1 Drilling Equipment

The simulator supports drilling and subsequent completion tools to be run to a depth of
30,000ft. The equipment available for selection includes:
 Drill Bits.
 Drill Collars.
 Heavy Weight Drill Pipe.
 Drill Pipe.
 Tubing.
 Casing and Liners.
 Packers.
 Casing Shoe.
The equipment selected affects the overall response of the Simulator while the
performance of the selected equipment is affected by the simulated downhole
conditions.
8.4.1.1 Drilling Bits

A range of drilling bits in various IADC types and sizes are available. The simulator
employs a modified version of the Amoco Research drilling model. Drilling bits can
be fitted with up to four nozzles of varying sizes. During drilling the physical selection
characteristics of the drill bit are fixed, although the Instructor can supply an
alternative bit during a round trip. If the incorrect bit is selected for the formation and
drilling parameters, the rate of penetration may be minimal. The model accounts for
mismatches in bits with the formation being drilled.
8.4.1.2 Drill Collars

An unlimited number of 30 ft sections of drill collars are available in a range of API
standard sizes selected by the Instructor.
8.4.1.3 Heavy Weight Drill Pipe
An unlimited number of 30 ft sections of heavy weight drill pipe are available in a
range of API standard sizes selected by the Instructor.
8.4.1.4 Drill Pipe

Sufficient drill pipe is available in 30-ft lengths to enable a well to be drilled to a depth
of 30,000ft (Measured Depth). The mathematical model considers all relevant API
properties of the drill pipe in its various calculations.
8.4.1.5 Tubing (Optional)

Sufficient tubing is available in lengths of 30 ft to give access to hole bottom at a
maximum depth of 30,000 ft.
8.4.1.6 Casing
Sufficient casing in 40 ft lengths is available to case-off a 30,000 ft hole. The
instructor can set casing sizes and specifications.
Casing can be run with or without a float. If a float is used then the effects of fluid
displacement in the Mud System must be taken into account. Filling the casing with
mud as it is run into the hole is set up through the Mud Control Terminal. Casing
running operations are optional.
8.4.1.7 Downhole Equipment

When Running Casing, a Casing Shoe is provided. The Instructor can also include a
Float in the Casing String.
When displacing a known cement volume from inside casing, bumping of upper and
lower plugs is simulated with an appropriate sharp pressure rise to show that a plug
has landed.
When running tubing, a packer can be lowered into the hole. This facility is provided
so that casing and formation integrity testing may be carried out.
8.5 Drawworks System
8.5.1 Driller's Window Graphics

Part of the Drawworks System is represented by means of a graphics display on a
Colour Monitor. An animated picture represents the major dynamic and static
components of a drilling rig floor. Appropriate pipe handling and drawworks controls
are located on the Drilling Controls Console.
The following static and dynamic components are represented on the Driller's Window
graphics monitor:
Static Elements displayed are:

 Rat Hole
 Mouse Hole
 Drill Floor
 Rotary Table Outline
 Top Drive (Optional)
Surface Graphics Dynamic Elements include:
 Travelling Block with Elevators
 Kelly
 Single Tubular Item (Drillpipe etc.)
 Stand
 Slips (In/Out)
 Top Drive Operation (Optional)
Through the graphics station, the student can observe the following:
 Movement of the travelling block
 Motion of the Top Drive (Optional)
 Motion of the Kelly and Kelly bushing
 Movement of the Drill String components
 Motion of the Rotary Table
During drilling and tripping operations, the position of a drill pipe connection and the
racking back of the current joint/stand can be viewed while in progress.
Subsurface Graphics Static Elements are displayed in a scale diagram and consist of
the following:
 Casing and Liners
 Casing Shoe
 Drill Pipe
 Heavy Weight Drill Pipe
 Drill Bit
 Formation Changes
Subsurface Graphics Dynamic Elements consist of the following:
 Movement of the various fluids in the drill string represented by different
colours.
 Movement of the various fluids in the annulus represented by different
colours. (The model is capable of thirty different fluid regions).
 Flow of formation fluid into the wellbore.
 Wellbore fluid flow into a loss zone or fracture.
Different tubular equipment types are identified by the use of size, shape and colour.
The equipment identified in this manner being:
 Drill Pipe.
 Heavy Drill Pipe.
 Drill Collars.
 Casing and Liners.
 Tubing.
 Drilling bit.
 Packer.
 Casing Shoe.
8.5.2 Drilling Controls

A range of controls, similar to those encountered on a rig floor, are mounted on the
Drilling Controls Console. Their operation causes the majority of the dynamic
elements, represented in the animated picture, to respond in a realistic manner. A
number of other dynamic operations are simulated by use of controls fitted on the
Drilling Controls Console. These operations are:
 Load/Unload Mousehole
 Latch/Unlatch Elevators
 Travelling Block Swing Left/Right.
The following Drawworks controls are provided:
 Hand Brake
 Hand Throttle
 Breakout/Makeup Control
 Rotary Control
 Drawworks Main Clutch
The system reacts to operational control according to the selected equipment
characteristics and the loads imposed by the string and well. Movement of the
Travelling Block and its load is shown on the Driller's Window.
The Drawworks can be run with 8, 10, 12 or 14 hoist lines provided the appropriate
scale faces are fitted to the Hook Load/Weight on Bit indicator. The Instructor can
alter the diameter of the Drawworks drum and the transmission velocity ratios.
The driller can lower the drill string under the control of the drawworks brake to tag
bottom. He can increase or decrease the amount of WOB using the brake or the hoist.
The change in WOB is shown on the Hook Load and WOB pointers.
The response of the gauge to changes in WOB is representative in real time and easy
to control in a way suitable for training in relation to field equipment. The
displacement - WOB relationship, reflects the length of the drill string and its weight
in the mud in use.
The WOB is modelled by examining the compression of the stretch in the string
caused by its own weight in the mud. The effect is treated as a compression spring
with a linear rate and having an uncompressed length equal to the drill string’s own
weight-induced stretch. Zero string compression produces no WOB. Full
compression produces maximum WOB, which is equal to the total weight of the string
in mud. During a normal exercise, the string would be correctly maintained in tension
with the WOB less than the weight of the collars. Lowering the string on to the bottom
compresses it and increases the WOB. This effect is modelled for all tubulars handled
in the specification of the simulator.
The stretch in the string is proportional to the square of the length of the string, in
accordance with accepted tables and equations of stretch. The constant of
proportionality is set to match standard stretch tables and is available to the instructor
for tuning. A minimum stretch is set for short strings to improve WOB control for the
driller. The driller can exercise control of the brake and maintain, dynamically, the
WOB during drilling within reasonable, real operating limits of the order of +/- 5,000
lb.
Vertical movement of the Travelling Block occurs in response to operation of the

Drawworks Controls provided at the Drilling Controls Console. Lateral movement
allows the block to be positioned in any of the four main positions. These positions are
selected at the Drilling Controls
Console by use of the Swing Left/Right Control and correspond to:

 Rat Hole.
 Rotary Table.
 Mouse Hole.
 Rack.
The rating of the Drawworks Motor, current and horse power, can be set by the
Instructor during exercise preparation as can be the number of Hoisting Lines and the
Line Break strength. If these pre-selected values are exceeded during operation of the
system the appropriate fault conditions are experienced. In addition, the critical sound
effects are simulated and the Drawworks respond in a realistic manner.
8.6 Blowout Prevention and Well Control System
The simulator is very precise in modelling the operation of the blowout preventers to
ensure correct actions by the driller and accurate response on the control system
instrumentation. Modelling is in accordance to API specifications 16E and RP53.
These models can be customised to meet regulatory requirements worldwide.
8.6.1 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 backpressure to control downhole 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 is 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:

 Two Manual Chokes.
 Manual Choke Inlet and Outlet Isolation Valves.
 Two Remote Chokes.
 Remote Choke Inlet and Outlet Isolation Valves.
 Drill Pipe Pressure Gauge.
 Casing Pressure Gauge.
 Outlet Valves to Flare and Mud Gas Separator.
 Two Choke Line Inlets
 Connection to Standpipe Manifold
 Connection to Kill Line
The Manual Choke Valve has 10 turns from fully open to 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 wellbore. Proprietary models developed for the Swaco
choke are used to simulate the flows through the choke and 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.
Field recorded choke sounds provide an example of the noise made by a fluid as it
passes through the choke. The type of sounds played back are dependent on the type of
fluid passing through the manifold.
 A low frequency, low amplitude squeal is heard whenever mud or a kick
influx liquid is circulated.
 A high frequency, high amplitude squeal is heard when gas is circulated.
8.6.2 Surface BOP Control Console

The purpose of the Surface BOP Console 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 Ram.
 Middle Pipe Ram.
 Lower Pipe Ram.
 Kill Line Valve.
 Choke Line Valve (HCR Valve).
 Annular Pressure Regulator.
 Master Valve.
 Gauges for Accumulator Pressure, Annular Pressure, Manifold
 Pressure and Rig Air Pressure.
 Flow Meter Reset
The surface BOP is modelled on a 13 5/8" 10,000 psi 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 drillstring
elements and tool joints within the stack. Their operation is also governed by possible
malfunctions.
When the master air valve is held ON, the supply of air is fed to the spring-centred
pilot valves so that they become capable of moving the 4-way hydraulic valves which
control the movement of the BOP closing units.
The warning lights on the BOP master panel show the position of the 4-way hydraulic
valve.
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 closure 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 drillpipe and heavy drillpipe 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 that inhibit the normal working of the BOP
stack.
When running a liner section on drillpipe, the pipe rams will seal on the pipes but not
on the liner or pipe joints.
8.6.3 Drill String Valves

Drillstring valves are used to prevent the movement of influx fluid up the drillstring.
Training can be provided in the operation of drillstring valves during well control.
Three types of drillstring 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 during an exercise, should
the student request them.
When a non-return valve is operational, a shut-in drillpipe pressure is obtained by
circulating slowly until the valve is cracked open.
Controls for the installation and operation of the safety and non-return valves are
situated on the Drilling Controls Console.
8.6.4 Subsea BOP Control Console

The purpose of the Subsea BOP Control Console is to provide training in proper
Subsea BOP operation and interpretation of the instrumentation available to identify
correct operation or potential failures. The model has been tuned in consultation with
qualified subsea engineers to ensure proper delays, sequencing and reactions
throughout all operations.
The console is equipped with two annular, four ram preventers, two kill line inlets, two
choke line outlets and eight fail-safe valves. Each of the BOPs and Fail-safe Valves
have illuminating push button controls for OPEN/BLOCK/CLOSE. The simulator
models an 18 3/4" 10,000 psi stack with a 21 1/4" riser and ID choke lines. For deep-
water operations an optional booster line is available and modelled entering the Lower
Marine Riser Package above the upper Annular Preventer. Maximum water depth
capability of the simulator is 10,000 ft.
A set of gauges enable the simulator operator to view the sequential pressure changes
and instrumentation reaction following the activation of any control function.
The model accounts for hang-off of the pipe on any of the pipe rams. Flexibility in
positioning of the choke lines enables circulation from immediately below any of the
pipe rams.
Accumulator sizing parameters set by the Instructor includes:

 Total Accumulator Volume
 Maximum Accumulator Operating Pressure
 Minimum Accumulator Operating Pressure
 Precharge Pressure
 Actuator Flow Rates
 Opening and Closing Value for all BOP Stack Elements
 Accumulator Pump In Pressure
 Accumulator Pump Out Pressure
 Accumulator Pump Output
Accumulator volume calculations are based on Boyles Law and are similar to those of
the NL Shaffer Composite catalogue.
8.6.5 Subsea Diverter System

The diverter system is provided for training in shallow gas diversion and stack gas
clearing procedures. In the case of a floating rig the simulator provides flexibility for
the diverter to be run alone or with the Subsea BOP stack.
The simulator models a Koomey Subsea Diverter Control Console. This system is
fixed with the shaker line beneath the diverter packer however can be modified to suit
the clients needs. Operation of the relevant controls follow regulatory authority
requirements in that closing the diverter packer immediately closes the shaker line and
opens the selected overboard line before the packer is closed.
The diverter accumulator system is separate from the Subsea BOP accumulator
however, it shares the same operational model.
Accumulator sizing variables set by the Instructor includes:

 Total Accumulator Volume
 Maximum Accumulator Operating Pressure
 Minimum Accumulator Operating Pressure
 Precharge Pressure
 Actuator Flow Rates
 Opening and Closing Value for all BOP Stack Elements
 Accumulator Pump In Pressure
 Accumulator Pump Out Pressure
 Accumulator Pump Output
8.7 Equipment and Operational Malfunctions
The simulator model 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.
8.7.1 Hoisting System Malfunctions

The Instructor can initiate the following malfunctions relating to the Hoisting System:
 Failure of Drive Motor
 Loss of Air Supply
 Drill String Overpull
8.7.2 Power System Malfunctions

The DrillSIM 's simulated Diesel-electric power supply system maintains a check on
supply availability and an on-going check of demand against supply limit. Supply limit
is controlled from the Drilling Controls Console. Supply failure is a general
malfunction caused by overload or initiated by the instructor at any time during an
exercise.
Failure of the electrical supply causes all electrical supply and transmission systems to
shutdown. This leads to the following:
 Loss of Mud Pump operations.
 Loss of Drawworks operations.
 Loss of Rotary Operations.
8.7.3 Rig Instrumentation Malfunctions

The instrumentation provided on the various the DrillSIM 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 that can be affected are as follows:
8.7.3.1 Drilling Gauges Console

 Weight on Bit/Hook Load.
 Rotary Torque.
 Rotary Table RPM.
 Pump Pressure.
 Mud Pump 1 SPM.
 Mud Pump 2 SPM.
 Mud Pump 3 SPM
Note: Malfunction of any SPM Gauge will also affect the associated SPM Counter
8.7.3.2 Standpipe Manifold

 Standpipe Pressure.
8.7.3.3 Choke Manifold

 Casing Pressure.
8.7.3.4 Remote Choke Control Console

 Casing - Pressure.
8.7.4 Fluid Handling System

The Instructor can initiate the following malfunctions relating to the Fluid Handling
System:
8.7.4.1 Mud Pumps

 Mud Pump 1 Total Failure
8.7.5 Air Supply Malfunction

The simulated Air Supply System maintains a check on supply availability. Loss of
air supply is a general malfunction, which can be initiated at any time during an
exercise and leads to failure of all air-operated equipment when reservoir pressure is
depleted below operating pressure.
8.7.6 BOP and Well Control Equipment Malfunctions

These include choke malfunctions and surface BOP stack Malfunctions:
8.7.6.1 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 only).
The simulator features 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.
8.7.6.2 Surface BOP Stack Malfunctions

The instructor may activate the following malfunctions:
 Annular Preventer Actuator Failure.
 Annular Preventer Leak
 Blind Ram Actuator Failure.
 Upper Pipe Ram Leak
 Upper Pipe Ram Leak
 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 as
when the failure malfunction was activated.
The hoisting and rotating drag of the rams and AP are included.
8.8 Downhole Effects
During simulated drilling operations, the efficiency of the drilling equipment is
affected by the characteristics of the downhole equipment and geological formations.
The resulting effects of these simulated characteristics are made apparent to the trainee
at the consoles by the instrumentation and facilities provided.
Many downhole effects are controlled by the Instructor and are either pre-defined in
the initial conditions or initiated as a simulated malfunction during the course of an
exercise. They can be considered in three groups:
 Geology.
 Bottom Hole Effects.
 Annular Mechanics.
8.8.1 Geology
Prior to commencement of an exercise, the Instructor selects the geological parameters
to apply throughout the exercise. These parameters represent a number of geological
layers together with their associated properties.
The simulated well geology, for each exercise, can comprise up to 10 formation layers.
A layer can be any thickness in intervals of one foot up to a combined total depth of
30,000 ft.
For each different exercise the relevant properties of six different rock formation types
can be specified. Each layer is specified as a particular rock type to provide the
exercise conditions required. The rock properties can be set to those of different rock
types (e.g., sandstone, limestone or shale) or to those of different samples of the same
general type (e.g., different layers of shale.)
The simulated formation properties of each layer include:

 Rock Strength.
 Abrasiveness.
 Fluid (oil, gas, water).
 Permeability.
A normal and abnormal formation pressure gradient is selectable for each exercise
with a specified transition zone over which the gradient changes. This provides for
training in the detection of abnormal pressures and management of a wide range of
realistic downhole pressure problems.
The Simulator tests for the occurrence of formation fracture producing lost circulation
when appropriate, during all exercises unless inhibited by the Instructor. The fracture
gradient and hence the local fracture strength of the wellbore is set by the instructor for
both the casing shoe and lost circulation zone. Realistic training can be given in the
management of well pressure to avoid formation fracturing and in leak-off testing.
The formation temperature gradient is set and arranged so that temperature increases in
proportion with well depth.
8.8.2 Leak-off Testing
The simulator can be used to provide training in the principles and system responses
associated with performing a leak-off test.
A leak-off test is usually carried out after drilling through the excess cement at the
casing shoe following a successful cementing operation. The simulator will model the
following steps in undertaking a Leak Off test:
 Set height of drill string so that bit is just off bottom.
 Circulate and clean out hole.
 Hoist the bit up into the casing.
 Close upper pipe rams or annular preventer.
 Line up through the cement pump and standpipe manifold.
 Pressure up the well in small volume stages and at a slow rate.
Initially all surface pressures are zero. Once pumping commences, the standpipe
pressure will increase linearly with flow rate until the leak-off point is reached. If
pumping continues a peak is reached. Following this peak a drop occurs until pressure
stabilises to a constant value or the propagation pressure.
From the surface pressure at leak off, the formation fracture pressure at the casing
show can be estimated.
The initial pressure rise is a function of mud compressibility and the volume of mud in
the enclosed system.
This slope will continue to rise until formation leak-off occurs.
Leak-off occurs on the first occasion at a value pre-set by the instructor. Following
formation rupture, the pressure reduces to the steady state value or propagation
pressure.
Subsequent fractures of the formation do not exhibit the overshoot effect but level off
immediately to the steady state pressure. This is true regardless of the reason for
fracture.
8.8.3 Bottom Hole Effects
Drilling efficiency is a function of the characteristics of both the drill bit and the
defined geological formation. These pre-selected factors affect the rate of penetration.
They are modified by the effectiveness of the simulated downhole equipment and
conditions and are dependent on:
 Bottom Hole Cleaning Efficiency.
 Tooth Wear.
 Bearing Wear.
 Differential Pressure.
 Formation Characteristics.
 Well Depth.
 Mud Properties.
 Rotational Speed.
 Weight-on-Bit.
The Bottom Hole Cleaning Efficiency is dependent on the fluid velocity through the
drill bit. The fluid velocity is dependent on the nozzles selected and the hydraulic
power delivered to the bit.
Bit and Bearing Wear are dependent on the type of formation selected, cleaning
efficiency, weight on bit, RPM and type of bit selected. Therefore, as an exercise
progresses a reduced penetration rate is experienced.
8.8.4 Downhole Malfunctions

The Instructor can initiate any of the following malfunctions during an exercise:
 Bit Washout.
 Drill pipe Washout.
 Bit Balling.
 Drilling on Junk.
When the Instructor initiates a Washout of the Bit, the observed effects indicate that
the drill bit has become detached from the drill string. This results in a sudden
decrease in ROP, a rapid reduction in the Standpipe pressure and a reduction in the
reactive torque at the Rotary Table.
When the Instructor initiates Drill Pipe Washout the observed effects indicate that a
split has developed in the drill pipe box. With the passage of time the split will
increase in size, leading to an increase in the flow of drilling fluid from the drill pipe to
the well annulus. This leads to pressure losses, mechanical weakening of the drill pipe
and eventual drill pipe twist off.
The effect of Bit Balling can be seen as a reduction in penetration rate. Furthermore,
attempts by the trainee to clean the bit can be controlled by the Instructor.
The effect of foreign objects in the well is observed as a total loss of penetration rate
and a variation in reactive torque at the Rotary Table.
8.8.5 Downhole Mechanics
Downhole Mechanics simulate the effects of drill string equipment performance and
the behaviour of the formation characteristics in the annulus. Rotary reactive string
torque acting against the drive is based upon the relationship between length and type
of drill string components in use.
8.8.6 Annular Malfunctions

Changes in reactive torque occur when the Instructor initiates related typical downhole
malfunctions. Examples of these are as follows:
 Pipe Twist-off.
 Stuck Drill bit.
 Sloughing.
 Differential Sticking.
 Under Gauge Hole.
The simulator accurately monitors the differential pressure between the annular
pressure at any depth and the formation pore pressure. If geological conditions are
suitable, the differential pressure may cause a kick, lost circulation or a combination
thereof.
It is possible for the trainee to maintain such a high degree of control over drilling
operations that he may not experience the effects of kicks or lost circulation. To
ensure a learning point is achieved for all members of the group there is a facility for
the Instructor to force initiation of these malfunctions.
8.8.7 Torque and Drag Malfunctions.

String torque is the sum of the viscous and drill pipe component friction. Any
variation in these affects the reactive rotary torque that, in turn, has an apparent effect
on the Rotary System.
The Instructor can initiate a range of downhole malfunctions, which will affect the
string torque during a simulation exercise.
When a length of drill pipe is over-torqued, a pipe twist-off may occur. Penetration
halts and drilling fluid flows up the annulus from the point of pipe fracture. A loss of
back-pressure is indicated by the Standpipe Pressure gauge. At the same time, the
Rotary Table Drive Motor increases speed.
The reactive torque applied to the drill string when a drill bit sticks could wind-up the
drill string and create a twist-off situation. Alternatively, the reactive rotary torque
may be sufficient to stall the Rotary Table Drive Motor.
Sloughing or the accumulation of solids in the annulus, causes drill string motion to be
restricted. The simulated vertical and rotary resistance to the motion of the drill string
indicate the effect. If no remedial action is taken, the Rotary Drive Motor may stall-
out.
Differential Sticking results when the drill collars are forced by differential pressures
against a low-pressure permeable geological formation. This scenario results in the
loss of drill string movement.
The effects of drill pipe wind-up are simulated and increased reactive torque is applied
to the Rotary Table.
A key-seat is formed when the rotary action of the drill string wears a groove into the
sidewall of the hole. Stuck pipe problems may occur when trying to pull the drill-
collars, stabilisers or drill bit up through the key-seat. This results in increased hook
load as the string is pulled through the restriction, resulting in overpulls and tight hole.
During a tripping out operation, the Instructor can increase the drag force applied to
the drill pipe, resulting in overpulls and tight hole.
8.8.8 Fluid Flow and Pressure Loss

Lack of control of the mud weight and pressures in the well will eventually lead to loss
of drilling fluid to the formation layers. This occurs when the fluid pressure increases
beyond the formation fracture pressure and causes a formation fracturewhich then
results in fluid being then lost to the formation. This results in decreased or lost
surface return flow and a consequent loss of fluid volume. Lost circulation effects may
occur naturally as part of a simulation exercise or can be initiated by the Instructor.
The Instructor can also inhibit the effect.
The rate of solids addition to the drilling fluid from the drilled formation cuttings
depends upon the rate of penetration. The consequent change in fluid density and
transport time of cutting to the surface are accounted for in simulation. At least one
formation may be designated as a potential kick zone.
All simulated formation layers exhibit formation pressure. If the hydrostatic head of
circulating fluid is not maintained at a sufficiently high level, an influx, or kick, of gas,
oil or salt water, into the drill hole, may occur resulting in:
 An increase in penetration rate.
 An increase in return flow-rate.
 A reduction in standpipe pressure.
 A pit volume gain.
Careless operation of kick control by the trainee could lead to formation fracture or
underground blowout. Kicks may occur naturally as part of the simulation exercise or
may be initiated, or inhibited deliberately by the Instructor.
If insufficient judgement or control is exercised during kick control either of the

following may occur:
 Multiple kicks - further influxes will be experienced.
 Underground blowout - a formation fracture will occur through overpressure
of the annulus and all fluid will be lost to the formation.
Raising the drill string too fast can cause a sufficient drop in effective hydrostatic
pressure to cause formation fluids to enter the borehole, i.e. 'swabbing'. Lowering the
drill string too fast can cause a pressure 'surge' sufficient to overcome the formation
pressure or the formation fracture pressure, resulting in lost circulation.
A loss of hydrostatic pressure caused by either swabbing or low annular mud level can
result in kick occurrence. Gas that migrates in a well which has not been shut-in, is
modelled by the Simulator with changes in pressure and volume increases in
displacement. A gas kick migrates at an accelerated rate controlled by the Instructor or
in a real time frame controlled by the software model.
8.9 Well Control
This part of the Supplement to the DrillSIM specification defines those aspects of the
simulation which deals with well control issues and associated phenomena occurring
underground. It assumed that industry accepted pit drills and procedures will be
adopted in controlling the various phenomena discussed.
8.9.1 Causes of Kicks

Well kicks are defined as the influx of fluid consisting of gas, oil or salt water into the
well bore by a pressure underbalance. 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 borehole. Formation pressure increases with depth depending on
the pore pressure gradient.
The model 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
initial condition set.
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 thickness of the zone.
The well snapshot configured prior to exercise establishes the depth of the borehole 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 (i.e. have the kick zone exposed
in the borehole wall, just beneath the bit or ready for the student to drill into).
Underbalance 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
 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 underbalance 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.
8.9.1.1 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 downhole 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 under-balanced when flow rate or downhole resistance is reduced.
An influx occurs at a rate depending on the magnitude of the imbalance.
8.9.1.2 Low Mud Weights in the Annulus

The hydrostatic pressure in the annulus at any point is a function of the hydrostatic
head exerted by the column of fluid and the density of the fluid above that point.
Low annular 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.
8.9.1.3 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 underbalance 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 drillstring being withdrawn during
tripping-out or through lost circulation due to formation fracture.
8.9.1.4 Swabbing on Trips
Downhole pressures exhibit a drop when the drillstring is withdrawn from the borehole
due to the piston effect of withdrawing a full gauge downhole tool (drill bit, stabilisers
etc).
The magnitude of the pressure drop depends on the geometry of the drillstring 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 has been 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 the driller takes no corrective action, the well will begin to
flow due to the underbalance created by the reduced hydrostatic head. This may also
pose a problem as the influx fluid progresses up the wellbore and encounters the other
exposed formations, this can lead to secondary influxes developing and changing a
minor problem into a severe one.
8.9.1.5 Lost Circulation

Lost circulation can occur as either a direct formation effect (encountering a very
permeable formation) or as the result of exceeding the formation fracture pressure of
the exposed formation(s).
Losses to the formation as a direct result of the formation properties (e.g. losses taken
to a permeable sandstone) may cause either partial or complete losses. This problem
can be solved by either pumping Lost Circulation Material (LCM) to plug the
formation pore spaces or by relying on the mud properties to develop a layer of filter
cake and accept the losses. If sufficient losses develop, the level of mud in the annulus
may drop to a level where the hydrostatic pressure will drop to a level where an influx
can occur.
A change in the formation fracture pressure with depth occurs, which is in part caused
by a variation in the Poissons Ratio of the formations with depth. When fracture
occurs, the rate of loss will be governed by the pressure difference across the fractured
zone.
Fracture occurs at one zone. For the purposed of the simulation, lost circulation will
only occur as the result of formation fracturing. It will not occur as a result of an
exposed low-pressure permeable formation.
The fracture pressure of the formations is a function of Poissons Ratio for the
formation, the over burden stress and the formation pressure.
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 modelled 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
will be lost. The percentage of losses can be changed by the instructor at any time and
can be set to anything up to 100%. Formation fracturing (which will lead to a loss of
circulation) can be inhibited by the instructor at will, allowing the instructor to train
the students in an exercise which would be unnecessarily complicated by lost
circulation problems.
A relationship is used to define Poissons Ratio as a function of depth for a typical

geological area. This relationship is suitable for general training.
8.9.1.6 Failure to Fill the Hole on Trips

The simulator model 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 can be significant enough to cause an exposed reservoir to flow
formation fluid into the wellbore.
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 is the only rig floor simulator worldwide that 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.
8.9.2 Types of Kicks
The simulator models three different types of kicks to provide the student with a
means of recognising the characteristics of a kick influx when closed in and 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 or Steam for the Geothermal Well option.
 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 wellbore model assumes the Instructor set
reservoir temperature and calculates the compressibility factor for the gas at the top of
the reservoir. Gas compressibility is recalculated on each iteration of the model and is
then used to determine the new volume of expanded gas.
It is possible to set the specific gravity of the salt-water kick fluid higher than the
specific gravity of the drilling fluid being used to drill the well.
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 borehole and underbalance
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 permeability.
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 will
stabilise.
Generally, the casing pressure exhibits a higher value than that of the drillpipe. 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 downhole 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 estimated density, the fluid type can be assumed.
All fluid types are handled assuming single-phase flow characteristics.
Oil influxes will be assumed to be “dead” containing no dissolving gas. Influx

expansion during migration will only occur in the case of a gas or optional steam
influx.
8.9.3 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.
For normal drilling operations, the pressure loss occurs in the annular space between
the drillstring and borehole.
During a well control circulation, the pressure loss exerted by the choke and associated
pipework is added. Frictional pressure losses are related to flow-rate. The bottom hole
pressure will change according to and depending on the flow-rate and the resistance to
flow, it is therefore possible that a balanced or overbalanced well may become
underbalanced when the mud pumps are stopped and the frictional losses fall to zero.
If a potential kick zone is exposed along the well path then this underbalance 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.
Downhole pressures are monitored dynamically for changes due to both hydrostatic
and frictional pressures. Whenever underbalance occurs and a kick zone is exposed to
the well bore, an influx will occur (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.
8.9.4 Multiple Kicks

The simulator will model multiple kicks to give the student experience in taking in
additional volumes of kick fluid during the process of killing a well.
The effect of the student’s control of the rate of circulation combined with the inherent
resistance to flow of the surface equipment may be sufficient to create underbalanced
pressures across potentially kicking formations. Unless otherwise prohibited, this
underbalance will result in an influx occurring.
Once the influx has been recognised, the trainee should begin to kill the well and
circulate out the influx fluid using his chosen method of control. However, if he/she
allows underbalance to occur again by careless operation of the mud pumps or choke
valves then a secondary kick will occur.
Downhole pressures are monitored dynamically for changes due to both hydrostatic
and frictional pressures. Underbalance 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 twenty 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.
8.9.5 Kick Influx Density
The simulation model enables accurate influx density calculation for training on the
effects of surface pressures while killing a kicking well. Determination of influx fluid
density and hence type will enable the trainees to prepare themselves for handling the
influx when it arrives on the surface. Furthermore it may dictate the method of well
control used to reduce casing shoe pressures in long open hole sections or require
bullheading 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 pressure exerted at bottom hole comprises the
sum of the individual pressures exerted by each fluid slug in the annulus and in turn
the individual component pressures depend upon the density of the 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 the kick formation pressure and the 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
drillpipe 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 to be constant throughout its length.
8.9.6 Influx Flow Rate

The magnitude of the formation fluid influx is entirely dependent upon the downhole
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 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.
8.9.7 Reservoir Drawdown and Stabilisation

The mathematical model simulates the decay and recharge of a formation during its
flow into the well. Standard reservoir engineering equations are used to build this
model.
The phenomena of drawdown 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 of the model enables formation flow testing and evaluation.
8.9.8 Gas Expansion

An influx of gas into the wellbore 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
stabilised. 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 downhole pressures respond dynamically to the volumes, heads and
densities of downhole 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 wellbore however the simulator models the influx temperature
reduction at a rate less than the geothermal gradient reduction as the influx moves up
the wellbore. Temperature of the moving influx is dependent on pumping and
migration rates.
8.9.9 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 drillstring 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. The
casing pressure will gradually increase as the bubble moves up the annulus until near
full formation pressure is indicated. Downhole pressures and drillpipe 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 blowout 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
0-7,000 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.
8.9.10 Underground Blowout

The simulator provides the Trainees with experience of the various sequences of
events that would lead to underground blowout.
The mathematical model dynamically monitors downhole conditions for kick influx
from high-pressure permeable formations and for formation fracture resulting in lost
circulation.
It is possible for both phenomena 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 blowout 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 underbalances, 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 backpressure 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 flow-rate.
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 models are totally independent in their operation.
Downhole 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 deactivated the
occurrence of an underground blowout 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 blowout effectively marks the end of a simulation

exercise. The possibility of recovery depends entirely on the degree of the problem
created by the student and the model.
8.9.11 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 modelled
during normal rig operation.
 Drillpipe Pressure.
 Casing Pressure.
With these limited facilities the student is able to monitor drilling performance,
diagnose malfunctions or anticipate and control impending hazardous situations in
both forward and reverse circulating modes.
The complete range of pressure changes 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 downhole circulating network.
During normal circulation, while drilling, surface pressures arise from frictional
pressure losses through the drillstring, bit nozzle and annulus. These pressures are
relative to mud flow-rate and efficiency.
In this situation drillpipe 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
drillpipe pressure depending on the bottom hole pressure and hydrostatic head exerted
by the mud column in the drillstring. This may result in zero reading of drillpipe
pressure if the formation is 'drawn down' dramatically.
Following a correct shut-in procedure both drillpipe 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.
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 'drillpipe' 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 drillpipe 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 travelled by
the 'pressure change' through the fluids being circulated.
8.9.12 Kicks While Drilling Surface Hole

The simulator models kicks from shallow formations while drilling surface hole. If
equipped with a Surface or Subsea Diverter system the necessary procedures can be
taken to divert the kick while displacing the well with heavy mud.
8.9.13 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 models 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 student’s 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 drillpipe 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 drillpipe 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.
8.9.14 Kicks While Tripping

Simulation models are available to demonstrate the phenomena experienced when an
influx of formation fluid occurs while tripping and to instruct them 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 drillstring.
 Low mud level in the annulus, due to displaced drillstring.
The primary surface symptom of a kick while tripping is improper hole fill up from the
trip tank. While hoisting the drillstring, a pressure reduction downhole 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 the driller does not take quick action.
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 blowout 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.
8.9.15 Stripping
The simulator is capable of handling a number of stripping methods in the
recommended volumetric method developed by Shell. The simulator provides a
separate strip tank to enable implementation of the Shell method.
Use of the annular preventer for stripping is preferred because it is a faster and simpler
operation. Also there is less wear and tear of annular units during stripping operations.
Pressure from the closing unit pumps is controlled by a regulator valve, which
maintains the chosen value of closing pressure to the annular preventer. The regulator
allows hydraulic fluid to flow back and forth between preventer and fluid reservoir to
control pressure. This feature will be useful as tool joints pass through the preventer
packing element. The regulation means that no pressure changes are seen on the BOP
panel gauge when joints pass through the preventer.
The choke manifold is aligned to the trip tank when stripping commences. The effects
of drag through the BOP and tool joints passing through the annular are seen on the
weight indicator and annular pressure gauge on the BOP control console.
As the pipe is stripped the casing pressure is maintained constant at the pre-calculated
value by choke adjustment. After stripping each stand in the choke is closed and the
pipe filled. An amount of mud equivalent to the wet displacement of the drillpipe is
drained from the Trip Tank into the Strip Tank.
These procedures are carried out until all the pipe is returned to bottom. At specific
intervals the casing pressure must be increased due to the expansion of the influx in
the well. When the pipe is returned to bottom the first step of the Driller's method can
be used to circulate out the influx.
8.9.16 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 models 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 Trainees' skills in
handling situations of this nature.
8.9.17 Kicks While Running Casing and Liners

The simulator can be used to provide training and experiencing of the influx of
formation fluids while running casing or liners.
The driller may detect an influx while running casing or liners by an excess of fluid
leaving the hole compared to that which should be displaced.
The following indications and facilities are assumed:

 Kick occurs.
 Detected by excess flow. B.O.P. can be closed.
 May or may not have float installed at bottom of string.
Discussion and definition regarding the Control Procedure must be achieved before the
simulation can be completed.
8.9.18 Driller's Method of Well Control

The simulation modelling 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 guideline 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 drillstring
pumping from the reserve tank. The lighter mud from the well enters the active
system from the Mud Gas Separation 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.
8.9.19 Wait and Weight Method of Well Control
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 mud of the required density, mixed in
the inactive tank is pumped into the well.
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 drillpipe pressure).
The casing pressure is held constant until the pump is at the kill rate. Adjustments to
the choke are made to bring the drillpipe 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.
When the well is shut-in and circulation has ceased, there exists the potential for a
stuck pipe to occur. The occurrence of stuck pipe during the wait and weight method
is an instructor initiated action. Experience has also shown gas will migrate a
significant amount before well killing can commence. The models allow for the
migration and the necessary bleed-off of pressure required to maintain bottom hole
pressure constant.
8.9.20 Bullheading
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, bullheading can be employed. Gas

influx size can be estimated from surface readings.
Bullheading 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 cement pump to the Kill Line are
opened and a mud volume in excess of volume of influx is pumped into the annulus.
Flow from the drillstring is blocked by closing either the lower Kelly valve or
installing an inside blowout 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 drillpipe pressure. The well is successfully killed with the
shut-in pressures are zero.
8.9.21 Volumetric Method of Well Control

In a kick situation if circulation is impossible due to a plugged drill string or there
being no pipe in the hole, constant bottom hole pressure must be maintained whilst the
influx migrates to surface. The simulator models 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 Mud
Gas Separation tank to the Trip tank or to the Strip tank to provide a smaller tank with
which to accurately gauge the bleed-off 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.
8.9.22 Concurrent Method of Well Control

The simulator model is capable of handling up to 50 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 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.
8.9.23 Low Choke Method of Well Control
The simulator enables this method of well control to be performed for any kick taken.
Typically the method is used for very shallow wells with minimal casing set. The
method is similar to the diversion of shallow gas with the diverter system however,
flow is through the choke manifold and possible multiple chokes.
The model will continuously feed additional gas to the system if the bottom hole
pressure is under reservoir pressure. Formation flow will be inhibited if the bottom
hole pressure is increased by high annular pressure losses and flooding the well with
heavy mud.
The model accounts for all increases in shoe pressure and will cause losses to occur if
the fracture gradient is exceeded during implementation of this method.
8.10 Cementing
The simulator provides the facilities for modelling primary single stage cementing
using a cement head.
8.10.1 Cement Head

The purpose of the cement head is to provide training in the correct operation of
cementing procedures.
The cement head operation allows use of the following facilities:

 Three valve manifold
 Two Plug Pins
 Two Plug Release Flags
 A rupturable Cement Plug
 A non-rupturable Cement Plug
 Selection of Spacer/ Lead slurry/ Tail slurry to the Cement Pump
Primary single stage cementing commences with the pumping of pre-wash chemicals
and/or a freshwater spacer down pre-run casing followed by the launch of a rupturable
cement plug. The instructor has the facility to specify the rupture pressure of the plug
or indeed the malfunction of incorrectly launching a non-rupturable plug in the first
instance.
The operation of the three valve manifold and the bottom plug pin model the launch of
the plug. The plug will not be launched unless the correct alignment of valves is used.
Upper Valve Closed
Middle Valve Closed Allows flow through the cement head
Lower Valve Open
Upper Valve Closed
Middle Valve Open Launch the bottom (rupturable) cement plug
Lower Valve Closed
Upper Valve Open
Middle Valve Closed Launch the top cement plug
Lower Valve Closed
A single selector allows the switching of input to the cement pump from spacer/pre-
wash to lead slurry and again to tail slurry on the Student Station.
The rig floor pumps screen enables monitoring of the number of strokes of each
cement type pumped.
Launch of the non-rupturable cement plug is achieved with the release of the top pin
and the correct operation of valves on the cement head manifold. The plug can be
launched using standard mud from either the active or reserve mud tanks.
The effect of pump pressure and/or hydrostatic head rupturing the lower plug at the
drill collar is modelled at the specified pressure. The top plug can be held under
pressure for the required setting time. (The option is available of using a float valve at
the drill collar).
8.10.2 Cement Pump Console Option (DrillSIM-5000)
The option is provided of a twin diesel engine cement pump control for use in
cementing operations.
The cement pump panel allows simulation of the following functions:
 Start diesel engine for each pump
 Stop diesel engine for each pump
 Observe engine RPM for each pump
 Select a gear ratio for the engine-to-pump transmission
 Observe a “lock-up” indicator lamp, which illuminates whenever the fluid clutch
for each pump is successfully engaged. On over-torque conditions, the fluid clutch
will slip and the lamp will be extinguished.
 Observe discharge pressure for each pump
 Observe and reset a flow totalizer for the combined pump output
 Observe a flow rate meter for the individual pump output
 Observe a flow rate meter for the combined pump output
If the optional cement pump console is not ordered, the standard DrillSIM-5000
drilling controls console provides for a single cement pump which then replaces Mud
Pump 1.
8.11 Workover Introduction
Please refer to Chapter 9 (Workover).
Workover Manual i
1. INTRODUCTION.....................................................................................................1
1.1 FULL-SIZE EQUIPMENT OVERVIEW..........................................................................................................1
1.2 WORKOVER MIMIC PANEL OVERVIEW - PAWSIM 5000......................................................2
1.3 WORKOVER MIMIC PANEL OVERVIEW - PAWSIM 500........................................................3
1.4 WORKOVER TOUCH SCREEN OVERVIEW - PAWSIM 50 & PAWSIM 20...................................4
2. EQUIPMENT HARDWARE........................................................................................5
2.1 FULL SIZE EQUIPMENT...........................................................................................................................5
2.1.1 Workover Manifold - Standard..........................................................................6
2.1.2 Wellhead & Christmas Tree - (Standard)............................................................8
2.1.3 Well Services BOP - optional............................................................................9
2.1.4 Auxiliary Pumping Console – optional..............................................................11
2.1.6 Workover Mimic Panel: PAWSIM-5000................................................................12
2.1.5 Workover Mimic Cabinet: PAWSIM-500............................................................15
2.1.6 Workover Screen – PAWSIM 50, PAWSIM 20 & DRILLSIM-5................................16
3. INSTRUCTOR STATION.........................................................................................17
3.1 CONFIGURING A WORKOVER EXERCISE: RIG SELECTION......................................................................18
3.2 WELLBORE GEOMETRY.........................................................................................................................21
3.3 CASING............................................................................................................................................... 21
3.4 PERFORATIONS.................................................................................................................................... 23
3.4.1 Tubulars – Setting up the work string..............................................................24
3.5 CONFIGURING TUBING AS THE WORKSTRING.........................................................................................25
3.6 TUBING............................................................................................................................................... 26
3.7 DOWNHOLE EQUIPMENT.......................................................................................................................27
4. STUDENT STATION – FULL SIZE EQUIPMENT........................................................28
5. SCOPE OF SIMULATION........................................................................................29
5.1 OPERATIONAL OVERVIEW.....................................................................................................................29
5.2 CONFIGURING A WORKOVER EXERCISE................................................................................................ 30
5.3 WORKOVER EXAMPLE OPERATIONS ON THE SIMULATOR........................................................................ 31
5.3.1 Well Control - Reverse Circulation...................................................................31
5.3.2 Flowing The Well..........................................................................................32
6. SUMMARY............................................................................................................33

DrillSIM/PawSIM Operator’s
Manual
Workover Manual 1
1. INTRODUCTION
This manual is a generic document for Well Servicing and Workover operations which covers
the full range of PAWSIM simulator equipment, from the full size rig floor environment to
the portable system and the screen based trainer. You should read only those sections that
apply to your physical equipment. Although the entire document may be of general interest,
only specific sections will apply to each installation depending on the equipment delivered
and the configuration implemented. The previous table sets out those sections most relevant
to the client installation.
The document features the styles of different equipment manufactured by Drilling Systems
for workover operations. The simulation equipment is configured to primarily address
workover well control training for the wellsite personnel according to guidelines and
regulations required by the various regulatory authorities. In most cases, once the well is dead
the exercise is deemed completed and this satisfies the competence testing requirements.
Essentially in the majority of exercises, the simulator requires the trainee to take over a
producing well and kill it with two circulations and prepare the well for further well servicing
or well intervention techniques. The first circulation will reverse out the tubing contents and
the second will remove the well fluids from the tailpipe annulus once the packer is pulled.
The PAWSIM simulator is unique in its modelling area in that wellbore fluids are completely
tracked under the packer and around the tailpipe region of the well. The workover simulator
can also be used to bring a well back on stream and metaphorically hand back responsibility
to the production department.
In general the software interfaces for monitoring and controlling the Workover equipment are
similar and specifically, the Instructor Interface is the same for all the equipment options. In
the full size equipment the student station interface is used by the trainee for control over key
parts of equipment, such as running tubing plugs and cycling the sliding sleeve to the open or
closed position. Since the Standpipe and Choke manifolds in the PAWSIM range of
simulators are modelled around the offshore, platform and jackup environment, it was
decided to implement a land style choke manifold for workover operations. This provides an
opportunity for the instructor to focus on a standard land operation offering an additional
dimension to the training. There are four workover options availble;
 PAWSIM - Full Size equipment, including Wellhead & Christmas Tree, land
manifold etc.
 Mimic Panel on a Stand for the PAWSIM-5000 Full Size, rig floor simulator
 Portable Mimic Panel for the PAWSIM-500, portable drilling and well control
simulator
 A screen based representation of a mimic panel for the PAWSIM 50, PAWSIM 20
and PAWSIM 5
1.1 Full-size Equipment Overview

The full size equipment sets out to provide realistic representation of those items found in the
field. The equipment includes:-

DrillSIM/PawSIM Operator’s
Manual
 The production tree (Christmas Tree); a full size representation mounted on top of
the Wellhead, fabricated from steel as one unit and provided with several valve
hand wheels, including a swab valve, master valve and two wing valves.
 The Workover steel manifold is a full size representation and is provided with
valve hand wheels, pressure gauges, a fixed bean choke, a manual choke and
remote choke that is controlled via the standard remote choke console.
 The Well Services BOP Control Console is a 1m x 1m panel mounted on to a
1.8m high stand and allows control over one annular, one blind ram and one pipe
ram.
 Sizing of the fixed bean choke is provided via the Instructor Interface. The
production choke is also configured through the Instructor Facility.
 The rig floor graphics depict a representation of the Wellhead and Christmas
Tree, status of the valve on the workover manifold and a cross sectional view of
the well services BOP.
 Tubing Plugs, downhole valves and circulation ports such as the sliding sleeve are
controlled via the workover menu on the student station. The packer is also seated
or unseated via the student station.
 The optional, auxiliary pumping console, provides a separate pumping unit to the
rig pumps. In this situation, it is possible to set up separate exercises for the
drilling simulator and the workover simulator at the same time.
1.2 Workover Mimic Panel Overview - PAWSIM 5000

A second option for the PAWSIM-5000 rig floor environment was developed where
classroom space was limited and full size equipment could not be installed. The design is
based around a 1m x 1m mimic panel mounted onto a 1.8m high stand with a screen-print of
the workover manifold, Wellhead and Christmas Tree. The equipment includes:-
 A production tree is depicted on the mimic panel. The production choke can be
configured through the Instructor Facility.
 The Wellhead is depicted on the mimic panel with several 2-position switches for
the wellhead valves.
 The Workover manifold is depicted on the mimic panel with a fixed bean choke,
set via the instructor facility manual choke (controlled via a rotary potentiometer)
and a remote choke controlled via the remote choke console.
 The Tubing and Annulus analogue pressure gauges are mounted into the panel.
 Digital flow in/out and two volume totatilisers are housed on the mimic panel.
the well services BOP. The standard Surface BOP is used if a specific well-
services BOP is not available.
controlled via pushbuttons on the mimic panel. The packer is also seated or
unseated using pushbuttons.
 Downhole valves and circulation ports such as the Tubing Plug and sliding sleeve
are controlled via illuminating push buttons on the mimic panel.
1.3 Workover Mimic Panel Overview - PAWSIM 500

The mimic panel for the portable PAWSIM-500 drilling and well control simulator is a
similar style to the full size mimic panel but sized appropriately for the 500-style cabinet. The
cabinet is 600mm x 600mm and lays back on its swinging arms to prevent gauge parallax
reading errors.
 The production tree and the Wellhead are depicted on the mimic panel with 2-
position switches for the valves. The production choke can be configured through
the Instructor Facility.
 The Workover manifold is depicted on the mimic panel with a fixed bean choke,
set via the instructor facility manual choke (controlled via a rotary potentiometer)
and a remote choke controlled via the remote choke console.
 The Tubing and Annulus analogue pressure gauges are mounted into the panel.
 Digital flow in/out and two volume totalisers are housed on the mimic panel.
the well services BOP. The standard Surface BOP is used if a specific well-
services BOP is not available.
controlled via push buttons on the mimic panel. The packer is also seated or
unseated via the use of pushbuttons on the mimic panel.
 Downhole valves and circulation ports such as the Tubing Plug and sliding sleeve
are controlled via illuminating push buttons on the mimic panel or via the
Workover control menu on the student touch screen
1.4 Workover Touch Screen Overview - PAWSIM 50 & PAWSIM 20
The touch screen version portable PAWSIM-50, PAWSIM-20 drilling and well control
simulator is a similar style to the portable 500-style cabinet.
 The production tree and the Wellhead are depicted on the screen with touch style
2-position switches for the valves. The production choke can be configured
through the Instructor Facility.
 The Workover manifold is depicted on the touch screen with a fixed bean choke,
set via the instructor facility manual choke (controlled via "inc" and "dec" touch
buttons) and a remote choke controlled via the remote choke screen / console.
 The Tubing and Annulus analogue pressure gauges.
 Digital flow in/out and two volume totalisers.
controlled via touch-buttons. The packer is also seated or unseated via the use of
touch buttons on screen.
2. EQUIPMENT HARDWARE
This section details the equipment specification for the three styles of workover option
produced by Drilling Systems. The three options include:-
 Full Size, equipment, including Wellhead & Christmas Tree, Steel Land Manifold
etc.
 Mimic Panel on Stand for the PAWSIM-5000 Full Size, rig floor simulator
 Portable Mimic Panel for the PAWSIM-500, portable drilling and well control
simulator
2.1 Full Size Equipment

The full size equipment offered with the PAWSIM-5000 drilling and well control simulator
includes the following options:-
 Workover manifold Standard
 Wellhead and Christmas Tree Standard
 Well Services BOP Optional
 Auxiliary Pumping Panel Optional
All the equipment is manufactured from steel. Drilling Systems is the only manufacturer to
offer steel components as standard. These components are deisgned to last a life-time and
withstand the day to day use by field seasoned personnel.
The steelwork is painted red, the system used in the field to denote high pressure pipework.
The equipment provides a sense of realism for the student and focuses the attention to the job
in hand.
2.1.1 Workover Manifold - Standard
The schematic below shows the layout of the full size steel manifold. There are 13 valves
controlled through manual hand-wheels that provide the open or closed status and one valve
for the manual choke that provides a variable position. The remote choke is controlled via the
remote choke console. Both the fixed bean choke on the workover manifold and the fixed
bean production choke are set via the Instructor Station.
The Workover manifold provides a connection from the rig pump (and/or optional auxiliary
pumps) to the annulus and tubing. This allows both forward and reverse circulation.
Downstream of the three chokes are connections to the Mud Gas Separator and the flare.
Fluid returns going to the Mud Gas Separator are returned to the active system whereas
returns directed to the flare are lost.
The output from the Mud Gas Separator can be directed either into the Active system or the
Trip tank for more accurate monitoring of the returned volume via the student station. The
direction of the flow can be changed by altering the state of the valve downstream of the
separator. If this valve is in the open position then the fluid coming out of the separator will
be going into the Trip Tank and if the valve is closed then the output from the seperator will
directed into the Active system..
The manifold valves are controlled via alloy cast hand wheels that must be turned 10 times to
move from fully open to fully close. A proximity switch is set at approximately mid-way
position changing the mathematical model’s interpretation of any valve from open to close.
The manual choke is controlled via alloy cast hand wheel that must be turned 10 times to
move from fully open to fully close. A 10-turn potentiometer is linked into the hand wheel
assembly and provides a variable analogue signal of the valve position status. This in turn
provides the operator with direct control of restricting the flow returning from the annulus or
tubing.
2.1.2 Wellhead & Christmas Tree - (Standard)
The full size Wellhead and Christmas Tree is fabricated from steel and stands some 3 metres
high. A stepladder is provided to enable trainee access to the upper valves on the Christmas
Tree.
The Wellhead system has three spools retaining three casing strings which can represent any
size required. However the actual physical sizes are:-
 20” Casing Head Housing with 2 outlets for ‘C’ Annulus
 20” x 13-3/8” Casing Spool with 2 Outlets for ‘B’ Annulus
 13-3/8” x 9-5/8”casing Spool with 2 outlets for ‘A’ annulus
Three gauges are mounted on the spool outlets to display pressure in each annulus. The
trainee lines-up the chicksan to a specific outlet via the Student Station for reverse circulation.
The Wellhead ‘Y’ block McEyoy style Christmas Tree one swab valve, one master valve and
2 wing valves. One left of the Christmas Tree is lined up to the workover manifold or
production and the right hand side for emergency kill purposes.
2.1.3 Well Services BOP - optional
The well services BOP is a separate panel mounted on a 2m stand and provides independent
pressure control over the well. The well services BOP is a specific item of equipment
installed when the client wished to focus on well service operations without using any of the
standard rig equipment, viz. a viz. the rig pumps. It is usually purchased in conjunction with
the auxiliary pumping console. The independent well services BOP console allows the
simultaneous execution of a drilling exercise and a workover exercise.
ANNULAR
PUMP
ACCUMULATOR PRESSURE MANIFOLD PRESSURE

OPEN CLOSE
DEC I NC
ANN ULAR
AI R PRESSURE
BLIND RAMS PRESSURE
OPEN CLOSE
MASTER AI R
PIPE RAMS
OPEN CLOSE
KILLLINE CHOKELINE
The well services BOP allows the trainees the ability to run and pull the completion and
circulate out well bore fluids under pressure. It can be connected to the tubing bonnet via a
wireline riser with the Christmas Tree installed or using the well services riser with the
Christmas Tree removed. These risers are not depicted graphically and the instructor must
inform the trainee of the actual configuration for better understanding. If the Well Services
BOP is installed the lights on the conventional rig BOPs will not light up when a well
services snapshot exercise is loaded. The well services BOP has the following ram and
preventers :-
 Annular Preventer
 Pipe Ram
 Blind Ram
 Choke Line
 Kill Line
Control over the open or closed status of the rams or annular is physically achieved by
throwing the respective lever.
The status of each ram is indicated by an open (green) or closed (red) lamp that is fully
modelled with the functionality of the lightening and operating sequence of the BOP.
A master control air valve, controls pneumatic power to the BOP control solenoids.
A green accumulator running lamp illuminates when the accumulator pumps is triggered by
low accumulator pressure.
The well services BOP has the following analogue gauges mounted into the face of the
panel:-
 Accumulator Pressure
 Annular Pressure
 Manifold Pressure
 Rig Air Pressure
2.1.4 Auxiliary Pumping Console – optional
PUMPPRESSURE TO AL FLOW PUMPPRESSURE
000 000
40 0 60 0 b p m- 3 mm/ i n 40 0 60 0
DR IL NI G RD IL NI G
2 0 0 SY ST EM S 8 0 0 2 0 0 SY TS ME S 8 0 0
0 00 1 0 00 0 0 00 1 0 00 0
OTT ALVOLUME PUMPED
000 000
b bl s m-3
T OAT L V OL MU E
PUMP 1 PUMP 2
RE S ET
000 000 OF F ON OF F ON
000 000
b p m- m3 m/ i n ENGINE b p m- m3 /mi n
P UM P 1 POWER P UM P 2
RPM T R NA S MI S OI N RPM
T RA NS MI S OI N
000 000 000 000
LOC K UP
OL C K
PU
PUMP 1 TH ROT T EL PUMP 2 THR OT T EL

N1 N1
2 2
3 3
4 4
5 5
P UMP 1 T R NA S S HIF T RE
P U MP 2 T R NA S S HIF T RE
PUMP 1 PUMP 1 PUMP 2 PUMP 2

S T A TR S HUT DOWN S HU T DOWN S T A TR
The Auxiliary Pumping Panel is an optional console representing a pumping unit specifically
for workover operations. The console can control two duplex or triplex pumps and these are
configured via the Instructor Station.
The key advantage to having the auxiliary pumping unit is to allow simultaneous operations
of the drilling simulator and the workover simulator. In this situation two groups of students
can be trained at the same time by two separate instructors.
The auxiliary pumpers console is also be used for cementing operations where the cementing
pack was ordered and installed. Again the console can be configured to control two Triplex
Pumps typically found on any modern day cementing skid unit.
The auxiliary pumpers controls include the following items for each engine:
 Gear Shifter
 Engine Throttle
 Pressure Gauge
 Power off/on switch
 Pump Output Rate Digital Meter
 Engine RPM Digital Meter
 Start-up and shutdown buttons
2.1.6 Workover Mimic Panel: PAWSIM-5000
TUBI NG PRESSURE
LF OW OUT MUD PUM PS/ OT T AL ST ROKES
R eset
DRIL L NI G SYST EMS
F L OWIN AUXPUMPS/VOL UMEPUMPDE

R eset
DRIL LSMI 05 0
T UBI GN
FL AREMANUAL CHOKE Pr o d c t io n
IF XDE CHOKE
PUMPS
REMOET CHOKE
DEGASSER C
ANNUL US
WEL L HEDA ANNULUS PRESSURE B

PACKER RELEASE REMOV ED SET
I SNT AL L EDDRILLING ANNUL US C B

YSST EMS A A
SL DI I GN
TUBI GNSL EEVE
PUG REMOVED CL OSE
SETOP NE
DRIL LSMI 05 0
1.8m
1.0m
The mimic panel simulates all the functionality of the full size Workover system including the
Wellhead, Production Tree, Production Choke, Workover manifold, the pressure gauges and
pushbutton controls to perform all of the necessary downhole tool operations.
The valves on the Workover manifold, Christmas tree and Wellhead are represented by 90
Degree switches, which are illuminated in the open position. This facility has been provided
to enhance visual clarity for the trainee. Two 150mm analogue pressure gauges provide
readings for tubing pressure and annulus pressure.
Four pairs of non-latching illuminating pushbuttons are provided to indicate the status of the
various surface and downhole ancillary related equipment:-
 Packer Set/Unset
 Sliding Sleeve Open/Closed
 Tubing Plug Installed/Removed
 Christmas Tree Installed/Removed
Note the packer is not pulled or set through the Driller’s brake but simply seated or unseated
via the pushbuttons. When the sliding sleeve is opened, communication is achieved from the
tubing to the annulus. The tubing plug can be set or retrieved through use of the pushbuttons.
It is assumed that a wireline unit is available and rigged up to undertake this work. When the
Christmas Tree is removed it is assumed that the tree is not in place and a flange with riser
spool connector is installed with direct connection to the BOPs. Therefore the standard
configuration is Wellhead with Christmas Tree in place but BOPs are assumed in place when
the Christmas Tree is removed via the pushbuttons.
Tip: The Instructor should rotate all the valves to the closed position to ensure none of the
lamps are illuminated. This will help prevent confusion for the trainee.
The use of non-latching pushbuttons means that the status of a particular item of equipment
can be configured and saved in a particular well snapshot and the instructor does not have to
then match up the latch position of the buttons with the light when a new exercise is loaded.
Depending on the nature of the well service operation, it may be necessary to pull the tubing
out of the well. In this case, the Christmas Tree must be removed. When the Christmas Tree is
removed the Well Services BOP is automatically installed to provide the operator with the
ability to run and pull the completion and maintain primary pressure control over the well. If
the well services BOP is not available then the simulator automatically uses the rig BOP as
default.
If the well service operation is solely to replace a Sub Surface Safety Valve, or replace
downhole equipment such as gas lift mandrels then tubing plugs can be set below the sliding
sleeve and the workover performed only with a lubricator and wireline unit. The Drilling
Systems wireline simulator WLS-5000/500 concentrates on wireline operations and these are
assumed outside the scope of simulation for the workover simulator. Likewise, pulling
packers using the rig floor consoles and control equipment and running drill stem tests are
covered by a further simulator, the DST-5000.
Digital Light Emitting Diode (LED’s) displays are provided to show:-

 Flow In of the well
 Flow Out of the well
 Volume Pumped
 Strokes Pumped
Reset push button are provided to reset the Volume and Strokes pumped, depressing these
buttons will re-set the display counters to zero.
Returns from the tubing can be lined up through the production choke and downstream to the
process facilities or lined up to the Workover manifold.
The annulus selector 3-position switch selects the annulus that will be connected to the
Workover manifold during forward or reverse circulation. A small illuminating light indicated
the selected annulus for visual clarity to the trainee.
The pump selection switch allows the trainee to select the rig pumps or the optional auxiliary
pumpers console. The auxiliary pumpers console when used in conjunction with the well
services BOP allows the Instructor to run different exercises on the workover equipment and
the rig floor environment simultaneously. The auxiliary pumps must be configured in the
Instructor facility.
The size of both the fixed bean choke and the production choke is configured by the instructor
through the Instructor Interface.
The workover panel provides an economical alternative to the full size equipment or an
advantage where space is limited. The mimic panel is not ideal for completely green trainees
since it requires a certain leap of knowledge in the mind of the trainee to transfer the real field
equipment in to the mimic screen-printed displays on the panel. Nonetheless the full scope of
workover operations are still available since the mathematical model behind the hardware is
exactly the same for all hardware options.
2.1.5 Workover Mimic Cabinet: PAWSIM-500
The workover mimic panel for the PAWSIM-500 simulator is similar to the full size mimic
panel but reduced in size to a 600mm x 600mm panel fascia. Otherwise all other functionality
is the same as set out in the section above and the reader is directed to read the section above.
TU BING PRESS URE

FL OW IN R I GP UMP S / T OTAL S TR OK ES
R ES ET
DR IL LNI G SYS TEM S
F LOW OU T A UX P U MPS / VOLU ME P UMP E D
R ES ET
FL ARE
M ANU AL CH OKE
TU BI NG
RI G PUM PS
PR ODU CTI ON
FI XED CH OKE
A UX PUM PS
DEC INC 1
R EM OTE CH OKE
DE GAS SER
A NNU LUS SEL ECTO R
A NNU LUS
2
AN NULUS PRESS URE

PAC KER PR OD UCT IO N TREE 3
S ET / REL EAS ED NI S TALL ED / RE MO VED
DR IL LNI G SYS TEM S
TU BI NGSL DI I NG SL EEVE REM OPVLEUDG / I NSTA LLED CLO SED / O PEN
D RI LLSI M 500
2.1.6 Workover Screen – PAWSIM 50, PAWSIM 20 & DRILLSIM-5
The mini-portable well control simulator, PAWSIM 50, PAWSIM 20 and the software based
DRILLSIM-5 provide optional workover operations on screen. Hardware panels are not
provided and all functions can achieved by the use of the touch screen in the case of the
PAWSIM 50 and PAWSIM 20 or via the or mouse in the case of the PAWSIM 5.
Otherwise all screen buttons and controls have an effect on the software in exactly the same
manner as their hardware alternatives.
3. INSTRUCTOR STATION
The instructor station is used to set-up and configure a specific workover exercise and then
monitor key data during the training session. This section describes how this is achieved.
3.1 Configuring a Workover Exercise: Rig Selection
In order to initiate a workover exercise the Instructor must either select a workover baseline
snapshot provided by Drilling Systems within the baseline snapshot exercises or configure a
new workover exercise through the Instructor Station. This is achieved by first selecting the
workover rig from the Rig Selection Screen. Note that options with ghosted text are not
available at the time of selection. The currently selected rig will change and the previously
selected BOP will be removed.
 Flow Nipple or Riser Internal Diameter
On a land rig the flow nipple I.D. (internal diameter) is generally set to match the I.D. of the
BOP stack. If a 13 5/8” 5000 psi BOP stack is used the I.D. of the flow nipple should be set to
13.625 inches. For simplicity sake the mathematical model considers the BOPs to be the same
I.D. as the flow nipple or riser. When setting the I.D. for the marine riser a typical marine
riser I.D. is 19.25 inches.
Caution: Never set the Flow Nipple or Marine Riser I.D. less than the I.D. of the casing.
 Flow Line to Ground Level or Seabed
This button is used to set the height of the flow line from ground level or seabed. Typical
distances of the flow line from the rotary table are 5 ft (1.5 m) for a land rig and 15 ft. (4.6 m)
for a floater. The model fixes the sub height on a land rig to be 30 ft. (9.14 m), therefore the
flowline to ground level setting would be 25 ft. (7.6 m).
 RKB to Seabed
This button is used to set the distance from the rotary table to the seabed for floating vessel
operations.
 Sea Depth
This button is used to set the water depth. Air gap can be calculated by subtracting this value
from the value of RKB to Seabed. The model considers the gradient of the seawater to be
0.445 psi/ft (10.07 kPa/m), (10.07 BAR/10m). Seawater hydrostatics, formation pressures and
reduced fracture gradients must be calculated using this gradient.
 Choke Line Internal Diameter
This button is used to set the I.D. (internal diameter) of the choke and kill lines. This value is
typically set to 3 in. (76.2 mm) for both land and floating vessel operations.
 RKB to Bit Depth
This button is used to set the depth of the bit in the well. The mathematical considers all drill
string members to be 30 ft. (9.14 m ) long therefore when setting the bit position it should be
set in multiples of this length. If the bit depth is set to hole depth the model will calculate the
nearest bit position as a multiple of 30 ft. (9.14 m) and place the bit in that position when the
simulator is put into the run mode.
 Choke Line Friction Factor
To comply with IWCF requirements of 150 psi (1035 kPa), (10.4 Bar) minimum chokeline
friction loss, this button can be used to adjust the model calculated friction loss to the desired
value. For example if the choke line friction loss measured in 525 ft (160 m) water is only 50
psi (345 kPa) with a 10 ppg (1.2 S.G.) mud, the Choke Line Friction Factor can be set to 3 or
4 to bring the choke line friction loss up over 150 psi.
Select the Bop Equipment icon, to determine which types of equipment can be installed.
Clicking or touching the icons will toggle them between Enabled and Disabled. Based on the
rig selected and BOP equipment enabled or disabled, the drawing of the currently selected rig
displays all the equipment that has been installed.
3.2 Wellbore Geometry
Use the Wellbore Geometry menu to configure the set casing or the liner in hole and wellbore
profile. The perforations option is specific to Workover and will only be highlighted when a
workover snapshot is loaded or the workover selected. Note: It is currently is not possible to
have a liner hung off inside a casing string.
3.3 Casing
 Casing Outside Diameter

This button is used to set the outside diameter of the casing in the hole. Casing data can be
acquired from a standard engineering handbook such as the IFP Drilling Data Handbook.
When selecting casing for the well make sure the planned bit size will fit inside the casing.
 Casing Inside Diameter
This button is used to set the inside diameter of the casing in the hole. Casing data can be
acquired from a standard engineering handbook such as the IFP Drilling Data Handbook.
When selecting casing for the well make sure the planned bit size will fit inside the casing.
 Casing Weight
This button is used to set the weight of the casing in the hole. Casing data can be acquired
from a standard engineering handbook such as the IFP Drilling Data Handbook.
 Collapse Pressure
This button is used to set the Collapse Pressure of the casing in the hole. Casing data can be
acquired from a standard engineering handbook such as the IFP Drilling Data Handbook
 Tensile Strength
This button is used to set the Tensile Strength of the casing in the hole. Casing data can be
acquired from a standard engineering handbook such as the IFP Drilling Data Handbook
 Depth of Set Casing
This button is used to set the Measured Depth of the casing in the hole. True Vertical Depth
of the set casing can be calculated using standard directional well planning calculation
methods found in Section J of the Green Book (IFP Drilling Data Handbook).
3.4 Perforations
The instructor can set up the style of completion, barefoot or perforated. Selection of both the
depth to the top of the perforations and the length of perforations, will result in a pop-up
calculator appearing to facilitate data input. Casing Perforated, toggles between Yes and NO.
 Casing Perforated
To actuate the perforations ensure that this toggle switch is set to ‘YES’. Otherwise
communication from the reservoir bearing formation. If the casing/liner shoe depth of the set
casing/liner is lesser than the top of the reservoir producing formation then it is assumed that
a barefoot completion has been configured. In this case the productivity of the flowing well is
based on the full thickness of the reservoir producing formation. If the set casing/liner shoe
depth is deeper than the reservoir formation and the casing perforated option is set to ‘NO’
then the well will not flow when under-balanced.
 Depth of Perforations
This is the measured depth from the surface that the production casing or liner has been
perforated. The instructor must ensure the casing shoe is greater than the top of perfs depth
plus the length of perfs. In addition the perforations must be across the denominated reservoir
zone.
 Length of Perforations
This represents the section length that has been perforated in the production casing or liner.
The length of perforations has bearing on the kh factor and must be set up realistically
otherwise reservoir draw down will be restricted. The production zone will only be
considered as the length of the perforations that are within a reservoir producing zone.
3.4.1 Tubulars – Setting up the work string
The Instructor must now configure the tubulars in the hole. Via Snapshot Configuration, there
are three options:-
 Drillstring – for drilling & well control mode
 Casing – for Cementing Operations
 Tubing for workover operations
Once the workover rig is selected the only available option on this screen will be tubing. The
current selection is highlighted in yellow. Although only one option is available for a given
mode, it serves to highlight the options available.
3.5 Configuring Tubing as the workstring
Once the tubing button has been selected, the Instructor sets up the key information about the
tubing. The picture of the flow head at the top of the riser is used when the Christmas Tree is
in place and circulation required. When the Christmas Tree has been removed and the BOPs
enabled it is assumed that a circulation head is installed. It is not possible to trip the tubing
out of the hole on the PAWSIM-5000, this is only possible on the Drill Stem Testing series of
simulators. There are three configuration requirements on the tubulars screen: the depth of the
work string, the tubing details and the downhole equipment.
3.6 Tubing
 Tubing Outside Diameter

This button is used to set the outside diameter of the tubing in the hole. Tubing data can be
 Tubing Inside Diameter
This button is used to set the inside diameter of the tubing in the hole. Tubing data can be
 Tubing Weight
This button is used to set the weight of the tubing in the hole. If Premium Class tubing is used
then enter only the nominal weight of the tubing. Tubing data can be acquired from API
RP7G or the IFP Drilling Data Handbook.
 Tubing Tensile Strength
This button is used to set the tensile strength of the tubing in the hole. The model fails the
tubing at the set tensile strength. Tensile failure of the tubing occurs just under the rotary
table. Tubing tensile data can be acquired from API RP7G or the IFP Drilling Data
Handbook.
 Tubing Maximum Torque
This button is used to set the torsional strength of the tubing in the hole. The model fails the
tubing at the set torsional strength and results in torsional failure of the tubing to occur just
under the rotary table. Tubing torsional data can be acquired from API RP7G or the IFP
 Cross Sectional Area of the Tubing
This button is used to set the cross sectional area of the tubing. Cross sectional area can be
calculated or acquired from API RP7G or the IFP Drilling Data Handbook.
 Number of Joints
This button is used to set the total number of joints of tubing available to the student for the
exercise. The button does not set the number of joints of tubing in the hole. If the student runs
out of tubing an operator error message will be displayed on the maintenance terminal and on
the instructor station.
3.7 Downhole Equipment

 Height of Packer from End of String
The Packer Depth is entered as a height from the bottom of the tailpipe/end of string. This
format of entry helps reduce data entry inconsistencies.
 Height of Tubing Plug from End of the String
Although there are normally two tubing plug nipples in a typical string for the purposes of
workover operations we are generally concerned only with the lower plug. The tubing plug
nipple depth is entered as height above the bottom of the string/end of tailpipe. This entry
format as opposed to a tubing plug depth helps reduce data entry inconsistencies. The tubing
plug acts as a safety device during Christmas tree removal and BOP installation.
 Height of Sliding Sleeve from End of the String
The sliding sleeve allows communication between the tubing and annulus. Fluids are tracked
though this circulation port. Its position is entered as a height above the bottom of the
tailpipe/end of string. This entry format as opposed to a sliding sleeve depth helps reduce data
entry inconsistencies.
4. STUDENT STATION – FULL SIZE EQUIPMENT
The student station on the full size PAWSIM-5000 simulator requires several additional
features that are available on the mimic panel equipment hardware. Therefore this screen is
only relevant to the full size equipment installation.
The screen is accessible if the snapshot has been configured for workover operations.
 Packer Set/Removed
 Christmas Tree Installed Removed
 Tubing Plug Removed/Installed
 Sliding Sleeve Open/Closed
 Production Choke – To Manifold – To Production
The buttons will show the current status by changing to yellow when the function is activated.
In addition, two on screen digital displays for flow in and flow out of the well are shown.
Two onscreen reset buttons are available for resetting the current display values to zero.
5. SCOPE OF SIMULATION
The Workover package enables the crew to be trained in the techniques necessary to shut-in a
producing well. Plan the killing procedure and safely kill the well to the point where the
production tubing and packer may be removed from the well to allow Workover to be
achieved if tubing removal is required. The simulation facilities allow the crew to plan the
killing procedure for: -
 Wells of varying depths up to 30,000ft
 Wells of varying annular geometry
 Tubing of varying and mixed cross-sectional area
 Tubing can containing various downhole valves and circulation ports
Initially, the crew can shut in the producing well by choking back and closing the production
valve on the Christmas Tree. All tubing and annular pressures can be monitored throughout
the operation. Full well control facilities are provided through the PAWSIM downhole model
to undertake the well kill operation. This includes reverse circulation and bull heading. The
sliding sleeve valve can be operated via a push button on the mimic panel or via the student
touch screen to open the tubing to the annulus at the appropriate point in the killing operation,
facilitating removal of production fluids from the production string. Furthermore the packer
can then be pulled via the push button on the mimic panel or via the student touch screen and
the wellbore fluids below the packer circulated up the annulus and on to the production
facilities. To assist the instructor monitoring the exercise an overview of the process is
represented on the Instructor Facility along with all of the standard real time data displays
offered by the PAWSIM range of simulators.
5.1 Operational Overview

The Workover package allows the trainee Workover crew to decide on the appropriate course
of action depending of the various well parameters in order to kill the well. This may be: -
 Bull heading the product, and kill fluid back into the formation by pumping down
the tubing with the packer set.
 Circulating the contents of the tubing through the opening above the packer, into
the annulus.
 Circulating down the annulus, with the sliding sleeve valve open, up the tubing
through the choke.
 Circulating down the annulus, with the sliding sleeve valve open and the
production tree-tubing valve closed.
Note - When the Workover software is activated the only pressure gauges that are available to
the operator are the Tubing and Annular pressure gauges provided on either the Workover
mimic or the full size Workover manifold and Wellhead.
Gauges on the standpipe manifold, choke manifold and drilling gauges console are not used
during a Workover exercise.
5.2 Configuring a Workover Exercise
The following list of settable parameters are directly applicable to the Workover software
module:
Tubing Configuration
 Tubing OD
 Tubing ID
 Weight
 Maximum Torque
 Cross Sectional Area
 Number of Joints Available
 Depth of tubing
Reservoir Configuration
 Bull Heading Differential Pressure
 Geothermal Gradient
 Gas Density
 Oil Density
 Water Density
 Formation Fluid - Gas, Oil and Water
 Permeability
 Formation Pressure
 Rock Strength
Casing/Production Liner Configuration
 Casing OD
 Casing ID
 Weight
 Collapse Pressure
 Depth Of Casing
Perforation Configuration
 Depth of Perforations
 Length of Perforated section
 Casing Perforated - Yes/No
General Parameters
 Annulus Migration Rate
 Tubing Migration Rate
5.3 Workover Example Operations on the Simulator
5.3.1 Well Control - Reverse Circulation
Load a Producing Well snapshot and put the simulator into run.
 Close the production wing valve
 The tubing pressure will increase as the reservoir recharges. The operator should
read the tubing pressure every minute until stabilised. The final pressure is
reservoir pressure less head of influx.
 Shut the master valve and remove production choke to connect tubing to manifold.
 Connect Annulus C to manifold
 Line up manifold to reverse circulate into Annulus and out through tubing to the
Mud Gas Separator.
 Using Pump 1 (Rig Pump) slowly pressure annulus to 50 psi and then stop the
pump
 Set the tubing plug
 Open the sliding sleeve
 Crack the choke open and slowly bring the pump up to kill rate. Adjust the choke
to maintain a constant tubing pressure whilst bringing the pump up to speed. Read
and record pump pressure. Now adjust choke to maintain constant pump pressure
until the influx is out.
 Pump start displayed on instrumentation tubing pressure remains constant. Pump
pressure builds to circulating pressure. Tubing pressure slowly decreases as influx
is vented from the well.
 Stop pump
 Open choke
 Observe balanced annulus and tubing
 Shut choke.
 Remove the production tree.
 Install the BOP
 Connect Kelly/flowhead to tubing.
 Close the sliding sleeve
 Remove the tubing plug
 Close the annular preventer
 Release the packer
 Crack the choke and slowly bring the pump up to kill rate
 Adjust the choke to maintain the pump circulating pressure
 The pump pressure will build to circulating pressure and the tubing pressure
increases then decreases as the trapped influx is removed from the well.
When all the influx has been removed:
 Stop the pump
 Open the choke and check for flow.
 Close the choke
 When no flow is observed, the tubing and annulus are balanced.
 Breakout Kelly/flowhead and rack in rat hole.
 Select the INSTALL production tree / Wellhead option
 Set the packer.
Save snap shot called "Balanced Well"
5.3.2 Flowing The Well
Load Balanced Well snapshot and put the simulator into run.
 Set the tubing plug
 Open the sliding sleeve
 Align manifold to forward circulate down the tubing and out through the manifold.
 Adjust the fluid weight in the reserve tank to be diesel.
 Set the reserve tank volume to that required to fill the tubing to 100ft above the
sliding sleeve.
 Open the reserve tank suction valve and close the active tank suction valve.
 Open the choke and slowly bring the pump up to speed.
 Pump the contents of the reserve into the tubing.
 Pump pressure shows a steady increase as the tubing fills with diesel
 Stop the pump.
 Shut the choke using the remote/manual choke and shut the sliding sleeve
 Line up the choke to the tubing.
 Bleed off some of the tubing pressure.
 Tubing pressure will decrease as the pressure is bled off.
 Remove the tubing plug.
 Tubing pressure will increase as the influx flows in.
 Slowly open the choke and flow the well.
 There will be a steady increase in flow out. The operator should observe the influx
on the downhole graphics.
 Close the choke.
 Close the production wing valve and install the production choke.
 The flow out will stop and observe the steady increase in tubing pressure as the
well stabilises.
 Open the production wing valve.
 The flow out increases and the tubing pressure decreases steadily until a constant
flow rate is established.
Save snap shot called "Flowing Well"

6. SUMMARY
The PAWSIM workover option is a powerful simulator that can be used confidently for
training wellsite personnel in well servicing and workover operations. Its primary function is
for training in well control techniques for a producing well or bringing a dead well back on
stream after a workover.
Depending on the configuration, the workover simulator can be run as a standalone simulator
or linked into the core drilling consoles and equipment.
As software is released the screens captures used in this manual may be vary from those
viewed on your software interfaces. However the look and feel of each screen will be similar.

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Compact Portable Drilling & Well Control Simulator

Drilling Systems (UK) Ltd

Working to Support Industry Standards

DrillSIM Operators Manual

1.1 General Information

1.2 DrillSIM Overview

1.2.1 Computer Equipment

DrillSIM Operators Manual

1.2.2 Simulation Control

The DrillSIM simulation software is a fully integrated modular package that is

1.2.4 DrillSIM-5000 Standard Equipment

1.2.5 DrillSIM-5000 Optional Equipment

1.2.6 DrillSIM-500 Standard Equipment

1.2.7 DrillSIM-500 Optional Equipment

1.2.8 DrillSIM-50 Standard Equipment

1) Drilling Controls Console & Gauges Console

1.2.9 DrillSIM 20 Standard Equipment

1) Virtual Choke Panel

There is no actual hardware supplied with the DrillSIM-5, as it is a PC based version

1.3.1 Normal Operation

1.3.3 Operational Malfunctions

DrillSIM Operators Manual

2. POWER UP & POWER DOWN PROCEDURES.............................................................1

DrillSIM Operators Manual

2. POWER UP & POWER DOWN PROCEDURES

2.2 DrillSIM-5000 (Serial Number 5000-042 or before)

DrillSIM Operators Manual

CAUTION: EXTREME CARE MUST BE TAKEN TO AVOID DEPRESSING ANY OTHER

2.2.2 Powering up the Simulator Consoles

 Check the MAINS supply is on.

2.2.3 Powering up the Simulator Peripherals

2.2.5 Logging Into the System Computer Maintenance Terminal

2.2.6 Logging In To the Simulator

2.2.7 Loading A Snapshot on the Instructor Station

2.2.8 Power Down Sequence

At the VAX or Alpha or Alpha Station

2.2.9 Recovery From a Power Failure

2.3.1 Powering up the Simulator Consoles

 Check the MAINS supply is on.

2.3.2 Powering up the Simulator Peripherals

2.3.3 Student Station Touch Screen

2.3.4 Initialising the DrillSIM Simulation Software

2.3.5 The Instructor Interface

2.3.7 Power Down Sequence

The system will confirm which targets will be shutdown

2.4.1 Power Up Procedures

 Ensure the components of the simulator are correctly connected.

2.4.2 The Instructor Interface

2.4.3 Loading A Snapshot

2.4.4 Power Down Sequence

2.5.1 Power Up Procedures

Enter a choice… (1)

2.5.2 Logging In To the Simulator

2.5.3 Loading A Snapshot

2.5.4 Power Down Procedures

2.6.1 From the ‘START’ menu

2.6.2 From the Desktop

The DrillSIM-5 installation program will automatically create a shortcut

2.6.4 Shut Down Sequence

 The Instructor Interface computer is now return back to Windows.

DrillSIM Operator’s Manual

3. CONTROLS AND INSTRUMENTATION

DrillSIM Operator’s Manual

3.1.1 Mud Pump 1 Speed Control