Unique Simulation Development Enhances Safer Operation for Downhole Well Test Tools

Abstract

In recent years, economic pressure has driven the oil and gas industry to downsize its work force and seek more efficient solutions for providing operational needs. In many cases, this redirection of efforts has required highly technical methods to meet the newly driven functional parameters. These actions, while necessary, have brought with them new problems in terms of operational experience and training. For example, in today's industry, the average worker, who generally has less experience than his predecessor, is asked to understand and safely use an expanded scope of equipment that has become significantly more complex. A unique simulator that helps to resolve many of the operational and training problems that have surfaced in today's workplace has been developed and will be discussed in this paper. The simulator uses a multi-media type environment that is capable of submerging the operator into the simulation to provide the oilfield end user with the ability to understand and properly operate sophisticated equipment. These simulations allow engineers to effectively convey complex technical information, specific to a given tool or piece of equipment, to operators, trainers, and oil company personnel. While these tool and equipment simulations are valuable in their own right, of even greater benefit is the merging capability of the "global simulator," which allows dynamic assembly of the individual tool simulations into a system. The resulting simulation offers the operators the safety advantage of "practicing" the effects and/or dangers that can result from changes in operations before a system is actually used. This paper will discuss the concepts of the equipment simulator and global simulator methodology, and an actual case history will be used to describe in detail how the equipment simulator was used throughout the development, testing, training and operation of a new generation well test tool. The information shown will conclude that the use of the simulator will provide unparalleled development and training support for future oilfield equipment and training applications. Introduction Simulation History. Simulators have been used to expand the understanding of processes and systems in numerous industries for many years. There are various forms and levels of simulation, depending on the application. Mathematical simulators typically have a data-set input that generates a data-set output. This type of simulation is used predominantly in the scientific and engineering community. Finite element analysis and reservoir analysis are examples of mathematical simulations. Physical simulators, on the other hand, are generally the concepts developed for use in the training of operators for efficient use of equipment and systems. The most well known example of a physical simulator is the program that flight trainers have used for years to train pilots. Because of recent enhancements to computer technology, increased performance capabilities have been noted in programming for the personal computer (PC). As a result, physical simulation has now become available for PC use in the "games" format, and thus, the proliferation of flight simulator games. It is of interest to note here that a flight simulator game on the personal computer, although not of the same caliber as the fully submerging physical simulations that are used to train pilots, still offers an effective method for teaching flight skills. What has been added recently to the simulator equation is the development of multi-media authoring systems for the personal computer. These programming tools have tilted the economic scales in favor of generating simulations for a broad scope of applications. Although all industries have needed the capabilities of physical simulators, they simply have not been able to afford either the time or money to produce them. This has now changed. With the advent of good multi-media authoring systems and today's more powerful personal computers, the industrial markets are now able to produce physical simulations of equipment and systems that could not have been cost justified just a few years ago. P. 413