修井作业机械化装置的系统仿真与实验研究
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摘要
在石油与天然气生产过程中,修井作业是一个重要的环节。我国大部分油田都已进入开发中后期,修井任务越来越繁重,目前绝大部分修井作业尤其是小修作业,仍采用传统的机械化水平很低的人工作业方式,劳动强度高,安全性差,作业环境也十分恶劣。为使修井工人远离井口,降低修井作业的劳动强度,提高修井作业的效率,实现安全修井作业,研制开发适用于我国油田情况的修井作业机械化系统是大势所趋。
本文在充分调研分析现场修井作业工艺及国内外各种钻修井机械自动化技术的基础上,提出并设计了一套实现管柱拉送排放、管柱抓取、管柱扶正、对中及管柱上卸扣的机械化装置,本文主要对其起升系统和上卸扣系统的建模理论问题和系统仿真问题进行了研究和分析。
在修井作业机械化系统的总体设计方案和各组成部分的详细结构设计方案基础上,基于SolidWorks软件创建出整套系统的三维实体模型。
采用多刚体运动学与动力学理论,研究了吊环吊卡系统运动学、动力学理论模型,推导建立了吊卡的位移、速度和加速度等运动学方程,进行了吊环吊卡摆出过程的逆向动力学分析。基于ADAMS机械系统动力学分析软件,分别对扶正手摆出过程、扶正手推送油管过程及吊环吊卡摆出过程进行了机液系统联合仿真,获得了工作部件的各种动态特性,找到有利于工作部件运动的液压系统参数,为实际液压系统设计与元件的选择提供理论依据。对油管与完全摆出状态的扶正手的接触碰撞过程及油管与扶正手摆向井口的接触碰撞过程进行了系统仿真研究,分析了扶正手承接件的材料、油管重量及节流阀开口大小对接触碰撞过程的影响。
文中利用功率键合图理论以及模块化方法建立了修井作业机械化系统的功率键合图模型,对上卸扣系统进行了重点分析,将其简化为阀控非对称缸、阀控马达及定量泵-溢流阀等液J压单元。基于解析建模法,应用物理学、流体力学、动力学定律和方程推导其数学模型及传递函数,为其仿真实验奠定了理论基础。在此基础上,采用AMESim软件建立起上卸扣系统的仿真模型,进行了变参数仿真实验研究,掌握了各参数变量随时间变化的规律,这些研究工作为评价上卸扣系统的工作性能提供了理论依据。
文中最后对试验样机及现场试验情况进行了介绍,将试验测得的结果与仿真结果进行了对比,就试验数据与仿真数据之间的误差及其成因进行了分析,验证了系统理论模型的正确性,证明利用系统仿真技术来研究系统动态特性是可行的,仿真结果对于全面深入掌握系统工作特性具有指导意义。
Workover operation is important in the oil and gas production. As most oilfileds in our country have entered into the later period, workover tasks become more and more heavy. But the traditional operation mode with lower level mechanical automation is still used in most cases, especially in common maintance. Workover wokers work in high labor intensity and poor safety, and the working environment is also very poor. In order to let the workover wokers far away from wellhead, reduce labor intensity, increase the operational efficiency and realize safe operation, it is a general trend to design and develop new type of workover mechanical system to satisfy actual situations.
In this paper, based on full investigation and analysis of the progress of workover operation and domestic and aboard workover and drilling mechanical automation technology, a system scheme that can better realize draging pipe, feeding pipe, pushing pipe, grasping pipe, centralizing pipe, make-up and break-out pipe by mechanical automation is put forward. This system mainly consists of integrated hydraulic tong system and hoisting system. The paper is mainly focused on the research and analysis about modeling and simulation of hoisting system and make-up and break-out system.
The paper finished overall design of the new type workover mechanical system, and the detailed and reasonable design of all components of the system are given. The 3D models of the system are created in SolidWorks software.
According to multiple rigid body kinematics and dynamics, research and analysis of modeling ring-elevator system are made. The kinematics equations of elevator including position, velocity and acceleration are derived. The inverse dynamics analysis is also made for the ring-elevator system. Based on ADAMS, the mechanical-hydraulic simulation of the swinging out manipulator, its pushing oil pipe and the swinging out rings-elevator are made respectively. Various dynamic characteristics of the composition parts are obtained, and hydraulic system parameters are founded, which is beneficial to the work of composition parts and provides theoretical basis for the selection of actual hydraulic component. The mechanical-hydraulic simulations, including the process of contact-impact between oil pipe and centralizing manipulator that in the state of swinging out completely and the state of the oil pipe swinging to the wellhead are simulated. The influence of the materials of supporting part of centralizing manipulator, the weight of oil pipe and the open size of throttle valve in the process of contact-impact are also analyzed.
The properties of workover mechanical system lie in good structure design and the ability of quick and accurate response, and the system coupling relationship constrains its performance. That is, it decides whether the performance of the whole system is good or not. In this paper, bond graph and modular approach are used to establish oil pipe make-up and break-out system. The system is simplified as a valve controlled asymmetrical cylinder, valve controlled motor, quantitative pump-relief valve and so on. Based on physics, fluid mechanics, and dynamics, the mathematical model and transfer function are obtained, which is the theoretical foundation of the system simulation. On this basis, AMESim is used to modeling oil pipe make-up and break-out pipe system, then making the simulation experiments of variable parameters. These studies provide theoretical basis for evaluating the performance of oil pipe make-up and break-out system.
The paper introduces experimental prototype and field test at last. Contrast of test results and simulation results is made, and the error between the test data and the simulated data are analyzed. The correctness of theoretical models of the system is verified, and simulation techniques are feasible to study system dynamic characteristics. The simulation results are helpful to understand the working characteristics of the system thoroughly and comprehensively.
本文在充分调研分析现场修井作业工艺及国内外各种钻修井机械自动化技术的基础上,提出并设计了一套实现管柱拉送排放、管柱抓取、管柱扶正、对中及管柱上卸扣的机械化装置,本文主要对其起升系统和上卸扣系统的建模理论问题和系统仿真问题进行了研究和分析。
在修井作业机械化系统的总体设计方案和各组成部分的详细结构设计方案基础上,基于SolidWorks软件创建出整套系统的三维实体模型。
采用多刚体运动学与动力学理论,研究了吊环吊卡系统运动学、动力学理论模型,推导建立了吊卡的位移、速度和加速度等运动学方程,进行了吊环吊卡摆出过程的逆向动力学分析。基于ADAMS机械系统动力学分析软件,分别对扶正手摆出过程、扶正手推送油管过程及吊环吊卡摆出过程进行了机液系统联合仿真,获得了工作部件的各种动态特性,找到有利于工作部件运动的液压系统参数,为实际液压系统设计与元件的选择提供理论依据。对油管与完全摆出状态的扶正手的接触碰撞过程及油管与扶正手摆向井口的接触碰撞过程进行了系统仿真研究,分析了扶正手承接件的材料、油管重量及节流阀开口大小对接触碰撞过程的影响。
文中利用功率键合图理论以及模块化方法建立了修井作业机械化系统的功率键合图模型,对上卸扣系统进行了重点分析,将其简化为阀控非对称缸、阀控马达及定量泵-溢流阀等液J压单元。基于解析建模法,应用物理学、流体力学、动力学定律和方程推导其数学模型及传递函数,为其仿真实验奠定了理论基础。在此基础上,采用AMESim软件建立起上卸扣系统的仿真模型,进行了变参数仿真实验研究,掌握了各参数变量随时间变化的规律,这些研究工作为评价上卸扣系统的工作性能提供了理论依据。
文中最后对试验样机及现场试验情况进行了介绍,将试验测得的结果与仿真结果进行了对比,就试验数据与仿真数据之间的误差及其成因进行了分析,验证了系统理论模型的正确性,证明利用系统仿真技术来研究系统动态特性是可行的,仿真结果对于全面深入掌握系统工作特性具有指导意义。
Workover operation is important in the oil and gas production. As most oilfileds in our country have entered into the later period, workover tasks become more and more heavy. But the traditional operation mode with lower level mechanical automation is still used in most cases, especially in common maintance. Workover wokers work in high labor intensity and poor safety, and the working environment is also very poor. In order to let the workover wokers far away from wellhead, reduce labor intensity, increase the operational efficiency and realize safe operation, it is a general trend to design and develop new type of workover mechanical system to satisfy actual situations.
In this paper, based on full investigation and analysis of the progress of workover operation and domestic and aboard workover and drilling mechanical automation technology, a system scheme that can better realize draging pipe, feeding pipe, pushing pipe, grasping pipe, centralizing pipe, make-up and break-out pipe by mechanical automation is put forward. This system mainly consists of integrated hydraulic tong system and hoisting system. The paper is mainly focused on the research and analysis about modeling and simulation of hoisting system and make-up and break-out system.
The paper finished overall design of the new type workover mechanical system, and the detailed and reasonable design of all components of the system are given. The 3D models of the system are created in SolidWorks software.
According to multiple rigid body kinematics and dynamics, research and analysis of modeling ring-elevator system are made. The kinematics equations of elevator including position, velocity and acceleration are derived. The inverse dynamics analysis is also made for the ring-elevator system. Based on ADAMS, the mechanical-hydraulic simulation of the swinging out manipulator, its pushing oil pipe and the swinging out rings-elevator are made respectively. Various dynamic characteristics of the composition parts are obtained, and hydraulic system parameters are founded, which is beneficial to the work of composition parts and provides theoretical basis for the selection of actual hydraulic component. The mechanical-hydraulic simulations, including the process of contact-impact between oil pipe and centralizing manipulator that in the state of swinging out completely and the state of the oil pipe swinging to the wellhead are simulated. The influence of the materials of supporting part of centralizing manipulator, the weight of oil pipe and the open size of throttle valve in the process of contact-impact are also analyzed.
The properties of workover mechanical system lie in good structure design and the ability of quick and accurate response, and the system coupling relationship constrains its performance. That is, it decides whether the performance of the whole system is good or not. In this paper, bond graph and modular approach are used to establish oil pipe make-up and break-out system. The system is simplified as a valve controlled asymmetrical cylinder, valve controlled motor, quantitative pump-relief valve and so on. Based on physics, fluid mechanics, and dynamics, the mathematical model and transfer function are obtained, which is the theoretical foundation of the system simulation. On this basis, AMESim is used to modeling oil pipe make-up and break-out pipe system, then making the simulation experiments of variable parameters. These studies provide theoretical basis for evaluating the performance of oil pipe make-up and break-out system.
The paper introduces experimental prototype and field test at last. Contrast of test results and simulation results is made, and the error between the test data and the simulated data are analyzed. The correctness of theoretical models of the system is verified, and simulation techniques are feasible to study system dynamic characteristics. The simulation results are helpful to understand the working characteristics of the system thoroughly and comprehensively.
引文
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