钻柱液压升沉补偿系统设计研究
摘要
钻柱升沉补偿装置是海洋钻井的重要设备。海洋钻井所采用的半潜式钻井平台和钻井浮船在波浪的作用下将产生周期性的升沉运动,并使钻柱上下往复运动引起井底钻压的变化,甚至使钻头脱离井底影响钻进的效率,降低钻头和钻杆寿命,产生操作的安全隐患,在恶劣天气下甚至导致无法钻进和被迫停工,造成了巨大的经济损失。为此浮式钻井平台必须对钻柱升沉运动采取适当的补偿措施。
本文对目前使用的钻柱升沉补偿系统的结构、工作原理、补偿效果及能耗进行比较分析,在此基础上提出一种新型的钻柱液压升沉补偿系统,并对该系统进行设计、分析系统性能,以期在补偿效果和能耗方面有所提高。
文中对目前使用的各种钻柱升沉补偿装置的结构及工作原理进行了分析比较,包括游车与大钩间装设的升沉补偿装置、天车上装设的升沉补偿装置、死绳上装设的升沉补偿装置,发现游车与大钩间装设的升沉补偿装置,不需特制井架及天车,游动滑车及大钩也均可采用标准通用者,减少了加工制造的复杂性,易于投入钻井生产,因此最终确定新型钻柱升沉补偿系统采用将补偿缸装设在游车与大钩之间,并且双缸倒置的形式。
对被动式、主动式和半主动式游车与大钩间装设的升沉补偿装置性能进行比较分析。建立三种系统的数学模型和仿真模型,并利用AMESim系统仿真软件对各系统进行仿真计算,分析各自的性能,从补偿效果和能耗方面对三种不同供能方式的系统进行比较。计算表明半主动式系统的补偿效果比被动式升沉补偿系统好,能耗比主动式升沉补偿系统小,因此确定在半主动式系统的基础上,研究进一步改善补偿效果和节能的方法。
在前面分析比较的基础上,提出新型钻柱升沉补偿系统的方案,采用补偿缸有杆腔主动控制、无杆腔被动的形式简化半主动式系统复杂的结构,并采用有杆腔泵控加阀控的形式,以期获得较好的节能效果。对新型钻柱升沉补偿系统的结构、液压系统进行设计计算,研究整个系统的工作原理,在此基础上建立该系统的数学模型,利用AMESim仿真软件对系统进行仿真,和现有升沉补偿系统的性能进行比较,确定新型钻柱升沉补偿系统的可行性。
为了实际验证系统的性能,本文最后设计了新型钻柱升沉补偿系统的试验台,包括结构设计和液压系统设计。通过试验可以为新型钻柱升沉补偿系统的改进提供依据。
Drill string heave compensation system is vital device of offshore drilling operation. Themovement of drill ships or semi-submersible drilling rigs with the waves of the sea presents aunique problem in drilling with these types of rigs. Heave, however, removes weight from thedrill bit as the ship or rig rides to the crest of a wave, and puts weight back on the drill bit as theship or rig rides down into the trough between waves. This fluctuation in the force applied on thedrill bit severely hinders an operator's ability to drill the well bore. To account for the problemsassociated with heave, floating drilling rigs are equipped with a heave compensation system. Theheave compensation system is typically in the form of an active heave drawworks system or asystem that is an integral part of the drilling derrick or mounted directly on an extension of thetraveling block. When functioning properly, these primary heave compensation systems arecapable of protecting against the effects of heave.
The object of the article is to introduce and compare drill string compensation systemgenerally used in the terms of structure, operating principle, hook displacement and energyconsumption, and to disclose a new type drill string compensation system on this basis, designand system performance investigation including with a view to improve compensation results andreduce energy consumption.
First, structure and operating principle of several kinds of drill string compensators arecompared, including compensator mounted between travelling block and hook, crown mounteddrill string compensator and that mounted on the dead line. By the advantage of easy-made rig,crown block, and standard traveling block and hook, compensator mounted between travellingblock and hook with reverse cylinder is chosen to develop new type of drill string compensationsystem.
Then in accordance with classification method of the passive, active and semi-active system,the performance of compensator mounted between travelling block and hook is studied deeply.Mathematical mode, simulation model are set up. The models are simulated and calculated by themeans of AMESim. The three kinds of system based on different way of energy providing areanalyzed and compared in the terms of hook displacement and energy consumption according to the simulation results. Because of good performance of semi-active system, new method toimprove performance of compensator can be developed on the basis of it.
On the base of previous work, new drill string compensation system is proposed. Thecompensation cylinders of new system have their rod end controlled and piston end worked inthe passive way to simplify the system. The rod ends of cylinders are controlled with both pumpand valve in order to save energy. Function principle is studied, the structure and hydraulicsystem are designed and calculated, and at last mathematical model is set up. The model issimulated with AMESim. The performance of the system is analyzed from the simulation resultsand compared with systems currently being used. Then the feasibility of new drill stringcompensation system is confirmed.
In order to verify the actual performance of the system, experimental system is needed. Newtype of drill string heave compensation system is designed at the end of the paper, including thestructural design and hydraulic system design. Through experiments, basis for the new drill stringheave compensation system to improve will be provided.
本文对目前使用的钻柱升沉补偿系统的结构、工作原理、补偿效果及能耗进行比较分析,在此基础上提出一种新型的钻柱液压升沉补偿系统,并对该系统进行设计、分析系统性能,以期在补偿效果和能耗方面有所提高。
文中对目前使用的各种钻柱升沉补偿装置的结构及工作原理进行了分析比较,包括游车与大钩间装设的升沉补偿装置、天车上装设的升沉补偿装置、死绳上装设的升沉补偿装置,发现游车与大钩间装设的升沉补偿装置,不需特制井架及天车,游动滑车及大钩也均可采用标准通用者,减少了加工制造的复杂性,易于投入钻井生产,因此最终确定新型钻柱升沉补偿系统采用将补偿缸装设在游车与大钩之间,并且双缸倒置的形式。
对被动式、主动式和半主动式游车与大钩间装设的升沉补偿装置性能进行比较分析。建立三种系统的数学模型和仿真模型,并利用AMESim系统仿真软件对各系统进行仿真计算,分析各自的性能,从补偿效果和能耗方面对三种不同供能方式的系统进行比较。计算表明半主动式系统的补偿效果比被动式升沉补偿系统好,能耗比主动式升沉补偿系统小,因此确定在半主动式系统的基础上,研究进一步改善补偿效果和节能的方法。
在前面分析比较的基础上,提出新型钻柱升沉补偿系统的方案,采用补偿缸有杆腔主动控制、无杆腔被动的形式简化半主动式系统复杂的结构,并采用有杆腔泵控加阀控的形式,以期获得较好的节能效果。对新型钻柱升沉补偿系统的结构、液压系统进行设计计算,研究整个系统的工作原理,在此基础上建立该系统的数学模型,利用AMESim仿真软件对系统进行仿真,和现有升沉补偿系统的性能进行比较,确定新型钻柱升沉补偿系统的可行性。
为了实际验证系统的性能,本文最后设计了新型钻柱升沉补偿系统的试验台,包括结构设计和液压系统设计。通过试验可以为新型钻柱升沉补偿系统的改进提供依据。
Drill string heave compensation system is vital device of offshore drilling operation. Themovement of drill ships or semi-submersible drilling rigs with the waves of the sea presents aunique problem in drilling with these types of rigs. Heave, however, removes weight from thedrill bit as the ship or rig rides to the crest of a wave, and puts weight back on the drill bit as theship or rig rides down into the trough between waves. This fluctuation in the force applied on thedrill bit severely hinders an operator's ability to drill the well bore. To account for the problemsassociated with heave, floating drilling rigs are equipped with a heave compensation system. Theheave compensation system is typically in the form of an active heave drawworks system or asystem that is an integral part of the drilling derrick or mounted directly on an extension of thetraveling block. When functioning properly, these primary heave compensation systems arecapable of protecting against the effects of heave.
The object of the article is to introduce and compare drill string compensation systemgenerally used in the terms of structure, operating principle, hook displacement and energyconsumption, and to disclose a new type drill string compensation system on this basis, designand system performance investigation including with a view to improve compensation results andreduce energy consumption.
First, structure and operating principle of several kinds of drill string compensators arecompared, including compensator mounted between travelling block and hook, crown mounteddrill string compensator and that mounted on the dead line. By the advantage of easy-made rig,crown block, and standard traveling block and hook, compensator mounted between travellingblock and hook with reverse cylinder is chosen to develop new type of drill string compensationsystem.
Then in accordance with classification method of the passive, active and semi-active system,the performance of compensator mounted between travelling block and hook is studied deeply.Mathematical mode, simulation model are set up. The models are simulated and calculated by themeans of AMESim. The three kinds of system based on different way of energy providing areanalyzed and compared in the terms of hook displacement and energy consumption according to the simulation results. Because of good performance of semi-active system, new method toimprove performance of compensator can be developed on the basis of it.
On the base of previous work, new drill string compensation system is proposed. Thecompensation cylinders of new system have their rod end controlled and piston end worked inthe passive way to simplify the system. The rod ends of cylinders are controlled with both pumpand valve in order to save energy. Function principle is studied, the structure and hydraulicsystem are designed and calculated, and at last mathematical model is set up. The model issimulated with AMESim. The performance of the system is analyzed from the simulation resultsand compared with systems currently being used. Then the feasibility of new drill stringcompensation system is confirmed.
In order to verify the actual performance of the system, experimental system is needed. Newtype of drill string heave compensation system is designed at the end of the paper, including thestructural design and hydraulic system design. Through experiments, basis for the new drill stringheave compensation system to improve will be provided.
引文
[1]方华灿．海洋石油钻采装备与结构[M]．北京：石油工业出版社，1990：10-100
[2] FeryD．Heave compensation[EB/OL]．http://everything2.com/title/Heave%2520compensation．2002，04，08
[3] Umesh A.Korde．Active heave compensation on Drill-ships in irregular waves[J]．Oceanengineering，1998，25(7)：541-561
[4] Leland R．Robichaux，Jan T．Hatleskog．Semi-active Heave compensation system forMarine Vessels[P]．United States：005209302A．May 11，1993
[5]栾苏，于兴军．深水平台钻机技术现状与思考[J]．石油机械，2008，36(9)
[6] R?谢菲尔德．浮式钻井设备及其使用[M]．北京：石油工业出版社，1988：190-200
[7]王庆丰，王海波．基于恒定压差的水下拖体被动升沉补偿系统[P]．中国专利：CN101032996，2007，09，12
[8]方华灿．海洋钻井船升沉补偿装置的设计[J]．石油矿场机械，1976(5)：25-37
[9]方华灿．海洋钻井船升沉补偿装置工作理论的初步研究[J]．华东石油学院学报，1978(3)：56-67
[10]方华灿．海洋钻井绳索作业时升沉补偿问题的研究[J]．华东石油学院学报，1980(3)：20-32
[11]余佑官，龚国芳，胡国良．AMESim仿真技术及其在液压系统中的应用[J]．液压气动与密封，2005(3)：28-31
[12] Roodenburg，Pieter，Dirk．HEAVE MOTION COMPENSATION[P]．Worldorganization：WO/2007/145503 A1，2007，12，21
[13]吕东，何将三，刘少军．深海采矿被动式升沉补偿系统设计及仿真分析[J]．矿山机械，2003：6
[14]肖体兵，吴百海．深海采矿扬矿管重载被动型升沉补偿系统的研究[J]．液压与气动，2007(1)：13
[15]吴百海，龙建军，等．海洋采矿起伏补偿电液控制信号采集的研究[J]．液压与气动，2002 (7)：18-19
[16]方华灿．海洋钻机的起升机件的强度问题的研究[J]．石油矿场机械，1982(2)：6
[17]肖体兵，吴百海，罗忠辉．重型扬矿管主动升沉补偿系统的设计与仿真研究[J]．机床与液压，2002(6)：47-50
[18]吴百海，邹大鹏，冶占武，等．深海采矿长行程升沉补偿油缸的同步检测与控制[J]．机床与液压.2004(10)：35-37
[19]邱显焱，刘少军，等．深海采矿升沉补偿系统的自调整模糊控制仿真[J]．中南大学学报(自然科学版)，2006，37(4)：754-758
[20]肖奇军，吴百海，肖体兵，等．模糊-PID控制在深海采矿升沉补偿模拟系统中的应用[J]．液压与气动，2004(10)：49-51
[21]黄锴．1000m海试采矿系统升沉补偿系统控制方法探讨及虚拟样机研究[D]．长沙:长沙中南大学机电工程学院，2003：70-75
[22]黄锴，刘少军，肖永山．基于ADAMS的深海采矿装置升沉补偿系统仿真研究[J]．计算机仿真，2003，20(10)：57-59
[23] Anthony Bruce Duncan，Richard Galen Sprague，Author Hor Ting Chin．DRILLSTRING COMPENSATOR[P]．United States Patent：US3804183，1974，4，16
[24]郑克强．国外海洋钻采成套设备概况[J]．兰州：石油矿场机械，1978：51-60
[25]雷天觉．新编液压工程手册(下)[M]．北京：北京理工大学出版社，1998：1383-1399
[26]吕英民．材料力学(I)[M]．北京：石油大学出版社，1994：244-262.
[27] Anthony Bruce Duncan，Richard Galen Sprague，Author Hor Ting Chin．DRILLSTRING COMPENSATOR[P]．United States Patent：US3804183，1974，4，16
[28] Magne Mathias Moe，Age Kyllingstad．Inline Compensator For A Floating Drillrig[P]．United States：US7231981B2，2007，06，19.
[29] Gary L，Egbert，Philip L. Ziegler III．Drill String Compensator with ImprovedTransloaders[P]．United States：US5066059，1991，11，19
[30]杨毅．自适应控制在波浪补偿系统中的应用研究[D]．武汉：武汉理工大学，2007：19
[31] Douglas W.J. Nayler，Gerald W. Gilson，Fred C. Tilker，etc．Position Indicator For DrillString Compensator[P]．United States：US4466488，1984，08，21
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[39]肖体兵,吴百海.轻载主动型升沉补偿模拟试验系统的仿真和实验研究[A].中国海洋学会2005年学术年会论文汇编[C].银川:中国海洋学会,2005:161-165
[2] FeryD．Heave compensation[EB/OL]．http://everything2.com/title/Heave%2520compensation．2002，04，08
[3] Umesh A.Korde．Active heave compensation on Drill-ships in irregular waves[J]．Oceanengineering，1998，25(7)：541-561
[4] Leland R．Robichaux，Jan T．Hatleskog．Semi-active Heave compensation system forMarine Vessels[P]．United States：005209302A．May 11，1993
[5]栾苏，于兴军．深水平台钻机技术现状与思考[J]．石油机械，2008，36(9)
[6] R?谢菲尔德．浮式钻井设备及其使用[M]．北京：石油工业出版社，1988：190-200
[7]王庆丰，王海波．基于恒定压差的水下拖体被动升沉补偿系统[P]．中国专利：CN101032996，2007，09，12
[8]方华灿．海洋钻井船升沉补偿装置的设计[J]．石油矿场机械，1976(5)：25-37
[9]方华灿．海洋钻井船升沉补偿装置工作理论的初步研究[J]．华东石油学院学报，1978(3)：56-67
[10]方华灿．海洋钻井绳索作业时升沉补偿问题的研究[J]．华东石油学院学报，1980(3)：20-32
[11]余佑官，龚国芳，胡国良．AMESim仿真技术及其在液压系统中的应用[J]．液压气动与密封，2005(3)：28-31
[12] Roodenburg，Pieter，Dirk．HEAVE MOTION COMPENSATION[P]．Worldorganization：WO/2007/145503 A1，2007，12，21
[13]吕东，何将三，刘少军．深海采矿被动式升沉补偿系统设计及仿真分析[J]．矿山机械，2003：6
[14]肖体兵，吴百海．深海采矿扬矿管重载被动型升沉补偿系统的研究[J]．液压与气动，2007(1)：13
[15]吴百海，龙建军，等．海洋采矿起伏补偿电液控制信号采集的研究[J]．液压与气动，2002 (7)：18-19
[16]方华灿．海洋钻机的起升机件的强度问题的研究[J]．石油矿场机械，1982(2)：6
[17]肖体兵，吴百海，罗忠辉．重型扬矿管主动升沉补偿系统的设计与仿真研究[J]．机床与液压，2002(6)：47-50
[18]吴百海，邹大鹏，冶占武，等．深海采矿长行程升沉补偿油缸的同步检测与控制[J]．机床与液压.2004(10)：35-37
[19]邱显焱，刘少军，等．深海采矿升沉补偿系统的自调整模糊控制仿真[J]．中南大学学报(自然科学版)，2006，37(4)：754-758
[20]肖奇军，吴百海，肖体兵，等．模糊-PID控制在深海采矿升沉补偿模拟系统中的应用[J]．液压与气动，2004(10)：49-51
[21]黄锴．1000m海试采矿系统升沉补偿系统控制方法探讨及虚拟样机研究[D]．长沙:长沙中南大学机电工程学院，2003：70-75
[22]黄锴，刘少军，肖永山．基于ADAMS的深海采矿装置升沉补偿系统仿真研究[J]．计算机仿真，2003，20(10)：57-59
[23] Anthony Bruce Duncan，Richard Galen Sprague，Author Hor Ting Chin．DRILLSTRING COMPENSATOR[P]．United States Patent：US3804183，1974，4，16
[24]郑克强．国外海洋钻采成套设备概况[J]．兰州：石油矿场机械，1978：51-60
[25]雷天觉．新编液压工程手册(下)[M]．北京：北京理工大学出版社，1998：1383-1399
[26]吕英民．材料力学(I)[M]．北京：石油大学出版社，1994：244-262.
[27] Anthony Bruce Duncan，Richard Galen Sprague，Author Hor Ting Chin．DRILLSTRING COMPENSATOR[P]．United States Patent：US3804183，1974，4，16
[28] Magne Mathias Moe，Age Kyllingstad．Inline Compensator For A Floating Drillrig[P]．United States：US7231981B2，2007，06，19.
[29] Gary L，Egbert，Philip L. Ziegler III．Drill String Compensator with ImprovedTransloaders[P]．United States：US5066059，1991，11，19
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