TR368 旋挖钻机钻杆结构设计与有限元分析含2张CAD图
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旋挖钻机钻杆结构设计与有限元分析含2张CAD图
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Available online at ScienceDirect Procedia Engineering 73 ( 2014 ) 143 149 Geological Engineering Drilling Technology Conference (IGEDTC), New International Convention Exposition Center Chengdu Century City on 23rd-25th May 2014 The Development of Deep Borehole Permanent-magnet Motor Direct Drive Top-Driving Drilling Rig Liu Jiaronga*, Ran Lingjie aa Beijing Institute of Exploration Engineering, Beijing 100083,China Abstract At present, in our country the main deep drilling rigs are rotary disk drilling rig, spindle-type drilling rig and full hydraulic motor head drive drilling rig, and most of foreign drilling rig equipment are full hydraulic motor head drive drilling rigs. These rigs have many disadvantages; they cannot meet the demand of deep drilling. As the major breakthroughs were made in the development of high power permanent magnet frequency conversion motor, it is possible to develop the permanent-magnet motor direct drive top-driving drilling rig, so the efficiency of drilling can be improved. In this paper, the difficulties of deep drilling and existing problems of deep drilling rigs are analyzed, and direct drive permanent magnet motor top-driving drilling rig and its parameters and characteristics are introduced. The development of deep borehole permanent-magnet motor direct drive top-driving drilling rig accords with the requirements of drilling technology development and innovation concept, it is the development direction of deep core drills renewal, will promote the development of geo-drilling technology. 2014 The Authors. Published by Elsevier Ltd. 2014 Published by Elsevier Ltd. Open access under CC BY-NC-ND license. Selection and peer-review under responsibility of Geological Engineering Drilling Technology. Selection and peer-review under responsibility of Geological Engineering Drilling TechnologyKeywords: Deep Drilling; Permanent-Magnet Motor; Direct Drive Drilling Rig; Frequency Converting Control 1. Introduction In recent years, with the rapid development of economy, our country pay more attention to resources, energy security, stepped up environmental protection, clean energy exploration and development investment, the mineral resources and clean energy (such as shale gas, hot dry rock geothermal etc.) exploration workload will be increased. Resources survey and exploration work has turned to the deep and the west area, it is predicted that if the depth of * Corresponding author. Tel.: +86-13810036048. E-mail address: 13810036048163.com 1877-7058 2014 Published by Elsevier Ltd. Open access under CC BY-NC-ND license. Selection and peer-review under responsibility of Geological Engineering Drilling Technology doi: 10.1016/eng.2014.06.182 the exploration and evaluation to under 2000 m underground metallic ore deposits in China and new energy reserves will increase sharply. In foreign countries, deep boreholes are mostly drilled by full hydraulic motor head drive drilling rig, which are produced by the United States, Canada, Australia, Sweden, Germany etc, can drill at most 2500m with N series caliber. In China, there are commonly two main types deep drilling rig: spindle-type drilling rig and full hydraulic motor head drive drilling rig, which can drill maximum deeply 1500 m with N series caliber. A spindle-type drilling rig has certain defects: stroke is short, speed range is narrow, intelligent degree is not high; The efficiency of full hydraulic motor head drive drilling rig whose drill stand is short is low. Using these rigs, the drill-pipe stand cannot be used, reaming and back reaming cannot be realized. The efficiency of drilling is low, and they cannot solve complex accidents happened in borehole. The motor of oil top-drive is excitation frequency conversion motor, its torque is too big, and speed is too low, reduce speed and increase torque through the speed reducer. At low load, ordinary frequency conversion motor the efficiency and power factor is low, fever is serious, the frequency conversion control system is more complex, high cost, top-drive parameters cannot meet the requirements of the core drilling, it is difficult to be applied in geological system. 1In recent years, as the major breakthroughs were made in the development of high power permanent magnet frequency conversion motor, it is possible to develop the control operation simple permanent-magnet motor direct drive top-driving drilling rig. 2. Deep Drilling Difficulties and Top-driving Drilling Rig Design Requirements 2.1. Deep drilling difficulties Deep core drilling construction cycle is long, and the stability of borehole wall is poor, borehole wall exposed time is long, drilling fluids filtration for long time makes swell of borehole wall and the wall of borehole unsteadily, even blocking or sticking accidents. 1As the drilling deepening, workload of horizontal hole and directional hole also increased, the existing drilling work efficiency is low; at the same time, the increase of weight of drilling tools and number of drilling trip resulted in the damage to the wall of borehole, and increased the unforeseen possibility of drilling accidents. 1During deep borehole directional drilling and horizontal drilling, accidents frequently occur would greatly increase the accident treatment time, the complexity of the accident and the construction cost. 2.2. Top-driving drilling rig design requirements According to the conditions and characteristics of deep drilling, and analyzed the existing problems of drilling rigs, puts forward higher requirements on the rig and the new design idea: x In the event of hole shrinkage, blocking or sticking accidents, for strata reason, existing drilling rigs cannot ream and back ream, Especially in deep hole directional drilling or horizontal drilling, hole accidents occurred more so that affect the efficiency of dealing with accidents. Therefore in the process of drilling rig design, the drilling rig does not require the kelly and its power unit can ream or back ream at any height of the stroke. Especially in the directional drilling, it can improve the drilling efficiency. x The stroke of existing drill rig is too short, that cannot drill with drill-pipe stand. The stroke of full hydraulic motor head drive drilling rig is less than 6m, spindle-type drilling rig has short stroke and needs to recheck. Both of the rigs have low drilling efficiency and long drilling auxiliary time, which lead to rising drilling cost. In geo-drilling process, for strata reason and drilling technology, when blocking or sticking accidents happened, frequent replacement of bit and extracting core are required. To solve the above problems, a top-drive drilling system with more than 20 m stroke need to be developed, to avoid happening hole collapsing shrinkage and breaking, etc. When sticking in the trip, with the back tongs, top-driving can quickly connect drilling tools, ream and back ream with drill standwithin 20 m stroke, saving more than 50% on makeup and breakout of the auxiliary time, can save 20% of drilling time. x At present, some of vertical shaft drill and hydraulic power head drill need the kelly, in the deep drilling, each time run in hole and pull out of hole, easily induced hole collapsing, shrinkage and breaking, etc. Bit repeatedly broken rock, which is unfavorable for coring. In the design process, the ability of makeup and breakout must be strengthened so the labor intensity of driller can be reduced, improve the speed of the makeup and breakout, drilling auxiliary time can be reduced. x In the deep drilling, the brake band winch failure rate is high, the chuck cant effectively stuck drill pipe, the pipe loss is big, cant accurately control the drilling speed and bit pressure. New equipment design requires a good operating performance, centralized display the parameters of the drilling and circulating fluid, control and record the parameters in the process of drilling, have good economic performance, safe and reliable, easy maintenance, etc.x The deep of geological core drilling is defined by 55.5 mm and 71 mm pipe, because of the complexity of the deep drilling, the need of multilayer casing, drilling structure requires its drilling diameter is bigger than in the shallow hole drilling, cant completely drill with the defined pipe, can only use a bigger diameter drill pipe, torque and the hoisting capacity of the current rig will become inadequate, when handling the accident of the output torque, pulling force of the drilling rig, is not enough, the ability of dealing with borehole accidents is insufficient.1 So to strengthen drilling torque and hoisting capacity, improve the speed of deep borehole construction lifting drilling tools is necessary. Especially in geological system, because of its many coring drilling technology, in complex stratum hole, the trip time and the blocking or sticking accidents are more, so it is particularly necessary to enhance the hoisting capacity of drilling rig. x The efficiency of fully hydraulic drilling rig is low (less than 50%), but its energy consumption is large, the hydraulic oil should be replaced periodically, high use cost, prone to failure, and it is not easy to find out and deal with. So design high efficiency and power factor of the permanent magnet motor direct top-driving rig can effectively improve the efficiency of energy conversion. 3. The Design of Permanent Magnet Motor Direct-drive Top-driving Drilling Rig 3.1. Designing of the whole machine The top-driving drilling system can directly drive the pipe from the derrick top, drill along the drill track, complete the drill pipe rotary drilling, stand drilling with circulating mud, mechanical makeup and breakout, ream or back ream with drilling fluids, etc. Permanent magnet direct drive top-driving drilling rig has not been applied both at home and abroad; it is the first time deep borehole permanent-magnet motor direct drive top-driving drilling rig has been developed. The rig includes: derrick, drill track, permanent magnet motor direct drive device, draw works, mud pump and control system, etc. (Fig. 1) 3.2. The design of permanent magnet motor direct drive top-driving device Permanent magnet motor direct drive the top-driving device to work, no gear transmission in the device, circulating fluid through the hollow shaft motor rotor, hollow shaft at both ends is combined with the water swivel and drill pipe, drill pipe transmits torque, so it can avoid damage of the drill pipe. In complex strata, when drilling tools are jammed, top-driving device can rapidly connect drill string with backup wrench, ream and back ream with pump circulation within 20 m stroke, it can reduce the probability of jamming or blocking accidents To improve the automation level of drilling rig, reduce drilling auxiliary time, top-driving device can realize makeup and breakout with back-up wrench. The balance device, at the top of the top-driving device, is designed to protect the drill pipe thread while makeup and breakout. Fig.1 General Assembly Drawing of Drilling Rig 3.3. The design of winch The permanent magnet motor directly drive the winch, no gear transmission, for the first time in geo-drilling rig adopts double broken line winch, during run in hole and pull of hole, stepless speed regulation can be realized. During run in hole, energy consumption braking can be used by permanent magnet motor. In an emergency, safety clamp brakes also can be used. It fundamentally solves the common drill in gear drive, parking, sealing and lubrication problems, and improves the reliability of the site operation. (Fig. 2) Fig.2 Permanent Magnet Motor Driven Winch 3.4. Control system design The frequency conversion control system and drilling parameter gathering feedback control system control the drilling speed and bit pressurecan realize automatic drill, frequency conversion stepless speed regulation, no friction brake, drill hover, and other functions. With the low speed and high torque permanent magnet motor drive and control system, top drive drilling rig uses the current international advanced full digital vector control of ac frequency conversion technology and automation, intelligent control technology, computer control technology, field bus communication and process control technology, operators in the driller station centralized control by PLC, and a variety of control program of drilling rig telex, detection system, hydraulic system, electric control system of the operation of each part of the mechanical system, to implement the intelligent of the drilling rig, automatic control. (Fig. 3) Fig.3 The control system of drilling rig 4. Performance Parameters and Characteristics of the Drilling Rig 4.1. The performance parameters of the drilling rig The performance parameters of the drilling rig are as following: x Drive mode: Permanent magnet frequency conversion motor direct drive drill pipe and winch; x Top-drive motor parameters: Power (260 kW), rated frequency 55 Hz; x Maximum final hole diameter: 150 mm; x Rated torque: 15 kN.m; x Maximum torque: 30 kN.m; x Rated speed: 165 r/min; x Speed range: stepless speed regulation from 0 to 360 r/min; x Winch power: 520 kW; x Fast line pull: 135 kN, fast line speed of not less than 10 m/s; x Derrick height: 33 m; x Hook load: 1350 kN (10 lines); x Water swivel diameter: 65 mm; x Stroke: 26m. The top-driving drilling system can directly drive the pipe from the derrick top, drill along the 26 m drill track, complete the drill pipe rotary drilling, stand drilling with circulating mud, mechanical makeup and breakout, ream or back ream with drilling fluids, etc drilling technology. Blocking or sticking accidents caused by various reasons can be timely and effective solved by top drive drilling rig; at the same time, the rig can drill with drill stand, which would greatly improve the drilling speed. 4.2. The characteristics of the drilling rig When sticking accident happened during run in hole and pull of hole, top-driving rig can realize the long stroke (more than 20 m) drill, reaming and back reaming with mud circulating, which reduce the probability of the accidents, the time of dealing with accidents. The top drive has elevators, rings, water swivel and back-up wrench, it can directly connect drill pipe at any height in the stroke, ream or back ream with drilling fluids, Efficiency and power factor of asynchronous motor is very low, the efficiency of hydraulic drilling rig is less than 50%, oil has pollution to the environment, and the permanent magnet motor efficiency and power factor can reach more than 90% under the condition of low load rate.2 Top drive device and winch both use the permanent magnet motor as their engine, energy saving can reach more than 20%, which can realize the goal of energy conservation and emissions reduction (Fig. 4). Permanent magnet motor directly drive drill pipe and winch, not through the gear transmission, with the characteristics of high transmission efficiency, convenient maintenance, and low failure rate. The top drive drilling rig can realize characteristic of drilling process as follows: Reaming and back reaming with drilling fluids during the process of run in hole and pull of hole, drill stand drilling, single drill pipe drilling. This can effectively solve the complex problems encountered in the process of deep-drilling. Fig.4 Asynchronous Motor, Permanent Magnet Synchronous Motor Efficiency and Power Factor, and the Curve of Load Factor 5. Conclusions Top drive device is one of the three new technologies of modern drilling equipment, which can realize stand drilling, connect drilling tools in the derrick on any height with mud circulating, and ream and back ream during the process of run in hole and pull of hole, reduce the accident rate, drilling time and save drilling cost in deep-drilling. 5 Now almost all of offshore oil drilling platform has been equipped with the top drive device. In the design of a new type of drilling rig of the land, top drive device also has been considered. In international market, the construction team equipped with top drive device is essential condition to participate in bidding. Thus equipped with top drive drilling rig has become a trend in the development of contemporary drilling technology. In the next years, the number of deep geological exploration and scientific drilling holes, directional drilling holes, shale gas exploration, hot dry rock exploration bore, oil and gas exploration holes whose depth is more than 2000 m are no less than 10000 each year (excluding oil drilling, exploration engineering magazine statistical data in 2011). So highly efficient drilling rig is required in the complex stratum, the new generation of permanent magnet directdrive top drive multi-purpose geological drilling rig can meet this requirement, and fill the blank of the domestic industry and solve the problem of lack of proper drilling rig in drilling of deep hole, horizontal hole and directional hole. The development of deep hole permanent magnet motor direct drive top-driving drilling rig accord with the requirements of drilling technology development and innovation concept, is the development direction of the deep hole core drill, will promote the development of geological drilling technology. References: 1 Bu Weiling. The development trend of foreign drill top drive drilling device J. Petroleum Machinery. 2009. 2 Wang Yongqin, Li An, Wu Yongting. TDS - 11SA top drive system fault tree analysis J. Oil field machinery, 2009. 3 Hou Jiangdong Yang Yang. TD500/1000 type top drive application in ocean drilling J. Oil field machinery, 2010. 4 Li Peng, Mou Xinming, Gao Ming. Top drive center pipe strength finite element analysis J. Oil field machinery, 2009 5 Li Shizhong. Core drill some suggestion on improving J. Journal of exploration engineering, 2000 (5) : 11-13. 2014年5月23 -25日，地质工程钻探技术大会(IGEDTC)，成都世纪城新国际会展中心深孔永磁电机直驱式顶驱钻机的研制刘Jiaronga*,跑Lingjiea摘要目前，我国主要的深井钻机有盘式钻机、主轴式钻机和全液压马达头驱动钻机，而国外钻机设备大多为全液压马达头驱动钻机。这些钻机有许多缺点;他们不能满足深井钻探的需求。随着大功率永磁变频电机发展取得重大突破，发展永磁电机直接驱动顶驱钻机成为可能，从而提高钻井效率。摘要分析了深井钻井的难点和深井钻机存在的问题，介绍了直驱式永磁电机顶驱钻机及其参数和特点。深钻孔永磁电机直驱式顶驱钻机的发展符合钻井技术发展的要求和创新理念，它是深钻孔钻机更新换代的发展方向，将推动地质钻井技术的发展。20142014作者。出版单位:Elsevier ltd .作者:Elsevier Open accessLtd根据CC BY-NC-ND许可证。地质责任地质工程工程钻探钻探技术。技术关键词:深钻;永磁电机;直驱式钻机;频率转换控制1.介绍近年来，随着经济的快速发展，我国更加重视资源、能源安全，加大环境保护力度，对清洁能源的勘探开发投资，对矿产资源和清洁能源(如页岩气、干热岩地热等)的勘探工作量将会增加。资源勘查工作已转向深部和西部地区，预测如果在深部和西部地区*通讯作者。电话:+ 86 - 13810036048。电子邮件地址:13810036048 163.com1877-70582014由爱思唯尔出版在CC BY-NC-ND许可证下开放访问。地质工程钻探技术的筛选与同行评议我国地下2000米以下金属矿床的勘探评价和新能源储量将大幅增加。国外钻深孔多采用全液压马达头驱钻机，由美国、加拿大、澳大利亚、瑞典、德国等国生产，N系列口径最多可钻2500米。在我国，常用的深井钻机主要有两种类型:主轴式钻机和全液压马达头驱动钻机，N系列口径最大深度可钻1500米。一种主轴式钻机有一定的缺陷:行程短、转速范围窄、智能化程度不高;全液压马达头驱式钻机机座短，效率低。使用这些钻机，不能使用钻杆支架，不能实现扩眼和反扩眼。钻井效率低，无法解决复杂的钻井事故。油顶传动电机为励磁变频电机，其转矩过大，转速过低，通过减速器降低转速，增加转矩。在低负荷下，普通变频电机的效率和功率因数低，发热严重，变频控制系统比较复杂，成本高，顶驱参数不能满足岩心钻探的要求，难以在地质系统中应用。1近年来，随着大功率永磁变频电机发展取得重大突破，控制操作简单的永磁电机直接驱动顶驱钻机有可能发展起来。2.深井钻井难点及顶驱钻机设计要求2.1。钻进困难深部取心钻孔施工周期长，井壁稳定性差，井壁暴露时间长，钻井液长期过滤使井壁膨胀和井壁不稳定，甚至发生堵塞或卡钻事故。1随着钻井的加深，水平井和定向井的工作量也随之增加，现有的钻井工作效率较低;同时，钻具重量的增加和钻井起下钻次数的增加导致了井壁的损坏，增加了钻井事故的不可预见可能性。1在深孔定向钻井和水平钻井过程中，事故的频繁发生会大大增加事故的处理时间、事故的复杂性和施工成本。2.2。顶驱式钻机的设计要求根据深井钻探的条件和特点，分析了钻机存在的问题，对钻机提出了更高的要求和新的设计思路:x当发生井眼收缩、堵塞或卡钻事故时，由于地层原因，现有钻机不能进行扩眼和反扩眼，特别是深孔定向钻井或水平钻井，发生井眼事故较多，影响事故处理效率。因此，在钻机设计过程中，钻机不要求方钻杆及其动力装置可以在冲程的任何高度进行扩眼或反扩眼。特别是在定向钻井中，可以提高钻井效率。x现有钻机行程太短，不能用钻杆架钻井。的中风全液压马达头驱钻机小于6m，主轴式钻机行程短，需复检。两种钻机钻井效率低，钻井辅助时间长，导致钻井成本上升。在地质钻井过程中，由于地层原因和钻井工艺的原因，当发生卡钻事故时，需要频繁更换钻头和提取岩心。为解决上述问题，需要开发20 m以上冲程的顶驱钻井系统，以避免井壁发生塌缩、破孔等现象。在行程卡钻时，顶驱使用背钳，可在20米行程内快速连接钻具、铰孔、后铰孔与钻座，节省50%以上的补开辅助时间，节省20%的钻井时间。x目前一些立轴钻和液压动力头钻都需要方钻杆，在深井钻进时，每次下钻和出井，容易诱发井塌、缩松和断孔等。钻头多次破岩，不利于取心。在设计过程中，必须加强上扣和下扣的能力，从而降低钻机的劳动强度，提高上扣和下扣的速度，减少钻井辅助时间。x在深井钻进时，制动带绞车故障率高，卡盘不能有效卡钻钻杆，钻杆损耗大，不能准确控制钻进速度和钻头压力。新设备设计要求操作性能好，集中显示钻井和循环流体参数，控制和记录钻井过程中的参数，具有经济性能好、安全可靠、维护方便等特点。x地质岩心钻探的深度是由55.5毫米和
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