深水钻井补偿绞车的节能机理及解耦控制方案研究

Study on energy-saving mechanism and decoupling control scheme of compensation drawworks for deepwater drilling

为解决深水钻井电动补偿绞车能耗过高、钢丝绳磨损严重及运动耦合的技术问题,针对不同钻井作业过程,分析电动补偿绞车的节能潜力,提出一套基于能量回收的新型液压驱动方案,可以对不同钻井作业过程中的负载重力势能及绞车回转系统的惯性动能进行回收与再利用;分析电动补偿绞车的运动耦合机理,进而提出多套软硬件解耦控制方案,可以实现升沉补偿运动与自动送钻运动的解耦控制。设计绞车补偿系统的关键结构参数,研制一套原理样机及其试验系统,并针对不同海况与工况进行仿真与试验研究。结果表明:新型液压驱动方案相对于电驱动方案具有明显的节能效果;绞车的大滚筒结构提高了钢丝绳的使用寿命;基于差动行星传动与基于双绞车驱动的两种硬件解耦方案控制效果良好,满足海洋浮式钻井的性能要求。

In order to solve the technical problems of electrodynamic compensation drawworks for deepwater drilling including high energy consumption,serious wear of wire rope and motion coupling,a new type of hydraulic power system based on energy recovery is putforward according to the analysis on energy-saving potential of electrodynamic compensation drawworks under different processes of offshore drilling operations. The hydraulic power system can recover and reuse the gravitational potential energy and inertial kinetic energy of system in the process of different drilling operations. The software and hardware-decoupling control schemes which can realize the decoupling control of heave compensation movement and automatic bit feed movement are putforward according to the analysis on motion coupling mechanism of electrodynamic compensation drawworks. Then, the key structural parameters of the drawworks compensation system are calculated, and the principle prototype of compensation drawworks and the test system are developed. Simulation and experimental studies on the compensation drawworks are carried out under different sea conditions and working states. The results show that the new type of hydraulic power system has significant energy saving effect compared with the electrodynamic compensation drawworks. The service life of wire rope is increased by using the drawworks drum with large diameter. Moreover, the control effect of hardware decoupling schemes based on the differential planetary transmission and dual drawworks is good, which can meet the performance requirements of the offshore floating drilling.