石油钻机电动绞车特性分析及控制研究
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摘要
通过调研,掌握了国内外石油钻机绞车的发展现状与趋势,对现有在用电驱动钻机绞车进行了结构分析,了解了其优缺点,为进行新型钻机绞车设计奠定了基础。与传统机械钻机绞车和直流电驱动钻机绞车相比,由于交流变频电驱动钻机绞车有着非常明显的优势和非常高的技术性能,当今石油钻机绞车正在向着交流变频电驱动方向发展。
针对我国传统绞车存在着传动复杂、效率低、送钻不均匀、钻压不稳定等缺点,本文设计了一种新型电机直驱单轴绞车结构型式:JC30DB-WZ型交流变频电驱动单轴绞车,可满足恒扭矩、恒功率等多种工况要求。通过对滚筒和滚筒轴的刚度和结构强度进行ANSYS有限元分析,确保了设计可靠性。该绞车采用两台大功率、低速、大扭矩变频电机从滚筒轴两端直接驱动滚筒,形成电机外置与滚筒一体化单轴绞车结构型式,去掉了大型齿轮减速箱、离合器等传动部件,电磁涡流刹车或水刹车等辅助刹车不复存在,具有结构简单新颖、调速范围宽、适应能力强等优点。技术参数符合SY/T5532-2002《石油钻机用绞车》标准要求,可广泛适用于国内外3000米交流变频电动钻机。
为深入研究钻机起升系统的动态特性,本文结合钻井工艺及钻机工作过程,对钻机起升系统运动学和动力学进行了理论分析。建立了考虑钢丝绳和井架弹性的起升系统力学模型,对该微分方程组进行了理论求解;采用传递函数的方法,进行Simulink仿真,得到了起升系统的振动频率、系统的响应和大钩的动载系数,并分析了大钩位移波动和加速度波动特性。然后结合实际的钻具组合和JC30DB-WZ型交流变频电驱动绞车的工作特性,在考虑钻柱与井壁摩擦阻力情况下,通过编程得到微分方程初值问题的数值解,并对求解结果进行了详细分析,得到了考虑摩擦阻力情况下的动载系数。分别对初速为零和初速不为零的两种工况进行了讨论,为提高绞车控制精度提供了依据。为进一步深入研究钻柱与井壁摩擦阻力对起升系统的影响,在同时考虑电机特性和摩擦阻力的情况下,本文采用了ADAMS仿真软件,对JC30DB-WZ型交流变频电驱动单轴绞车起升系统进行了仿真计算与分析。结果表明:钻机在起升过程中存在着动载,动载系数随着起升条件的变化而改变;由于钻柱下放到井底,在起升过程中,钻柱与井壁产生摩擦,使得起升过程的平稳性变差;不考虑钻柱与井壁摩擦时,起升的不稳定系数为1%左右;当考虑钻柱与井壁摩擦产生随机载荷后,加剧了起升过程的不平稳性,使得大钩动载荷增加,滚筒与大钩速度呈现出明显的不均匀性。为降低起升时的动载系数,可采用控制电机特性的方法减少起升动载荷。
基于JC30DB-WZ型交流变频单轴绞车,设计完成了与绞车一体化的自动送钻传动系统,当正常钻进需要使用自动送钻时,可以通过自动送钻中辅助电机、减速器经小齿轮直接驱动大齿轮,带动滚筒工作,从而悬提钻具,控制钻压,实现自动送钻;当绞车主电机出现故障需要使用应急功能时,系统可以上提井下钻具,防止井下可能发生的各种事故。
针对石油钻机自动送钻过程控制中存在着复杂、非线性、不确定性系统的问题,设计完成了基于模糊控制的计算机恒钻压控制系统,该系统采用双环路控制结构,内部将反映钻速的测速编码器信号进行反馈构成局部负反馈回路,外部将钻压测量信号进行反馈构成另一路负反馈回路。在控制算法上采用了模糊控制思想。另外,初步探讨了非线性粒子滤波技术在自动送钻方面的应用,并对钻头钻进速度进行预估计。
通过现场实时采集钻机实际钻井过程中相关参数,从工程实验角度分析了这种钻机的实际起升特性、井架的起升动载、起升系统的固有频率、绞车扭矩与转速特性等,通过与前面理论分析和仿真结果相比较,结果表明试验研究结果与理论研究结果还是比较吻合的,从而进一步丰富、完善理论研究结果。
The development status and trend of oil drilling rig and electrically-driven drawworks home and abroad were mastered through research. Structural analysis was carried out on electrically-driven drawworks at work, and their advantages and disadvantages were found out in order to design new electrically-driven drawworks for drilling rig. Compared with traditional mechanical drilling rig and direct current driven drilling rig, AC variable-frequency electrically-driven drilling rig and drawworks have extremely obvious advantages and high technical performance. As a result, oil drilling rig and drawworks are increasingly developing heading AC variable-frequency electro-drive nowadays.
Aimed at the shortcomings of our traditional drawworks such as complexity in transmission, low precision in control, trouble in maintenance, low efficiency in transmission, asymmetry in bit feed, instability in bit weight, a new type of drawworks structural model was designed: model JC30DB-WZ single shaft drawworks of AC variable-frequency motor direct-drive , which can fulfill the multi-working condition requirement such as constant torque and permanent power. The design reliability was assured through ANSYS finite element analysis of the Stiffness and Strength of roller and roller shaft. In this drawworks, the roller is directly driven through shaft couplings by two special AC variable-frequency electric motors which are of high-power, low speed and great torque, without the supplemental parts of large gear reducer casing and large clutch, etc. Auxiliary brakes such as eddy current brake and hydraulic brake no longer exist, forming a single shaft roller drawworks model with motor out-laid and roller integrative. This model has advantages of structural novelty, wide timing range, high precision, and strong adaptability. Its technical performance and parameters can meet the standard of SY/T5532-2002“the drawworks used on oil drilling rig”. It can satisfy the drilling operation request of model ZJ30/1700DB drilling rig, and can be widely used in matching of 3000 meters AC variable-frequency drilling rig home and abroad.
Combining Drilling technology and working process of drilling rig, the kinematics and dynamics processes analysis were carried out on drilling rig hoisting. Influential Factors on control performances of AC variable-frequency electrically-driven drawworks were found out, which can create the theory foundation for making our own AC variable-frequency drawworks control system.
The simulation software ADAMS was used to calculate and analyze model JC30DB-WZ AC variable-frequency electrically-driven drawworks hoisting system. Results show: dynamic force exits during hoisting; the dynamic force coefficient changes when hoisting conditions change; the stability becomes worse during hoisting because of the friction between drillstring and wellpore; instability coefficient is about 1% without the consideration of the friction; after considering the random load the instability during the hoisting is increased, such increasing the load of the hook and unbalancing the velocity of roller and hook. Besides, different combination of drilling tools will affect the friction of drillstring. In order to reduce the dynamic force coefficient, we can use the method of control the characteristics of the motor. In fact, decreasing the starting current can efficiently reduce the dynamic force during hoisting.
The development status and trend of automatic bit feed system home and abroad were analyzed, as well as the latest research result and the problems during design and use processes. Automatic bit feed system and control methods based on motor auxiliary and drawworks mainframe integrative were offered. Using fuzzy control theory, problems in control the complex, nonlinear, uncertain system were solved. All these problems are rather difficult to solve during automatic bit feed in oil drilling rig. The technical performance and reliability of drawworks on drilling rig were greatly improved by intellectualized control using computer.
Through the related parameter acquired in the field while drilling, from project experiment angle, the actual performance of the rig hoisting system, the dynamic load of the derrick, the natural frequency, and the torque and rotate speed of the drawworks have been analysed. By contrast with the results of testing and theory research , the result shows that the test research result and theoretical research result still coincide fairly, which further perfects and enrich the theoretical result.
针对我国传统绞车存在着传动复杂、效率低、送钻不均匀、钻压不稳定等缺点,本文设计了一种新型电机直驱单轴绞车结构型式:JC30DB-WZ型交流变频电驱动单轴绞车,可满足恒扭矩、恒功率等多种工况要求。通过对滚筒和滚筒轴的刚度和结构强度进行ANSYS有限元分析,确保了设计可靠性。该绞车采用两台大功率、低速、大扭矩变频电机从滚筒轴两端直接驱动滚筒,形成电机外置与滚筒一体化单轴绞车结构型式,去掉了大型齿轮减速箱、离合器等传动部件,电磁涡流刹车或水刹车等辅助刹车不复存在,具有结构简单新颖、调速范围宽、适应能力强等优点。技术参数符合SY/T5532-2002《石油钻机用绞车》标准要求,可广泛适用于国内外3000米交流变频电动钻机。
为深入研究钻机起升系统的动态特性,本文结合钻井工艺及钻机工作过程,对钻机起升系统运动学和动力学进行了理论分析。建立了考虑钢丝绳和井架弹性的起升系统力学模型,对该微分方程组进行了理论求解;采用传递函数的方法,进行Simulink仿真,得到了起升系统的振动频率、系统的响应和大钩的动载系数,并分析了大钩位移波动和加速度波动特性。然后结合实际的钻具组合和JC30DB-WZ型交流变频电驱动绞车的工作特性,在考虑钻柱与井壁摩擦阻力情况下,通过编程得到微分方程初值问题的数值解,并对求解结果进行了详细分析,得到了考虑摩擦阻力情况下的动载系数。分别对初速为零和初速不为零的两种工况进行了讨论,为提高绞车控制精度提供了依据。为进一步深入研究钻柱与井壁摩擦阻力对起升系统的影响,在同时考虑电机特性和摩擦阻力的情况下,本文采用了ADAMS仿真软件,对JC30DB-WZ型交流变频电驱动单轴绞车起升系统进行了仿真计算与分析。结果表明:钻机在起升过程中存在着动载,动载系数随着起升条件的变化而改变;由于钻柱下放到井底,在起升过程中,钻柱与井壁产生摩擦,使得起升过程的平稳性变差;不考虑钻柱与井壁摩擦时,起升的不稳定系数为1%左右;当考虑钻柱与井壁摩擦产生随机载荷后,加剧了起升过程的不平稳性,使得大钩动载荷增加,滚筒与大钩速度呈现出明显的不均匀性。为降低起升时的动载系数,可采用控制电机特性的方法减少起升动载荷。
基于JC30DB-WZ型交流变频单轴绞车,设计完成了与绞车一体化的自动送钻传动系统,当正常钻进需要使用自动送钻时,可以通过自动送钻中辅助电机、减速器经小齿轮直接驱动大齿轮,带动滚筒工作,从而悬提钻具,控制钻压,实现自动送钻;当绞车主电机出现故障需要使用应急功能时,系统可以上提井下钻具,防止井下可能发生的各种事故。
针对石油钻机自动送钻过程控制中存在着复杂、非线性、不确定性系统的问题,设计完成了基于模糊控制的计算机恒钻压控制系统,该系统采用双环路控制结构,内部将反映钻速的测速编码器信号进行反馈构成局部负反馈回路,外部将钻压测量信号进行反馈构成另一路负反馈回路。在控制算法上采用了模糊控制思想。另外,初步探讨了非线性粒子滤波技术在自动送钻方面的应用,并对钻头钻进速度进行预估计。
通过现场实时采集钻机实际钻井过程中相关参数,从工程实验角度分析了这种钻机的实际起升特性、井架的起升动载、起升系统的固有频率、绞车扭矩与转速特性等,通过与前面理论分析和仿真结果相比较,结果表明试验研究结果与理论研究结果还是比较吻合的,从而进一步丰富、完善理论研究结果。
The development status and trend of oil drilling rig and electrically-driven drawworks home and abroad were mastered through research. Structural analysis was carried out on electrically-driven drawworks at work, and their advantages and disadvantages were found out in order to design new electrically-driven drawworks for drilling rig. Compared with traditional mechanical drilling rig and direct current driven drilling rig, AC variable-frequency electrically-driven drilling rig and drawworks have extremely obvious advantages and high technical performance. As a result, oil drilling rig and drawworks are increasingly developing heading AC variable-frequency electro-drive nowadays.
Aimed at the shortcomings of our traditional drawworks such as complexity in transmission, low precision in control, trouble in maintenance, low efficiency in transmission, asymmetry in bit feed, instability in bit weight, a new type of drawworks structural model was designed: model JC30DB-WZ single shaft drawworks of AC variable-frequency motor direct-drive , which can fulfill the multi-working condition requirement such as constant torque and permanent power. The design reliability was assured through ANSYS finite element analysis of the Stiffness and Strength of roller and roller shaft. In this drawworks, the roller is directly driven through shaft couplings by two special AC variable-frequency electric motors which are of high-power, low speed and great torque, without the supplemental parts of large gear reducer casing and large clutch, etc. Auxiliary brakes such as eddy current brake and hydraulic brake no longer exist, forming a single shaft roller drawworks model with motor out-laid and roller integrative. This model has advantages of structural novelty, wide timing range, high precision, and strong adaptability. Its technical performance and parameters can meet the standard of SY/T5532-2002“the drawworks used on oil drilling rig”. It can satisfy the drilling operation request of model ZJ30/1700DB drilling rig, and can be widely used in matching of 3000 meters AC variable-frequency drilling rig home and abroad.
Combining Drilling technology and working process of drilling rig, the kinematics and dynamics processes analysis were carried out on drilling rig hoisting. Influential Factors on control performances of AC variable-frequency electrically-driven drawworks were found out, which can create the theory foundation for making our own AC variable-frequency drawworks control system.
The simulation software ADAMS was used to calculate and analyze model JC30DB-WZ AC variable-frequency electrically-driven drawworks hoisting system. Results show: dynamic force exits during hoisting; the dynamic force coefficient changes when hoisting conditions change; the stability becomes worse during hoisting because of the friction between drillstring and wellpore; instability coefficient is about 1% without the consideration of the friction; after considering the random load the instability during the hoisting is increased, such increasing the load of the hook and unbalancing the velocity of roller and hook. Besides, different combination of drilling tools will affect the friction of drillstring. In order to reduce the dynamic force coefficient, we can use the method of control the characteristics of the motor. In fact, decreasing the starting current can efficiently reduce the dynamic force during hoisting.
The development status and trend of automatic bit feed system home and abroad were analyzed, as well as the latest research result and the problems during design and use processes. Automatic bit feed system and control methods based on motor auxiliary and drawworks mainframe integrative were offered. Using fuzzy control theory, problems in control the complex, nonlinear, uncertain system were solved. All these problems are rather difficult to solve during automatic bit feed in oil drilling rig. The technical performance and reliability of drawworks on drilling rig were greatly improved by intellectualized control using computer.
Through the related parameter acquired in the field while drilling, from project experiment angle, the actual performance of the rig hoisting system, the dynamic load of the derrick, the natural frequency, and the torque and rotate speed of the drawworks have been analysed. By contrast with the results of testing and theory research , the result shows that the test research result and theoretical research result still coincide fairly, which further perfects and enrich the theoretical result.
引文
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