深水管道法兰自动连接机具关键技术研究及样机研制
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摘要
随着陆上石油资源逐渐枯竭,世界各国越来越重视海上油气的开采。同时,海油开采技术的不断进步,促使海洋石油的开发由浅水向深水发展。海底输油管道作为深水油气开发建设工程的重要组成部分,是连续输送大量油气最快捷、最安全和最经济可靠的运输方式。深水石油管道连接需依靠自动化连接机具完成。本文以国家“863计划”重大专项《深水海底管道铺设技术》的子课题《深水海底管道水下回接技术及AUT检验设备国产化技术研究》为依托,为满足深水海底石油管道连接作业需求,系统开展深水管道法兰自动连接机具的应用研究。研制具有自主知识产权的深水海底管道连接设备,对提高我国在深海石油开发领域的技术水平,降低深海石油开采成本具有重要意义。
论文综述了国内外海底管道连接技术的发展概况,并着重介绍深水管道法兰自动连接机具的国内外发展现状,并对它们的优缺点进行对比分析。
根据管道法兰自动连接机具的技术要求,参考国外相关技术装备的设计经验,并考虑国内现有技术条件,提出了深水管道法兰自动连接机具的总体技术方案,包括机械本体结构、液压系统以及控制系统。机具结构采用模块化设计方法,由螺栓库、螺母库、拉伸器库组成。在对机具结构设计分析的基础上,规划了机具的作业流程。
根据深水海底油气管道法兰连接作业需求,提出了一套法兰连接机具液压动力供给装置的设计方案,解决了水下遥控潜水器(ROV)与法兰连接机具机械结构联接和油路对接的难题。设计了具有滑台座的柔顺液压接头,以补偿对接装置初定位误差,降低对初定位精度的要求,从机械结构上保证了液压油路的精确对接。基于概率理论建立了油路对接成功概率模型,得到了对接成功概率与油路插头的尺寸精度、位置精度的关系。利用Matlab软件对油路插头精度进行数值计算,结果表明,该装置的油路对接成功率较高。
针对深水管道法兰自动连接机具20个螺栓同时引入螺母的难题,研制了一套螺栓引入机构,通过设置弹簧、聚四氟乙烯导向套和橡胶支撑环,保证螺栓可靠的引入螺母。针对水下作业环境,建立了螺栓引入螺母碰撞过程的数学模型。运用ADAMS动力学仿真软件,建立螺栓引入机构系统多体动力学模型,并对其作业过程进行动力学仿真,得到螺栓引入螺母过程的速度、位移曲线,为机具的实际作业运动控制提供依据。在螺栓引入机构试验样机上进行螺栓引入试验,结果表明螺栓能成功引入螺母,验证了螺栓引入机构结构设计的合理性。
运用多刚体运动学理论,通过对法兰自动连接机具的位姿变换矩阵求全微分,建立机具的误差模型,并进行误差的仿真计算,得到各结构参数对螺栓末端位姿误差的影响。对法兰自动连接机具进行误差匹配设计,结合机具的具体结构形式,设计了螺栓库转角误差调整机构,实现了对螺栓库转角误差的硬件补偿,提高了螺栓末端的定位精度。
研制深水管道法兰自动连接机具试验样机,搭建机具试验平台,在试验平台上进行机具的性能试验。为验证马达转速同步性能,进行了马达初始液阻测定试验、螺母套筒扳手机械摩擦试验、转速同步性调试试验,试验结果表明,设计的螺母库和液压同步控制回路能够保证20个马达转速同步误差为0.0447,满足法兰自动连接机具的作业要求。进行了法兰自动连接机具陆上综合调试试验,结果表明,设计的法兰自动连接机具在远程视频系统监控下成功完成两管道的法兰螺栓连接,达到了预期设计目标,为管道法兰自动连接机具的工程化应用打下了一定的基础。
Along with the gradual reduction of onshore oil reserves, countries all over the world have paid more and more attention to offshore oil exploitation. Meanwhile, the progress of the oil exploitation technology has been promoting the development of the offshore oil exploitation from shallow sea to deep sea regions. Subsea oil pipeline is an important part of construction project of deepwater oil and gas exploitation and the safest, most rapid, most reliable and most economical way of continuous transmission. However, the connecting of deepwater oil pipelines depends on an automation connection machines to connect the oil pipeline. This dissertation is part of the project "Deep sea pipeline technology" sub-project "Deepwater submarine pipeline tie-ins technology and AUT inspection equipment research at home" supported by national 863 hi-tech projects of China. According to the requirements for deepwater pipe connection, applied research on exploitation deepwater pipeline flange automatic connection tool was carried out. Therefore, in order to enhance our country's technology level in the field of offshore oil exploitation and decrease the costs of oil exploitation, it is very important to develop the deepwater subsea pipe automatic connection machine with proprietary intellectual property rights.
The development of submarine pipeline connection technology was reviewed in this paper. As a major concern, the recent trend of the deep water pipe flange automatic was emphasized. The advantages and disadvantages of the connection tool were analyzed.
The overall design scheme of deepwater pipe flange automatic connection tool was proposed based on the technical requirements of pipe flange automatic connection and the foreign design experience in the field of automatic connection tool and the current technical conditions in China, including the design of mechanical body structure, hydraulic system and control system. The machine structure, including the bolts magazine, nuts magazine, bolt tensile mechanism, was designed using the modular design method. Based on the structural design of machinery, pipe flange automatic connection tool operating procedures was planned.
According to the deepwater operational requirements of subsea oil pipe tie-ins, a hydraulic circuit docking device scheme for remotely operated vehicle (ROV) and deepwater pipe flange automatic connection tool was proposed. The study solves the problem of mechanical connection and oil circuit docking for ROV and underwater operation equipment. In order to reduce the positioning accuracy requirements of the early docking, compliant hydraulic connector with adjust dado was designed. The compliant hydraulic connector can compensate the early docking errors, which ensured oil circuit docking precision by the mechanical structure. Based on the probability theory, the probability model of oil docking was established, and the relationship of docking probability and the oil pin tolerance in size and position was gained. The precision of oil pin was calculated by Matlab, the calculation results show the docking probability of the device was high.
To solve the problem of 20 bolts synchronous lead-in nuts for deepwater petroleum pipeline flange connection tool, bolts lead-in mechanism was designed according to the operational requirements of deepwater pipeline flange connection tool. By setting the spring, polytetrafluoroethylene(PTFE) jacket and rubber support ring, bolt could be reliable lead-in the nut. For the deepwater environment, the mathematical model of collision that the bolt lead-in the nut was set up. The multi-body dynamic model of bolt lead-in mechanism system was built by ADAMS, and the speed and displacement curve of nut was gained by the study of its operating process dynamic simulation. The results provide basis for actual motion control. The experiment of bolt lead-in mechanism test prototype was performed. The experimental results showed that the bolt could successfully lead-in the nut, verify that the reasonableness of bolt lead-in mechanism design.
Using multi-body kinematics theory to homogeneous transformation matrix, the error model of deepwater pipe flange connection tool was established through total differential of the machinery pose transformation matrix. The error model of the tool was calculated by computer simulation, and the effect of the structure parameters on the bolt end pose error was analyzed. Based on the method of error matching design, the error on the deepwater pipe flange automatic connection tool was designed. Considering the specific structure of the connection tool, the adjusting mechanism of bolt angle error was also designed. Therefore, the hardware compensation of bolt angle error was achieved successfully, which improved the positioning accuracy of the bolt end.
The performance test of the automatic connection tool was performed in the prototype test platform of deepwater pipe flange automatic connection tool. The motor speed synchronization performance was investigated by the initial fluid resistance test of motor, mechanical friction test of nut wrench and speed synchronous debugging test. The results showed that the design of the nut magazine and the hydraulic control circuit could guarantee synchronous motor speed synchronization error of 20 was 0.0447, which met the flange automatic connection tool operational requirements. Land comprehensive debugging test was carried out, and the results showed that the design of pipe flange connection tool could complete two pipes connection under the remote video monitoring system. The pipe flange automatic connection tool prototype has laid a certain foundation for its engineering application, which has achieved the desired design goals.
论文综述了国内外海底管道连接技术的发展概况,并着重介绍深水管道法兰自动连接机具的国内外发展现状,并对它们的优缺点进行对比分析。
根据管道法兰自动连接机具的技术要求,参考国外相关技术装备的设计经验,并考虑国内现有技术条件,提出了深水管道法兰自动连接机具的总体技术方案,包括机械本体结构、液压系统以及控制系统。机具结构采用模块化设计方法,由螺栓库、螺母库、拉伸器库组成。在对机具结构设计分析的基础上,规划了机具的作业流程。
根据深水海底油气管道法兰连接作业需求,提出了一套法兰连接机具液压动力供给装置的设计方案,解决了水下遥控潜水器(ROV)与法兰连接机具机械结构联接和油路对接的难题。设计了具有滑台座的柔顺液压接头,以补偿对接装置初定位误差,降低对初定位精度的要求,从机械结构上保证了液压油路的精确对接。基于概率理论建立了油路对接成功概率模型,得到了对接成功概率与油路插头的尺寸精度、位置精度的关系。利用Matlab软件对油路插头精度进行数值计算,结果表明,该装置的油路对接成功率较高。
针对深水管道法兰自动连接机具20个螺栓同时引入螺母的难题,研制了一套螺栓引入机构,通过设置弹簧、聚四氟乙烯导向套和橡胶支撑环,保证螺栓可靠的引入螺母。针对水下作业环境,建立了螺栓引入螺母碰撞过程的数学模型。运用ADAMS动力学仿真软件,建立螺栓引入机构系统多体动力学模型,并对其作业过程进行动力学仿真,得到螺栓引入螺母过程的速度、位移曲线,为机具的实际作业运动控制提供依据。在螺栓引入机构试验样机上进行螺栓引入试验,结果表明螺栓能成功引入螺母,验证了螺栓引入机构结构设计的合理性。
运用多刚体运动学理论,通过对法兰自动连接机具的位姿变换矩阵求全微分,建立机具的误差模型,并进行误差的仿真计算,得到各结构参数对螺栓末端位姿误差的影响。对法兰自动连接机具进行误差匹配设计,结合机具的具体结构形式,设计了螺栓库转角误差调整机构,实现了对螺栓库转角误差的硬件补偿,提高了螺栓末端的定位精度。
研制深水管道法兰自动连接机具试验样机,搭建机具试验平台,在试验平台上进行机具的性能试验。为验证马达转速同步性能,进行了马达初始液阻测定试验、螺母套筒扳手机械摩擦试验、转速同步性调试试验,试验结果表明,设计的螺母库和液压同步控制回路能够保证20个马达转速同步误差为0.0447,满足法兰自动连接机具的作业要求。进行了法兰自动连接机具陆上综合调试试验,结果表明,设计的法兰自动连接机具在远程视频系统监控下成功完成两管道的法兰螺栓连接,达到了预期设计目标,为管道法兰自动连接机具的工程化应用打下了一定的基础。
Along with the gradual reduction of onshore oil reserves, countries all over the world have paid more and more attention to offshore oil exploitation. Meanwhile, the progress of the oil exploitation technology has been promoting the development of the offshore oil exploitation from shallow sea to deep sea regions. Subsea oil pipeline is an important part of construction project of deepwater oil and gas exploitation and the safest, most rapid, most reliable and most economical way of continuous transmission. However, the connecting of deepwater oil pipelines depends on an automation connection machines to connect the oil pipeline. This dissertation is part of the project "Deep sea pipeline technology" sub-project "Deepwater submarine pipeline tie-ins technology and AUT inspection equipment research at home" supported by national 863 hi-tech projects of China. According to the requirements for deepwater pipe connection, applied research on exploitation deepwater pipeline flange automatic connection tool was carried out. Therefore, in order to enhance our country's technology level in the field of offshore oil exploitation and decrease the costs of oil exploitation, it is very important to develop the deepwater subsea pipe automatic connection machine with proprietary intellectual property rights.
The development of submarine pipeline connection technology was reviewed in this paper. As a major concern, the recent trend of the deep water pipe flange automatic was emphasized. The advantages and disadvantages of the connection tool were analyzed.
The overall design scheme of deepwater pipe flange automatic connection tool was proposed based on the technical requirements of pipe flange automatic connection and the foreign design experience in the field of automatic connection tool and the current technical conditions in China, including the design of mechanical body structure, hydraulic system and control system. The machine structure, including the bolts magazine, nuts magazine, bolt tensile mechanism, was designed using the modular design method. Based on the structural design of machinery, pipe flange automatic connection tool operating procedures was planned.
According to the deepwater operational requirements of subsea oil pipe tie-ins, a hydraulic circuit docking device scheme for remotely operated vehicle (ROV) and deepwater pipe flange automatic connection tool was proposed. The study solves the problem of mechanical connection and oil circuit docking for ROV and underwater operation equipment. In order to reduce the positioning accuracy requirements of the early docking, compliant hydraulic connector with adjust dado was designed. The compliant hydraulic connector can compensate the early docking errors, which ensured oil circuit docking precision by the mechanical structure. Based on the probability theory, the probability model of oil docking was established, and the relationship of docking probability and the oil pin tolerance in size and position was gained. The precision of oil pin was calculated by Matlab, the calculation results show the docking probability of the device was high.
To solve the problem of 20 bolts synchronous lead-in nuts for deepwater petroleum pipeline flange connection tool, bolts lead-in mechanism was designed according to the operational requirements of deepwater pipeline flange connection tool. By setting the spring, polytetrafluoroethylene(PTFE) jacket and rubber support ring, bolt could be reliable lead-in the nut. For the deepwater environment, the mathematical model of collision that the bolt lead-in the nut was set up. The multi-body dynamic model of bolt lead-in mechanism system was built by ADAMS, and the speed and displacement curve of nut was gained by the study of its operating process dynamic simulation. The results provide basis for actual motion control. The experiment of bolt lead-in mechanism test prototype was performed. The experimental results showed that the bolt could successfully lead-in the nut, verify that the reasonableness of bolt lead-in mechanism design.
Using multi-body kinematics theory to homogeneous transformation matrix, the error model of deepwater pipe flange connection tool was established through total differential of the machinery pose transformation matrix. The error model of the tool was calculated by computer simulation, and the effect of the structure parameters on the bolt end pose error was analyzed. Based on the method of error matching design, the error on the deepwater pipe flange automatic connection tool was designed. Considering the specific structure of the connection tool, the adjusting mechanism of bolt angle error was also designed. Therefore, the hardware compensation of bolt angle error was achieved successfully, which improved the positioning accuracy of the bolt end.
The performance test of the automatic connection tool was performed in the prototype test platform of deepwater pipe flange automatic connection tool. The motor speed synchronization performance was investigated by the initial fluid resistance test of motor, mechanical friction test of nut wrench and speed synchronous debugging test. The results showed that the design of the nut magazine and the hydraulic control circuit could guarantee synchronous motor speed synchronization error of 20 was 0.0447, which met the flange automatic connection tool operational requirements. Land comprehensive debugging test was carried out, and the results showed that the design of pipe flange connection tool could complete two pipes connection under the remote video monitoring system. The pipe flange automatic connection tool prototype has laid a certain foundation for its engineering application, which has achieved the desired design goals.
引文
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