Projeto conceitual de bancada de laboratório para simulação de processo de perfuração de extrato rochoso

Abstract

The process of drilling oil and gas wells is costly and complex. In offshore situations, drilling occurs at depths of several kilometers below sea level and monitoring the efficiency of the operation becomes a major engineering challenge. For greater control of the process, it is essential to perform experimental tests to assess the influence of drilling parameters on the rate of penetration, in order to reduce operating costs in this process. Among the main ones, there are: the drill string rotational speed, the weight on bit, the flow of drilling fluids, the type of rock to be drilled, the bit type employed and the torque.Testing on real platforms is very expensive, in addition to limited feasibility, due to the constant demand of the oil and gas industry for more productivity. Therefore, small-scale drilling devices become the most accessible solution for understanding the behavior of the field drilling process. There are several initiatives for the development and operation of small-scale prototypes in laboratories around the world. At UTFPR, there is a demand for a similar device, however, the university does not have a solution of this nature yet. The general goal of this work is to develop the mechanical conceptual design of a laboratory bench to investigate the drilling process in rock extract for oil and gas extraction. After evaluating geometric and operational data from similar drilling devices, the Pahl & Beitz design methodology was applied for the development of a bench proposal. Among the results, eight laboratory bench designs were proposed. One of the concepts was chosen as the most constructive potential, it is a bench of 2.8 m tall, employing a servomotor connected to a ball screw system for vertical movement of the drill string. A DC motor provides power to rotate the drill string. The circulation system of the bench was developed employing the main tank, filter tank, reserve tank and centrifugal pump set, allowing drilling tests on various types of rocks. This work also addresses the main sensors utilized in the acquisition of drilling data, in addition to the spreadsheet for scaling the main drilling parameters, revealing the challenges of maintaining geometric, kinematic and dynamic similarities between devices of different sizes.