The purpose of this study is to determine the feasibility of replacing diesel with natural gas as a fuel source for modern drilling rigs. More specifically, this thesis (1) establishes a control baseline by examining operational characteristics (response, fuel usage, and cost) of an existing diesel-powered land rig during the drilling of a well in the Haynesville Shale; (2) estimates operational characteristics of a natural gas engine under identical conditions; and (3) draws a comparison between diesel and natural gas engines, determining the advantages and disadvantages of those fuel sources in drilling applications. Results suggest that diesel engines respond to transient loads very effectively because of their inherently higher torque, especially when compared with natural gas engines of a similar power rating. Regarding fuel consumption, the engines running on diesel for this study were more efficient than on natural gas. On a per-Btu basis, the natural gas engines consumed nearly twice as much energy in drilling the same well. However, because of the low price of natural gas, the total cost of fuel to drill the well was lowered by approximately 54%, or 37,000 USD. Based on the results, it is possible to infer that the use of natural gas engines in drilling environments is feasible, and in most cases, an economical and environmental advantage. First, when compared with diesel, natural gas is a cleaner fuel with less negative impact on the environment. Second, fuel cost can be reduced by approximately half with a natural gas engine. On the other hand, natural gas as a fuel becomes less practical because of challenges associated with transporting and storing a gas. In fact, this difficulty is the main obstacle for the use of natural gas in drilling environments. In conclusion, because of its minimal drawback on operations, it is recommended that in situations where natural gas is readily available near current market prices, natural gas engines should be utilized because of the cost savings and reduced environmental impact. In all other cases, particularly where transport and storage costs encroach on the cost benefit, it may still be advantageous to continue powering rigs with diesel because of its ease of use.

Após o acidente de Macondo (EUA, 2010), cujo prejuízo estimado é da ordem de US$ 42 bilhões, a análise de risco do BOP (Preventor de BlowOut) ganhou grande importância nos projetos de exploração e desenvolvimento de petróleo. O presente trabalho se aprofundou na análise de risco de falha no acionamento do preventor anular de BOP (uma das funções do BOP), mapeando a sensibilidade da manutenção, redundâncias do projeto e da vida útil dos componentes no risco de falha inerente ao seu funcionamento. Este estudo seguiu os fundamentos da inspeção baseada no risco e da manutenção centrada na confiabilidade, a partir das diretrizes das normas ISO 31.000 (gestão do risco) e API 581 (inspeção baseada no risco). Um modelo de confiabilidade foi construído com base na árvore de falhas do equipamento, a qual, por sua vez, foi construída com base no diagrama hidráulico do sistema e do respectivo FMEA (Failure Mode and Effect Analysis). Neste modelo, pressupõe-se uma taxa de falhas constante dos componentes ao longo do tempo para calcular o tempo médio entre falhas do sistema. O trabalho atendeu seus objetivos ao comprovar que o modelo numérico de confiabilidade é aderente às falhas de campo e da literatura. A análise de sensibilidade do modelo por meio da simulação numérica, mostrou que o aumento da qualidade das manutenções preventiva é a melhor estratégia para reduzir o risco de falha do BOP anular. Verificou-se ainda que o aumento da vida útil de alguns componentes é tão relevante quanto o incremento de redundâncias para a confiabilidade do BOP anular. / After Macondo accident (USA, April 2010), with an estimated loss of US $ 42 billion, the failure risk analysis of the BOP (BlowOut Preventor) gained great importance in oil exploration and development projects. This work has deepened in BOP annular preventer (one of BOP functions) failure risk analysis, mapping sensitivity of maintenance of its components in the probability of equipment failure, according to the guidelines of RBI techniques (Risk Based Inspection) and RCM (Reliability Centered Maintenance). Therefore, the methodology used is proposed by API 580 (2009) and API 581 (2008) standards of risk based inspection applied on a reliability model of annular BOP. This reliability model, in turn, was based on fault tree analysis (FTA) and FMEA (Failure Mode and Effect Analysis) over the equipment hydraulic diagram. As hypothesis, it is assumed a constant failure rate of components over time, in order to calculate the mean time between failures. It was proved that reliability calculated by numerical model is coherent to field failures observations and literature data. The sensitivity analysis by numerical simulation shows that improving inspections and preventive maintenance quality in some of BOP components can markedly reduce the risk of failure of annular BOP.

Após o acidente de Macondo (EUA, 2010), cujo prejuízo estimado é da ordem de US$ 42 bilhões, a análise de risco do BOP (Preventor de BlowOut) ganhou grande importância nos projetos de exploração e desenvolvimento de petróleo. O presente trabalho se aprofundou na análise de risco de falha no acionamento do preventor anular de BOP (uma das funções do BOP), mapeando a sensibilidade da manutenção, redundâncias do projeto e da vida útil dos componentes no risco de falha inerente ao seu funcionamento. Este estudo seguiu os fundamentos da inspeção baseada no risco e da manutenção centrada na confiabilidade, a partir das diretrizes das normas ISO 31.000 (gestão do risco) e API 581 (inspeção baseada no risco). Um modelo de confiabilidade foi construído com base na árvore de falhas do equipamento, a qual, por sua vez, foi construída com base no diagrama hidráulico do sistema e do respectivo FMEA (Failure Mode and Effect Analysis). Neste modelo, pressupõe-se uma taxa de falhas constante dos componentes ao longo do tempo para calcular o tempo médio entre falhas do sistema. O trabalho atendeu seus objetivos ao comprovar que o modelo numérico de confiabilidade é aderente às falhas de campo e da literatura. A análise de sensibilidade do modelo por meio da simulação numérica, mostrou que o aumento da qualidade das manutenções preventiva é a melhor estratégia para reduzir o risco de falha do BOP anular. Verificou-se ainda que o aumento da vida útil de alguns componentes é tão relevante quanto o incremento de redundâncias para a confiabilidade do BOP anular. / After Macondo accident (USA, April 2010), with an estimated loss of US $ 42 billion, the failure risk analysis of the BOP (BlowOut Preventor) gained great importance in oil exploration and development projects. This work has deepened in BOP annular preventer (one of BOP functions) failure risk analysis, mapping sensitivity of maintenance of its components in the probability of equipment failure, according to the guidelines of RBI techniques (Risk Based Inspection) and RCM (Reliability Centered Maintenance). Therefore, the methodology used is proposed by API 580 (2009) and API 581 (2008) standards of risk based inspection applied on a reliability model of annular BOP. This reliability model, in turn, was based on fault tree analysis (FTA) and FMEA (Failure Mode and Effect Analysis) over the equipment hydraulic diagram. As hypothesis, it is assumed a constant failure rate of components over time, in order to calculate the mean time between failures. It was proved that reliability calculated by numerical model is coherent to field failures observations and literature data. The sensitivity analysis by numerical simulation shows that improving inspections and preventive maintenance quality in some of BOP components can markedly reduce the risk of failure of annular BOP.

I det moderna samhället utgör metaller en viktig del. Boliden Minerals AB är en stor aktör inom gruvindustrin och är verksamma i Sverige, Finland, Norge och på Irland. I en komplex bransch med varierande arbetsförhållanden och farliga miljöer för de som arbetar i gruvorna är säkerhet en grundpelare. Automation och underhåll är viktiga faktorer för en ökad säkerhet, produktivitet och driftsäkerhet. För att utvinna mineraler ur berg är borrning och sprängning en viktig del i processen. Gruvbrytning omfattar dagbrott och underjordsbrytning och i det här arbetet har borrningsprocessen vid underjordsbrytning studerats. Boliden har planer på att införa autonom borrning av ort- och fällsalvor, som en del i deras gruvautomationsprojekt. Som ett första steg för att öka produktionen och utnyttjandegraden för maskinerna vill de utföra autonom borrning under lunchuppehåll och skiftbyten. Syftet med arbetet var att möjliggöra autonom borrning genom att ur ett underhållsperspektiv förbättra driftsäkerheten för borriggarna. Målet var att kartlägga de fel som uppstår på borriggen samt att föreslå åtgärder för att minska driftstörningarna. Utifrån dokumentation och intervjuer har kartläggningar gjorts över vilka fel som uppstår på borriggarna, hur rutinerna ser ut för tillsyn och underhåll samt vilka larm borriggarnas styrsystem kan ge. Kartläggningen av fel som uppstår har först gjorts med övergripande kategorier för att sedan på detaljnivå studera de områden som står för de flesta felen. Insamlat data, intervjuer och egna observationer har legat till grund för att ta fram förslag till hur driftsäkerheten kan ökas för borriggarna. I linje med tidigare studier visade resultatet att de områden som står för de flesta felen är slangar, med ca 30 % av de totala felen, följt av matare, borrmaskin och styrsystem. I studien utgjorde dessa fel 80–90% av totalt antal fel. Det finns många orsaker till att felen uppstår. Det beror bland annat på miljön som maskinerna arbetar i, mänskligt handhavande, vibrationer och nötningar. Förutom de dokumenterade felen utför operatörerna olika drifts- och underhållsåtgärder på maskinerna. Det omfattar bland annat att fylla på olja och byta borrkrona när dessa blir nötta. Driftstörningarna utgör ca 6 % av den totala tiden då borrmaskinen står uppkopplad vid gaveln. Driftsäkerheten kan ökas ytterligare på de områden där de flesta felen uppstår genom att vidta olika åtgärder. Slangbrott kan minskas genom att skydda slangarna på utsatta ställen och ha ett tätare förebyggande underhåll. I övrigt handlar åtgärderna mycket om att underhåll ska utföras på rätt sätt, att rätt förutsättningar ska finnas för att utför underhållet och att möjliggöra övervakning av borriggen när det inte finns någon operatör på plats. För att i framtiden möjliggöra autonom borrning är det viktigt att operatörerna får rätt utbildning så att de kan systemet och förstår vinningen med att använda det. Vidare finns det många områden för fortsatt utveckling innan maskinerna kan borra helt autonomt och många av dessa områden utgör en stor utmaning på grund av dess komplexitet. Under hela resan är det också viktigt att fortsätta ha människan som utgångspunkt och ett högt säkerhetstänk. / Metals are an important part of the modern society. Boliden Minerals AB is a major player in the mining industry and is active in Sweden, Finland, Norway and on Ireland. In a complex industry with varying working conditions and hazardous environments for those who work in the mines, safety is a cornerstone. Automation and maintenance are important factors for increased safety, productivity and reliability. In order to extract minerals from rock, drilling and blasting is an important part of the process. Mining includes surface and underground mining, and in this work the drilling process for underground mining has been studied. Boliden plans to introduce autonomous drilling for drifting, as part of their mining automation projects. As a first step in increasing the production and utilization of the machines, they want to perform autonomous drilling during lunch breaks and shift changes. The purpose of the work was to enable autonomous drilling by improving the reliability of drilling rigs from a maintenance perspective. The aim was to identify the faults on the drilling rig and propose measures to reduce the operational disturbances. Based on documentation and interviews, mapping has been made on the errors that occur on the drilling rigs, the procedures for supervision and maintenance, and which alarms the drilling rig’s control system can provide. The mapping of errors that occur was first made with overall categories, then studied at the level of detail for the areas that accounts for most of the errors. Based on collected data, interviews and observations, suggestions have been made for how the reliability can be increased on the drilling rigs. In line with previous studies, the result showed that the areas that account for most of the faults are hoses, with about 30 % of the failures, followed by feeder, rock drill and steering system. In the studie, these errors accounted for 80-90% of total errors. There are many reasons why the error occurs. Some of the biggest contribution factors are the environment in which the machines work, human handling, vibrations and wear and tear. In addition to the documented errors, operators perform various operating and maintenance measures on the machines. It includes filling oil and changing drill bits when they are worn out. The operating disturbances account for about 6% of the time when the drilling machine is in use. The reliability can be increased in areas where most of the errors arise by taking different actions. Hose breaks can be reduced by protecting the hoses in exposed areas and having a more throughout preventive maintenance. Other measures are to ensure proper maintenance, that the right conditions are provided and to enable monitoring of the drilling rig when there is no operator in place. In order to enable autonomous drilling in the future, it is important that operators get the right training so that they learn how to handle the system and understand the gain of using it. Furthermore, there are many areas for further development before the machines can drill completely autonomously and many of these areas represent a major challenge due to its complexity. Throughout this journey, it is also important to have a human-centered approach and a high level of security.

Esta tese apresenta, o projeto de uma perfuratriz que permite a execução de cinco tipos de fundação profunda, e o desenvolvimento de um ensaio de campo que possibilita avaliar as resistências por atrito lateral desenvolvidas entre o instrumento envolvido pelo solo escavado e o terreno natural. A perfuratriz foi projetada para executar estacas dos tipos hélice contínua monitorada, escavadas com trado mecânico, hélice segmentada monitorada, raiz e hollow-auger. As estacas dos tipos hélice contínua monitorada e as escavadas com trado mecânico são muito utilizadas no Brasil; as estacas raiz e hollow-auger são utilizadas em situações especiais e a estaca hélice segmentada monitorada é mais recente, mas sua aplicação tem tido um crescimento importante nos últimos dez anos. Para a perfuratriz multifuncional são apresentados cálculos e desenhos básicos dos principais conjuntos. Para a nova investigação de campo, denominada FDT - Full Displacement Test, é apresentado um desenvolvimento teórico com base no princípio universal da conservação de energia que, em termos práticos, resulta na obtenção da parcela de atrito lateral, denominado atrito lateral unitário equivalente (fse). Os resultados obtidos a partir dos dados aquisitados pelo sistema de monitoramento eletrônico da perfuratriz apresentaram-se concordantes entre si, indicando a possibilidade de praticamente se conseguir a repetibilidade do ensaio. Entre os diversos ensaios realizados, foi dada ênfase aos ensaios realizados no campo experimental de Fundações e Geotecnia da Faculdade de Engenharia Agrícola FEAGRI, da Universidade de Campinas - UNICAMP e foram feitas correlações com as resistências obtidas nas provas de carga estáticas realizadas no local por Albuquerque (2001), a partir dos ajustes feitos para o nível instrumentado na profundidade de 11,70 m para o qual foi determinado um fator (G2), para cada tipo de estaca ensaiada (escavada, hélice contínua e ômega). A partir dos ajustes feitos para o nível 11,70 m foram feitas previsões de capacidade de carga por atrito lateral para os outros níveis instrumentados (5,00 m; 11,10 m e 12,00 m), sendo que os resultados apresentaram-se concordantes. / This thesis presents the design of a drilling rig that allows the execution of five types of deep foundation, and the development of a field test that allows measuring the skin friction resistance developed between the instrument involved by the excavated ground and the natural soil. The drilling rig was designed to make continuous flight auger, bored pile, continuous flight auger with segmented auger, root pile and hollow-auger pile. The continuous flight auger and bored piles are widely used in Brazil; the root pile and hollow-auger pile are used for in special conditions, and the continuous flight auger with segmented auger, is although more recent, but its application has had increased application grown in over the last ten years. For the multifunctional drilling rig, calculations and basic designs of the main sets are presented. For the new field test denominated FDT - Full Displacement Test, a theoretical development based on the universal principle of energy conservation was made carried out resulting and the result, in practical terms, was to obtain in the attainment of the skin friction defined in this thesis as equivalent unit skin friction (fse). The results obtained from the data acquired by the electronic monitoring system of drilling rigs were consistent among themselves, indicating the possibility of practically achieve the repeatability of the test. Among the various tests performed, emphasis was given to tests in the experimental field of foundations and geotechnics, of the College of Agricultural Engineering FEAGRI, Campinas University UNICAMP, and were correlated to the skin friction resistance obtained from the static load tests performed on site by Albuquerque (2001), based on the adjustments done to the instrumented level depth of 11.70 m, for which a factor (G2) was given in each type tested (bored, C.F.A and omega). From the adjustments made to the 11,70 m level, load-bearing capacity of skin friction predictions were made for other instrumented levels (5.00 m; 11.10 m and 12.00 m) presenting consistent results.

Diesel engines operating the rig pose the problems of low efficiency and large amount of emissions. In addition the rig power requirements vary a lot with time and ongoing operation. Therefore it is in the best interest of operators to research on alternate drilling energy sources which can make entire drilling process economic and environmentally friendly. One of the major ways to reduce the footprint of drilling operations is to provide more efficient power sources for drilling operations. There are various sources of alternate energy storage/reuse. A quantitative comparison of physical size and economics shows that rigs powered by the electrical grid can provide lower cost operations, emit fewer emissions, are quieter, and have a smaller surface footprint than conventional diesel powered drilling. This thesis describes a study to evaluate the feasibility of adopting technology to reduce the size of the power generating equipment on drilling rigs and to provide ?peak shaving? energy through the new energy generating and energy storage devices such as flywheels. An energy audit was conducted on a new generation light weight Huisman LOC 250 rig drilling in South Texas to gather comprehensive time stamped drilling data. A study of emissions while drilling operation was also conducted during the audit. The data was analyzed using MATLAB and compared to a theoretical energy audit. The study showed that it is possible to remove peaks of rig power requirement by a flywheel kinetic energy recovery and storage (KERS) system and that linking to the electrical grid would supply sufficient power to operate the rig normally. Both the link to the grid and the KERS system would fit within a standard ISO container. A cost benefit analysis of the containerized system to transfer grid power to a rig, coupled with the KERS indicated that such a design had the potential to save more than $10,000 per week of drilling operations with significantly lower emissions, quieter operation, and smaller size well pad.

Esta tese apresenta, o projeto de uma perfuratriz que permite a execução de cinco tipos de fundação profunda, e o desenvolvimento de um ensaio de campo que possibilita avaliar as resistências por atrito lateral desenvolvidas entre o instrumento envolvido pelo solo escavado e o terreno natural. A perfuratriz foi projetada para executar estacas dos tipos hélice contínua monitorada, escavadas com trado mecânico, hélice segmentada monitorada, raiz e hollow-auger. As estacas dos tipos hélice contínua monitorada e as escavadas com trado mecânico são muito utilizadas no Brasil; as estacas raiz e hollow-auger são utilizadas em situações especiais e a estaca hélice segmentada monitorada é mais recente, mas sua aplicação tem tido um crescimento importante nos últimos dez anos. Para a perfuratriz multifuncional são apresentados cálculos e desenhos básicos dos principais conjuntos. Para a nova investigação de campo, denominada FDT - Full Displacement Test, é apresentado um desenvolvimento teórico com base no princípio universal da conservação de energia que, em termos práticos, resulta na obtenção da parcela de atrito lateral, denominado atrito lateral unitário equivalente (fse). Os resultados obtidos a partir dos dados aquisitados pelo sistema de monitoramento eletrônico da perfuratriz apresentaram-se concordantes entre si, indicando a possibilidade de praticamente se conseguir a repetibilidade do ensaio. Entre os diversos ensaios realizados, foi dada ênfase aos ensaios realizados no campo experimental de Fundações e Geotecnia da Faculdade de Engenharia Agrícola FEAGRI, da Universidade de Campinas - UNICAMP e foram feitas correlações com as resistências obtidas nas provas de carga estáticas realizadas no local por Albuquerque (2001), a partir dos ajustes feitos para o nível instrumentado na profundidade de 11,70 m para o qual foi determinado um fator (G2), para cada tipo de estaca ensaiada (escavada, hélice contínua e ômega). A partir dos ajustes feitos para o nível 11,70 m foram feitas previsões de capacidade de carga por atrito lateral para os outros níveis instrumentados (5,00 m; 11,10 m e 12,00 m), sendo que os resultados apresentaram-se concordantes. / This thesis presents the design of a drilling rig that allows the execution of five types of deep foundation, and the development of a field test that allows measuring the skin friction resistance developed between the instrument involved by the excavated ground and the natural soil. The drilling rig was designed to make continuous flight auger, bored pile, continuous flight auger with segmented auger, root pile and hollow-auger pile. The continuous flight auger and bored piles are widely used in Brazil; the root pile and hollow-auger pile are used for in special conditions, and the continuous flight auger with segmented auger, is although more recent, but its application has had increased application grown in over the last ten years. For the multifunctional drilling rig, calculations and basic designs of the main sets are presented. For the new field test denominated FDT - Full Displacement Test, a theoretical development based on the universal principle of energy conservation was made carried out resulting and the result, in practical terms, was to obtain in the attainment of the skin friction defined in this thesis as equivalent unit skin friction (fse). The results obtained from the data acquired by the electronic monitoring system of drilling rigs were consistent among themselves, indicating the possibility of practically achieve the repeatability of the test. Among the various tests performed, emphasis was given to tests in the experimental field of foundations and geotechnics, of the College of Agricultural Engineering FEAGRI, Campinas University UNICAMP, and were correlated to the skin friction resistance obtained from the static load tests performed on site by Albuquerque (2001), based on the adjustments done to the instrumented level depth of 11.70 m, for which a factor (G2) was given in each type tested (bored, C.F.A and omega). From the adjustments made to the 11,70 m level, load-bearing capacity of skin friction predictions were made for other instrumented levels (5.00 m; 11.10 m and 12.00 m) presenting consistent results.

The subject of this diploma thesis is determination of the cause of crack formation at the carriage Top drive for MND Drilling & Services company. The aim of the diploma thesis is to analyze the load states of the component. Furthermore, the aim is to create a computational model and boundary conditions and to create suggestions of improvements leading to the elimination of cracks. And finally, to evaluate the results of construction improvements..

Este trabalho apresenta a modelagem do sistema elétrico de potência de uma plataforma de perfuração dotada de sistema de posicionamento dinâmico. Para tanto, inicialmente são apresentados os conceitos fundamentais de tais unidades, servindo como base teórica e justificando a necessidade de tal estudo. Posteriormente, são apresentados de forma mais detalhada os sistemas de propulsão e geração com as respectivas estratégias de controle. Para a propulsão, estes são acionados por motores de indução trifásicos tendo velocidade controlada a partir da estratégia Direct Torque Control utilizando inversores de três níveis. Para a geração, são utilizados motores diesel como máquinas primárias acoplados a geradores síncronos trifásicos, juntamente com seus respectivos reguladores de velocidade e de tensão. Primeiramente, a operacionalidade destes modelos propostos é confirmada a partir de simulações no programa computacional MATLABR®, utilizando-se a ferramenta gráfica Simulink. Na sequência, a modelagem do sistema de potência completo é obtida no mesmo programa computacional, onde são incluídos os devidos cabeamentos, transformadores e cargas dinâmicas representando os equipamentos de perfuração e de baixa tensão. Utilizando-se de patamares de carga e comandos de velocidade de propulsores obtidos de uma plataforma real em operação de perfuração são realizadas simulações neste sistema completo, tanto com os barramentos de alta tensão interligados quanto segregados. Dentre os resultados obtidos, observa-se que os controles de tensão e de frequência são adequados, além da correta divisão de carga entre geradores a partir do método droop compensado. Por fim, com o intuito de mostrar a potencialidade do sistema obtido, são realizadas análises de curto-circuito mantendo os barramentos de alta tensão interligados, onde é possível observar a propagação da queda de tensão quando a falta ocorre em um barramento de baixa tensão, além das consequências para todo o sistema quando tais faltas são aplicadas no nível de alta tensão. / This work presents the electrical power system modeling of a drilling rig equipped with a dynamic positioning system. Initially, fundamental concepts of such units are presented, bringing a theoretical basis and justifying the need for this study. Subsequently, the propulsion and generation systems as well as their respective control strategies are presented in detail. In regard to the thrusters, they are driven by three-phase induction motors and their speed are controlled by Direct Torque Control strategy using three-level inverters. In respect of the generation system, the prime movers are modeled as diesel engines coupled to three-phase synchronous generators, in addition to their respective speed and voltage regulators. Firstly, the functionality of the proposed models is confirmed by simulations in MATLABR® using Simulink graphical tool. After, the modeling of the complete power system is obtained on the same software, which considers the inclusion of appropriate wiring, transformers and dynamic loads representing the drilling and low voltage equipment. By using load levels and thruster speed commands from an actual vessel during a drilling operation, simulations are carried out at the complete system, considering the high voltage busbars at either connected or segregated configuration. Among the obtained results, it is possible to observe suitable voltage and frequency controls, besides the correct generators load sharing in compensated droop mode. Lastly, to present the potentiality of the obtained system, a short-circuit analysis is performed with the high voltage busbars connected, where it is noticed the means of the voltage drop propagates through the system when the fault occurs at a low voltage busbar, besides the consequences when similar faults are applied at the high voltage level.

This diploma thesis deals with FEM analysis and optimization of carriage for top drive system of drilling rig Bentec 350 AC and it is defined as a development contract for company MND Drilling & Services a.s. Intensive drilling leads to damages and repeated occurrence of fatigue cracks on carriage especially along edges of welded ribs in their heat-affected zone. The aim of this thesis is to draft construction improvements of carriage which leads to elimination of damages. Realization of this modifications depends on correct definition of boundary conditions, analysis of damage occurrence as well as verification of carriage drafts with finite element method.