面向故障诊断的钻井泵动力学系统仿真分析

Fault-oriented Simulation Study of Drilling Pump Dynamic System and Its Application

钻井泵是石油钻井的核心设备,其状态正常与否直接影响钻井作业的顺利进行。通过建立系统的钻井泵动力端和液力端动力学模型,并编制软件实现了钻井泵动力学的系统仿真。利用该仿真软件全面分析了缸套泄漏、吸入阀与排出阀故障、连接件松动、弹簧失效等单一故障,以及这些故障的不同组合下,钻井泵运动参数的变化规律;结合钻井泵振动信号的基元分段处理,完成了钻井泵运动参数的统计分析,创建数据库实现了这些故障特征信息的日常维护与管理。研究表明,通过信号处理一般只能进行有限故障的定性识别,而采用基于仿真模型的钻井泵故障诊断方法可以为钻井泵运行状态的系统检测与各种故障的定量化诊断提供可靠的途径和手段。

Drilling pump is a pivotal equipment in oil and gas drilling, whether its status is normal or not directly affects drilling operation and drilling security. An integrated simulation model for drilling pump dynamic system was entirely established, and an appropriate software was developed by use of Delphi Tool. Using this simulation software for pump study, a comprehensive analysis of the cylinder leakage, suction valve and discharge valve failure, loosening connections, spring failure as well as various combinations of these faults were simulated. Combining with the Basic Operation Unit（BOU） method, all the similar component of the pump vibration signals acquired from drilling sites and pump simulation were aggregated into six subsets according to the vibration model of a triplex single acting reciprocating pump. Statistical analysis for different pump faults was carried out and quantitative relationships between motion parameters of every subset were also established. These fault information were stored into a diagnosis database in order to achieve the day-to-day drilling pump data maintenance and management. A lot of practice shows that drilling pump vibration signal processing can generally identify limited and qualitative pump faults, while the use of the dynamic simulation model-based drilling pump fault diagnosis method can easily provide a reliable mean or way to the drilling pump status detection and quantitative diagnosis for variety of pump failures.