Search

The process of making drill pipe connections is not only crucial in drill string integrity but also in assessing rigfloor safety. Almost 15% of recorded incidents in US onshore rigs occur due to improper make-up/tripping process as reported by IADC in 2015. Even with advances in pipe handling systems, human factors greatly influence the likelihood of errors which can lead to accidents. Training on simulators is a proven solution for innovation. The crew can better understand the rig equipment and prepare for potential risks. While drilling simulators exist for all aspects of drilling operations, a simulator for making drill pipe connections through human factor assessment is critically needed. This paper presents three unique approaches in building and using this much needed tool. One approach works like a visual interactive interface where the user can click and drag the rig components over to the rig floor and make a connection in a step-by-step manner. This enables a thorough understanding of the process and highlights errors if tasks are not performed sequentially. Another approach looks at the driller's screen where the user can control all the rig floor operations. This is a more realistic approach for a user who is well versed in the make-up process. The system works in real time and features a risk-meter that evaluates the process safety. The third approach is an automated interface for making connections. Before initiating the process, the user can choose among the different pipe handling systems, dope to be applied and rig crew assignments for the job. Different rig crews have combinations of experience, operational awareness and physical strength as attributes. The process begins with an animation of the make up process alongside a log of the process and description. Riskmeter and the option to pause-start are also features of this interface. These novel drilling simulators can play a crucial role in understanding and assessing the make up process on a rig floor. The simulators developed can be used for training new, and more experienced crews. The crew can be trained on the correct operational procedures, and create a profile evaluating the competency of the user. Since it features a safety meter that rates the ongoing process based on the handling system and crew selected, a comparative study was done and WAR (Weighted Assessment of Risk) was defined. The rig crew competency was analysed using these parameters. The tool could also be used for rig crew profiling and job assignments to improve safety and efficiency of tripping operations.