深水半潜式钻井平台钻机系统选型与布局优化研究
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摘要
本文结合国家高技术研究发展(863)计划海洋技术领域重大项目“深水半潜式钻井船设计与建造关键技术(课题编号:2006AA09A104)”,在大量运用和处理国外深水半潜式平台和海洋钻机各种数据基础上,运用复杂系统设计理论、数值分析和计算机仿真等技术,以提高深水钻井效率为主要目标,系统开展了平台钻机系统选型和布局优化设计等方面的研究。主要取得了如下研究成果:
1.深水钻井作业工艺关键路径优化研究
提高钻井作业效率是第六代半潜式钻井平台最重要设计目标,应用双井架钻机是提高(超)深水钻井作业效率的有效技术。本文采用并行工程理论和甘特图探讨双井架钻机并行作业和协作作业机理,突破钻井工艺顺序作业限制,将同一工序(过程)的部分辅助工作离线作业,优化了钻井作业关键路径;并进一步优化了配置双井架钻机钻井平台的单井和多井钻井作业工艺流程,显著缩短深水建井周期。在此基础上,初步建立了采用双井架钻机系统的钻井平台所需基本设备配置。
2.钻机系统选型优化研究
钻机系统决定平台钻井作业的效率,选择、配置深水半潜平台钻机系统是设计第六代半潜式钻井平台的关键。本文采用复杂大系统优化分解—协调理论,将深水钻机系统分解成钻机、材料输送系统、动力系统、控制系统和后勤服务系统等5个子系统,建立优化模型,重点对钻机和材料输送系统进行优化选型研究。研究了钻机结构配置与离线作业能力及作业效率关系,离线钻机配置越完整全面,作业效率提升越大,双井架钻机最大化发挥了并行与协作作业能力。双井架钻机相对离线钻机显著提高作业效率,但增加可变载荷和建造成本,受专利影响增加作业成本,采用投资回收模型和净现值模型综合分析表明:双井架钻机总体优于离线钻机。钻井材料的不同物化状态决定输送系统输送方式和配置,分别对钻井管具、专用设备和钻井液三类材料进行了输送方式和装备配置优化。从占用甲板面积、重心、总体布局和作业效率等因素对隔水管存储形式比分析可知,存储模式对总体布局影响大,立放模式有利于总体布局设计。分析影响隔水管作业的因素,提出了提高作业效率措施,尤其隔水管接头形式的选型应引起重视。
3.钻机系统布局优化研究
针对钻井系统布局兼有生产布局和复杂三维大系统布局特点,本文提出基于作业流程层次分解布局法,建立了布局理论、算法和布局流程。该方法以作业流程为基础,按材料输送系统输送模式划分子空间,子空间内进一步模块化,以模块为布局基本单位,对不同空间采用相应优化算法,完成布局初步方案。然后根据重心对平台布局进行调整,以提高稳性,最后进行安全规划,完成布局详细设计。该方案综合考虑作业效率、安全性、稳性和人因工程学多方面因素,具有工程操作可行性和优化性,在具有性能约束大系统三维布局设计方面具有独创性。以在建某863项目平台钻井系统为实例,设计布局方案,完成布局设计。采用三维软件对平台及钻井系统进行三维建模、装配仿真和作业流程动态仿真,进一步验证布局合理性。
4.钻台自动化装备优化布局和基于人因工程学钻井控制室设计研究
针对钻台自动化作业程度高的特点,基于三类不同管具作业流程和设备设施作业衔接关系,完成钻台自动化装备布局设计,有效协调各类管具的输送、暂存、交换和处理等自动化作业活动。综合运用数值计算和CAE仿真方法对双钻井中心在平台定位进行优化,确定了主辅钻井中心定位布局优化方案。
本文运用人因工程学原理和标准对目标平台钻机控制室进行设计,实现信息通信协调机制,信息过载处理和作业群体之间相互协调。设计中具体设计采用三级控制、显示方式,实现基于流程自动控制和手动控制有机结合的控制方式,改变控制室设计基于设备集成的理念,提高了作业功效。
The dissertation focuses on deepwater rigs system design for ultra-deepwater semi-submersible platforms/unites (SSDP/SSDU), which is a part of the“863”High Technology Research and Development Program of China (No.2006AA09A104)—the key technique research on SSDPs’design and construction. Aiming at improving the operation efficiency of deepwater drilling, the paper synthetically adopts theoretical research, numerical calculation and computer simulation and perfects well drilling technology, drilling system mode option and layout optimization based on application and processing external marine drilling rig and SSDP. The main achievements are summarized as follows:
1. Research on critical path optimization of deepwater drilling process
Not only does dual derrick rigs lead to profound revolution of well drilling technology, but also cause significant change on drilling rigs configuration. The theory of concurrent engineering and Gantt chart are applied to analyze mechanism of dual derrick rigs process flow which lies in two factors—concurrent operation and cooperative operation. Concurrent operation breaks through sequence operation and cooperative operation completes work by main and auxiliary rigs together. Drilling craft of exploration well and development well are made out and optimized by Gantt chart. The well drilling process shorten well construction period and improves benefit. At last, prime equipments supported dual derrick rigs are established which are base for subsequent work.
2. Research on rigs system mode option and configuration optimization
As driliing operation efficiency is determined by the drilling rigs system, selection and configuration of deepwater rigs system is key of the construction of 6th generation domestic SSDP. Based on theory of decomposition-coordination for complex large-scale system, deepwater drilling rigs system is divied into 5 sub-systems, including of rigs, material transportation system, power system, logistics service system and control system. Function relation of sub-systems and optimization model is set up and two sub-systems—rigs and drilling material transportation system are studied especially. The relation between offline operation ability and rigs configuration is studied that the the more offline equipments, the more work efficient. Two kinds of rigs—offline rigs and dual derrick rigs are compared by payback period and net present value (NPV) from viewpoint of efficiency, variable derrick load, patent and cost of construction. And result shows that the dual derrick rigs is more excellent as a whole. Transportation modes are determined by shape and quality of material modality, and they are divided into three modes—drilling pipes, large special equipment and drilling mud system, and optimized the process flow and equipment configuration. The paper analyses two risers storage models and equipment configuration, and compares to occupying deck area, center of gravity general layout and operation efficiency. The result shows that there is no evidence difference in center of gravity and system operation efficiency besides they have significant effect in general layout. Risers’operation efficiency factors are analyzed and measures to improve efficiency are put forward, of which risers’connector should be attached importance to. SSDP & drilling equipment management information system is set up for the sake of improving management and benefit of equipment option.
3. Study on layout optimization of rigs system
Rigs system layout integrates the characteristic of production system and complex three-dimensional (3-D) system layout. The dissertation firstly brings forward compound /integrated hierarchical division based on process flow and constitutes layout theory, arithmetic and layout process on the basis of complex large-scale composition- coordination. The method is based on operational flow and different transportation modes are marked out according to the shape and quality to material modality. Two hierarchy decompose—sub-space and modules,which are basic layout units,are brought into operation. We applied different layout arithmetic to mark out the upper and lower decks. That is, the upper deck was designed based on the lowest transportation cost while the lower deck’s calculations were based on the best-fit scope. Finally the center of gravity was taken into consideration and the general layout was adjusted according to result in an optimal center of gravity. The project strongpoint doesn’t only lies in taking into account efficiency, safety, stability and human factors engineer, but also engineer practicality and optimization, especially in 3-D layout with behavioral constraints. According to the layout programming, we take the 863 project in the scantling design as an example, implementing the layout of rigs system in details. In order to validate layout for further, 3-D modeling of SSDP and rigs system are constructed to carry into execution simulation of assembly and process flow moving.
4. Research on drill fllor layout optimization and driller cabin design based on human factors engineer.
Drill floor of semi-submersible drilling platform is the work center of drilling. And there are three different operation flows handled with drill pipes, large-diameter casings and risers. The driller layout principle and program are made certain based on process, linking up and manipulation relation and human factors engineer. All automated equipments on drill floor are collocated with layout principle and program and assorted with tubulars’transportation, temporary storage and handling. The main and auxiliary drilling centers are adopted 1:3—proportion off-center arrangement which is according to result of numerical calculation and ABAQUS simulation.
As driller cabin is the core control component of rigs system, and the target platforms equipments is so automatic that driller cabin traditional design can not meet with the trend. The human factors engineer is used to design the driller cabin. The paper applies ergonomic principles to design driller cabin and achieve mechanism of communication harmony and information overload and colony harmony. Third class control pattern are used in the course of collectivity design, that is: LCD—type of show, touch screen—type of main control, multifunctional chair—traditional type of manual control, which can carry out unify between process-based control to manual operation to change past equipment function-based integration. The new idea and technique presented in the paper can improve the design of the driller cabin.
1.深水钻井作业工艺关键路径优化研究
提高钻井作业效率是第六代半潜式钻井平台最重要设计目标,应用双井架钻机是提高(超)深水钻井作业效率的有效技术。本文采用并行工程理论和甘特图探讨双井架钻机并行作业和协作作业机理,突破钻井工艺顺序作业限制,将同一工序(过程)的部分辅助工作离线作业,优化了钻井作业关键路径;并进一步优化了配置双井架钻机钻井平台的单井和多井钻井作业工艺流程,显著缩短深水建井周期。在此基础上,初步建立了采用双井架钻机系统的钻井平台所需基本设备配置。
2.钻机系统选型优化研究
钻机系统决定平台钻井作业的效率,选择、配置深水半潜平台钻机系统是设计第六代半潜式钻井平台的关键。本文采用复杂大系统优化分解—协调理论,将深水钻机系统分解成钻机、材料输送系统、动力系统、控制系统和后勤服务系统等5个子系统,建立优化模型,重点对钻机和材料输送系统进行优化选型研究。研究了钻机结构配置与离线作业能力及作业效率关系,离线钻机配置越完整全面,作业效率提升越大,双井架钻机最大化发挥了并行与协作作业能力。双井架钻机相对离线钻机显著提高作业效率,但增加可变载荷和建造成本,受专利影响增加作业成本,采用投资回收模型和净现值模型综合分析表明:双井架钻机总体优于离线钻机。钻井材料的不同物化状态决定输送系统输送方式和配置,分别对钻井管具、专用设备和钻井液三类材料进行了输送方式和装备配置优化。从占用甲板面积、重心、总体布局和作业效率等因素对隔水管存储形式比分析可知,存储模式对总体布局影响大,立放模式有利于总体布局设计。分析影响隔水管作业的因素,提出了提高作业效率措施,尤其隔水管接头形式的选型应引起重视。
3.钻机系统布局优化研究
针对钻井系统布局兼有生产布局和复杂三维大系统布局特点,本文提出基于作业流程层次分解布局法,建立了布局理论、算法和布局流程。该方法以作业流程为基础,按材料输送系统输送模式划分子空间,子空间内进一步模块化,以模块为布局基本单位,对不同空间采用相应优化算法,完成布局初步方案。然后根据重心对平台布局进行调整,以提高稳性,最后进行安全规划,完成布局详细设计。该方案综合考虑作业效率、安全性、稳性和人因工程学多方面因素,具有工程操作可行性和优化性,在具有性能约束大系统三维布局设计方面具有独创性。以在建某863项目平台钻井系统为实例,设计布局方案,完成布局设计。采用三维软件对平台及钻井系统进行三维建模、装配仿真和作业流程动态仿真,进一步验证布局合理性。
4.钻台自动化装备优化布局和基于人因工程学钻井控制室设计研究
针对钻台自动化作业程度高的特点,基于三类不同管具作业流程和设备设施作业衔接关系,完成钻台自动化装备布局设计,有效协调各类管具的输送、暂存、交换和处理等自动化作业活动。综合运用数值计算和CAE仿真方法对双钻井中心在平台定位进行优化,确定了主辅钻井中心定位布局优化方案。
本文运用人因工程学原理和标准对目标平台钻机控制室进行设计,实现信息通信协调机制,信息过载处理和作业群体之间相互协调。设计中具体设计采用三级控制、显示方式,实现基于流程自动控制和手动控制有机结合的控制方式,改变控制室设计基于设备集成的理念,提高了作业功效。
The dissertation focuses on deepwater rigs system design for ultra-deepwater semi-submersible platforms/unites (SSDP/SSDU), which is a part of the“863”High Technology Research and Development Program of China (No.2006AA09A104)—the key technique research on SSDPs’design and construction. Aiming at improving the operation efficiency of deepwater drilling, the paper synthetically adopts theoretical research, numerical calculation and computer simulation and perfects well drilling technology, drilling system mode option and layout optimization based on application and processing external marine drilling rig and SSDP. The main achievements are summarized as follows:
1. Research on critical path optimization of deepwater drilling process
Not only does dual derrick rigs lead to profound revolution of well drilling technology, but also cause significant change on drilling rigs configuration. The theory of concurrent engineering and Gantt chart are applied to analyze mechanism of dual derrick rigs process flow which lies in two factors—concurrent operation and cooperative operation. Concurrent operation breaks through sequence operation and cooperative operation completes work by main and auxiliary rigs together. Drilling craft of exploration well and development well are made out and optimized by Gantt chart. The well drilling process shorten well construction period and improves benefit. At last, prime equipments supported dual derrick rigs are established which are base for subsequent work.
2. Research on rigs system mode option and configuration optimization
As driliing operation efficiency is determined by the drilling rigs system, selection and configuration of deepwater rigs system is key of the construction of 6th generation domestic SSDP. Based on theory of decomposition-coordination for complex large-scale system, deepwater drilling rigs system is divied into 5 sub-systems, including of rigs, material transportation system, power system, logistics service system and control system. Function relation of sub-systems and optimization model is set up and two sub-systems—rigs and drilling material transportation system are studied especially. The relation between offline operation ability and rigs configuration is studied that the the more offline equipments, the more work efficient. Two kinds of rigs—offline rigs and dual derrick rigs are compared by payback period and net present value (NPV) from viewpoint of efficiency, variable derrick load, patent and cost of construction. And result shows that the dual derrick rigs is more excellent as a whole. Transportation modes are determined by shape and quality of material modality, and they are divided into three modes—drilling pipes, large special equipment and drilling mud system, and optimized the process flow and equipment configuration. The paper analyses two risers storage models and equipment configuration, and compares to occupying deck area, center of gravity general layout and operation efficiency. The result shows that there is no evidence difference in center of gravity and system operation efficiency besides they have significant effect in general layout. Risers’operation efficiency factors are analyzed and measures to improve efficiency are put forward, of which risers’connector should be attached importance to. SSDP & drilling equipment management information system is set up for the sake of improving management and benefit of equipment option.
3. Study on layout optimization of rigs system
Rigs system layout integrates the characteristic of production system and complex three-dimensional (3-D) system layout. The dissertation firstly brings forward compound /integrated hierarchical division based on process flow and constitutes layout theory, arithmetic and layout process on the basis of complex large-scale composition- coordination. The method is based on operational flow and different transportation modes are marked out according to the shape and quality to material modality. Two hierarchy decompose—sub-space and modules,which are basic layout units,are brought into operation. We applied different layout arithmetic to mark out the upper and lower decks. That is, the upper deck was designed based on the lowest transportation cost while the lower deck’s calculations were based on the best-fit scope. Finally the center of gravity was taken into consideration and the general layout was adjusted according to result in an optimal center of gravity. The project strongpoint doesn’t only lies in taking into account efficiency, safety, stability and human factors engineer, but also engineer practicality and optimization, especially in 3-D layout with behavioral constraints. According to the layout programming, we take the 863 project in the scantling design as an example, implementing the layout of rigs system in details. In order to validate layout for further, 3-D modeling of SSDP and rigs system are constructed to carry into execution simulation of assembly and process flow moving.
4. Research on drill fllor layout optimization and driller cabin design based on human factors engineer.
Drill floor of semi-submersible drilling platform is the work center of drilling. And there are three different operation flows handled with drill pipes, large-diameter casings and risers. The driller layout principle and program are made certain based on process, linking up and manipulation relation and human factors engineer. All automated equipments on drill floor are collocated with layout principle and program and assorted with tubulars’transportation, temporary storage and handling. The main and auxiliary drilling centers are adopted 1:3—proportion off-center arrangement which is according to result of numerical calculation and ABAQUS simulation.
As driller cabin is the core control component of rigs system, and the target platforms equipments is so automatic that driller cabin traditional design can not meet with the trend. The human factors engineer is used to design the driller cabin. The paper applies ergonomic principles to design driller cabin and achieve mechanism of communication harmony and information overload and colony harmony. Third class control pattern are used in the course of collectivity design, that is: LCD—type of show, touch screen—type of main control, multifunctional chair—traditional type of manual control, which can carry out unify between process-based control to manual operation to change past equipment function-based integration. The new idea and technique presented in the paper can improve the design of the driller cabin.
引文
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