Functional Simulation Apparatus for Onshore Drilling Rig Operations

Abstract

ABSTRACT Functional Simulation Apparatus for Onshore Drilling Rig Operations The invention is a simulation model of an onshore drilling rig, designed to replicate key systems and operations used in oil and gas exploration. This scaled-down model includes operational features such as hoisting, rotary, mud circulation, and blowout prevention systems, providing a tangible learning tool for students and professionals in petroleum technology. Constructed with durable, lightweight materials, the model enables safe, hands-on interaction with core rig components, including a crown block, traveling block, rotary table, mud pump, and blowout preventer. The model operates in a controlled manner to simulate drilling processes, offering a comprehensive understanding of the drilling rig structure and operations in an educational context. Figure 1

Specification

Description:FIELD OF THE INVENTION
The present invention generally relates to the field of mechanical engineering with specific applications in educational and training systems for the petroleum technology industry, focusing on physical simulations of drilling equipment.

BACKGROUND OF THE INVENTION
Onshore drilling rigs are vital for petroleum exploration and extraction, encompassing complex systems that require specialized knowledge for operation and maintenance. Understanding these rigs demands familiarity with intricate mechanical, hydraulic, and electrical systems that work in unison to extract oil and gas resources from the subsurface. Conventional training methods are often limited to theoretical instruction, which can be challenging for students and trainees who lack direct experience with the technical and operational demands of a drilling rig. This gap in practical training has underscored the need for educational tools that can effectively replicate drilling operations in a safe, accessible manner.

Existing educational aids, such as diagrams, simulations, and virtual models, fall short of providing a tangible, hands-on experience essential for comprehending the complexities of drilling operations. Although virtual models and digital simulations are beneficial, they cannot fully capture the interactive, multi-sensory aspects of actual rig operations. Furthermore, full-scale rig systems are costly, and providing trainees or students with real-world exposure often poses logistical and safety challenges. There is a need for a practical, scaled-down model that allows users to directly engage with the components and processes involved in drilling, offering insights that are typically only available through on-site experience.

Prior attempts to create scaled models or training rigs have often lacked key functionalities, such as operational hoisting, rotary, and mud circulation systems that are integral to drilling. These models typically focus on single aspects of the rig, failing to provide a holistic representation of the entire system. Additionally, previous models may not incorporate safety mechanisms such as blowout preventers, which are crucial in understanding well control and ensuring safe operations. This lack of comprehensive models limits the effectiveness of hands-on training, as users are unable to observe how different systems interact under simulated drilling conditions.

The need for an innovative, functional model has become increasingly apparent within petroleum engineering and technology programs. An effective educational model should replicate all primary systems of an onshore drilling rig, including hoisting, rotary, mud circulation, and blowout prevention, while offering a safe, controlled environment for observation and operation. Such a model would serve as an invaluable teaching aid, bridging the gap between theory and practical application, enhancing students' and researchers' understanding, and improving workforce training for oil and gas companies.

With years of field experience and extensive technical knowledge of onshore drilling rigs, the inventor identified these educational gaps and set out to develop a working model that addresses these issues. Through careful design and engineering, this invention provides a scaled-down, functional replica of an onshore drilling rig, offering a complete educational tool for petroleum technology institutions, research laboratories, and industry training programs.

OBJECTS OF THE INVENTION
It is the main object of the invention to provide a functional model that accurately replicates key operations of an onshore drilling rig.

It is another object of the invention to provide an educational tool that bridges theoretical knowledge and practical applications.

It is another object of the invention to enable safe, cost-effective training simulations for students, researchers, and industry professionals.

It is yet another object of the invention to support experimental studies and testing of new technologies within the controlled environment of an educational model.

SUMMARY OF THE INVENTION
To meet the objects of the invention, it is disclosed here a functional simulation apparatus of an onshore drilling rig for training and demonstration, comprises: a hoisting system; a rotary system; a mud circulation system; a blowout prevention system; and a structural rig tower and rig floor, wherein the hoisting system includes a crown block and traveling block to simulate lifting and lowering of the drill string, the rotary system comprises a rotary table and connected to a master bushing and a Kelly drive bushing to simulate rotation of the drill string, the mud circulation system comprising mud pumps, mud tanks, a shale shaker, and a desander for simulating drilling fluid circulation and filtration, the blowout prevention system with hydraulic rams is to simulate well control mechanisms and the structural rig tower and rig floor support the hoisting and rotating systems to mimic the vertical structure of the drilling rig; and wherein the above components are interconnected in a manner to replicate the functions of a full-scale drilling rig and allow safe operation for practical demonstration purposes.

Further disclosed here a method of simulating drilling operations using the simulation apparatus, comprising steps of: operating the hoisting system to lift and lower a simulated drill string; rotating the drill string with the rotary system to demonstrate the penetration of subsurface materials; circulating drilling fluid through the mud circulation system to illustrate the transportation of cuttings to the surface; and engaging the blowout prevention system to simulate emergency well control and sealing of the wellbore.

BRIEF DESCRIPTION OF THE FIGURES
Figure 1 illustrates Model of onshore Drilling Rig.
Figure 2(a) illustrates the Crown block system.
Figure 2(b) illustrates the Traveling block system.
Figure 3 illustrates the Hoisting system.
Figure 4 illustrates the Rotary system.
Figures 5(a) to 5 (f) illustrate the Mud circulation system, including mud pumps and tanks.
Figure 6 illustrates the Blowout prevention system.
Figure 7 illustrates the Structural rig tower and floor.

DETAILED DESCRIPTION OF THE INVENTION
The present invention is a working model of an onshore drilling rig, designed to replicate the key components and operations of a full-scale drilling rig used in oil and gas exploration. This model provides a scaled-down but functional representation, intended for educational and research purposes, allowing students, researchers, and industry professionals to gain hands-on experience with the mechanics and processes of oil drilling.

The primary objective of this working model is to offer a detailed and interactive platform for understanding the operation of a drilling rig (Figure 1). It aims to bridge the gap between theoretical knowledge and practical understanding by providing a tangible, working system that demonstrates the core functions of drilling equipment. This invention is particularly useful in petroleum technology and engineering institutions, where it can be employed for training, research, and analysis.

Components and Systems
Crown Block and Traveling Block
The model as in Figure 2(a) and Figure 2(b) features a crown block, located at the top of the rig, through which the drill line is threaded. The drill line connects to the traveling block, a moving component that is hoisted or lowered to lift or lower the drill string into the wellbore. This system replicates the actual hoisting mechanism used in large-scale drilling rigs.

Hoisting System
The hoisting system as in Figure 3, demonstrates how the rig raises and lowers the drill string and other heavy equipment into the well. It includes draw works, which control the movement of the traveling block, and drill lines, which are used to hoist or lower loads.

Rotary System
The model as in Figure 4 includes a functional rotary table that provides the rotational motion required to drill into the subsurface. The rotary table is connected to Master bushing which is engaged to Kelly bushing, Kelly, and swivel, replicating the actual drilling process where the drill string rotates to penetrate the rock formation. The rotary system also demonstrates how the Kelly drive bushing engages with the rotary table to transmit torque to the drill string.

Mud Circulation System
The mud circulation system as in Figure 5(a) to Figure 5(f) replicates how drilling fluids (mud) are circulated during the drilling process. It includes:
Mud Pumps: Used to pump drilling mud into the well through the drill string.
Mud Tanks: Store the mud, which is mixed and transferred during operation.
Shale Shaker and Desander: The model includes these essential components to demonstrate how returning drilling fluids are cleaned of rock cuttings and other debris. The shale shaker separates the solids from the fluids, while the desander removes smaller particles. Mud pump crankshaft is included in the model, which powers the mud circulation system. The crankshaft drives the mud pump to create the high pressure required to circulate the drilling mud through the system and back to the surface.

Blowout Preventer (BOP)
A blowout preventer (Figure 6) is included in the model to demonstrate the safety mechanisms that prevent uncontrolled releases of oil or gas from a well. The BOP functions through hydraulic rams, showing how the system seals the wellbore to prevent blowouts during drilling operations.

High Mass Tower and Rig Floor
The rig's high mass tower and rig floor (Figure 7) are included in the model to replicate the structural components of an onshore drilling rig. These components provide support for the hoisting and rotating systems and demonstrate the rig's vertical structure, essential for operations like drill pipe handling and equipment assembly.

Operational Features
The model operates in a manner similar to full-sized drilling rigs, providing insights into how each system works in unison during oil drilling operations. The model can be used to simulate various rig operations such as: Hoisting (lifting and lowering) of the drill string, Rotating the drill string to simulate the drilling process, Pumping and circulating mud to demonstrate how drilling fluids clean and lubricate the wellbore while transporting cuttings to the surface, Using the blowout preventer to demonstrate safety measures and well control during drilling.

This invention offers immense benefits for students, researchers, and industry professionals by providing a real-world, hands-on learning experience in the operation of a drilling rig. Key educational benefits include:
Interactive learning: The model allows users to see, touch, and operate critical drilling systems, which helps bridge the gap between theoretical concepts and practical application.
Safety training: The inclusion of a functional BOP allows students to understand well control mechanisms and the importance of safety protocols in drilling.
Research and development: Researchers can use the model to explore innovative techniques and designs related to rig operations, equipment efficiency, and safety improvements.

Construction Materials
The working model is constructed using lightweight materials such as metal, which replicates the durability of full-scale drilling equipment while remaining manageable for academic use. Precision engineering ensures that the model operates smoothly, with each part crafted to reflect the actual dimensions and functionality of a real onshore drilling rig.

Conclusion
The working model of an onshore drilling rig is a distinctive and innovative invention that brings the complexity of oil drilling operations into an accessible educational format. By offering a scaled-down yet fully functional replica of a real drilling rig, it provides students, researchers, and industry professionals with a comprehensive understanding of the key systems and processes involved in drilling operations.

This model is particularly valuable for Petroleum Technology and Engineering institutions, where it serves as a practical teaching tool, giving future engineers hands-on experience with equipment they will use in the field. It not only bridges the gap between theoretical knowledge and practical application but also facilitates experiential learning in a controlled academic environment.

Applications and commercialization:
Applications:
Educational Institutions: The model serves as a hands-on educational tool in universities and technical institutes offering courses in petroleum technology and engineering. It provides students with practical exposure to drilling operations, bridging the gap between theory and practice. By simulating real-world drilling processes, students can learn about rig systems, mud circulation, and safety measures such as blowout prevention.
Training Programs: This model can be integrated into professional training programs for oil and gas industry personnel. New recruits or field engineers can use it to familiarize themselves with onshore drilling operations in a controlled environment before working on actual rigs. It enhances training effectiveness by offering live demonstrations of key operations like hoisting, rotary, and mud circulation systems.
Research and Development: Research institutions can leverage the model to conduct experimental studies on rig efficiency, system optimization, and safety improvements. Researchers can use the scaled-down functional rig to test innovations related to drilling technology, equipment durability, or new operational techniques without incurring the high costs associated with full-scale tests.
Industry Demonstrations: Oil and gas companies can use the model for industry demonstrations at trade shows, conferences, or as part of internal training sessions. It offers a portable, easy-to-operate way to showcase new technologies, processes, or safety mechanisms to clients, stakeholders, and investors.
Simulation and Testing: The model can be utilized to simulate various drilling conditions and operational challenges in a safe environment, making it suitable for both academic exercises and industrial testing of new drilling methods or equipment.

Commercialization:
Licensing to Educational Institutions: Universities and engineering colleges can purchase or license the model for their petroleum technology programs. By offering an interactive learning tool, these institutions can enhance the quality of education and attract more students to their programs.
Partnerships with Oil and Gas Companies: The model can be commercialized through partnerships with oil and gas companies for use in corporate training and safety simulations. These companies would benefit from a cost-effective method of training their workforce on key drilling processes and safety protocols.
Sales to Research Organizations: Research institutions involved in energy studies and petroleum technology could be key customers. The model provides a platform for innovative research and testing in drilling operations, allowing researchers to experiment with different techniques in a controlled, cost-efficient manner.
Industry Exhibitions and Demonstrations: The model can be marketed to trade shows and exhibitions as a demonstration tool. Companies and equipment manufacturers in the oil and gas sector could use the model to display their technology, engage with stakeholders, or educate potential clients about their innovations.
Customization for Specific Use Cases: The model could be further commercialized by offering customized versions for specific educational, research, or corporate needs. For example, universities could request models tailored to their curriculum, while companies may need versions focused on specific rig components or safety features.
E-learning and Virtual Integration: There is potential for virtual simulations and e-learning modules to complement the physical model. By offering a digital component, the model could reach a wider audience, providing interactive training through virtual reality or online platforms.
, Claims:WE Claim:

1. A functional simulation apparatus of an onshore drilling rig for training and demonstration, comprises:
a hoisting system;
a rotary system;
a mud circulation system;
a blowout prevention system; and
a structural rig tower and rig floor,
wherein the hoisting system includes a crown block and traveling block to simulate lifting and lowering of the drill string, the rotary system comprises a rotary table and connected to a master bushing and a Kelly drive bushing to simulate rotation of the drill string, the mud circulation system comprising mud pumps, mud tanks, a shale shaker, and a desander for simulating drilling fluid circulation and filtration, the blowout prevention system with hydraulic rams is to simulate well control mechanisms and the structural rig tower and rig floor support the hoisting and rotating systems to mimic the vertical structure of the drilling rig; and
wherein the above components are interconnected in a manner to replicate the functions of a full-scale drilling rig and allow safe operation for practical demonstration purposes.

2. The simulation apparatus as claimed in claim 1, wherein the hoisting system comprises a set of drill lines connected to a draw works system to control the upward and downward movement of the traveling block.
3. The simulation apparatus as claimed in claim 1, wherein the rotary system comprises a swivel to enable rotational motion of the drill string while allowing the mud circulation system to inject drilling fluid into the wellbore.

4. The simulation apparatus as claimed in claim 1, wherein the mud circulation system includes a crankshaft to power the mud pump, creating the necessary pressure for circulating the drilling fluid through the drill string and returning it to the surface.

5. The simulation apparatus as claimed in claim 4, wherein the mud circulation system includes a shale shaker for separating solid particles from the drilling fluid and a desander for removing finer particles from the fluid before it returns to the mud tanks.

6. The simulation apparatus as claimed in claim 1, wherein the blowout prevention system comprises a set of hydraulic rams within the blowout preventer to seal the wellbore during simulated drilling operations and controls for operating the rams to simulate emergency well control actions.

7. The simulation apparatus as claimed in claim 1, wherein the structural rig tower includes supports to maintain the stability of the rig during simulated hoisting and drilling operations.

8. The simulation apparatus as claimed in claim 1, wherein the rig floor is designed to support manual handling and assembly of simulated drill pipes and equipment during operational demonstrations.

9. A method of simulating drilling operations using the simulation apparatus as claimed in claim 1, comprising steps of:
operating the hoisting system to lift and lower a simulated drill string;
rotating the drill string with the rotary system to demonstrate the penetration of subsurface materials;
circulating drilling fluid through the mud circulation system to illustrate the transportation of cuttings to the surface; and
engaging the blowout prevention system to simulate emergency well control and sealing of the wellbore.

10. The method as claimed in claim 9, wherein the method comprising step of using the mud circulation system to demonstrate filtration of the drilling fluid through the shale shaker and desander to remove solid and fine particles, thereby replicating actual drilling fluid maintenance processes.

Documents