导管架调平夹持器齿形爪优化及同步控制技术研究
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摘要
近十几年来的全球大型油气田勘探实践表明，陆上油气资源已进入“平台期”，其产量增长几乎接近峰值，因而各国开始走向海中取油之路，因此海洋油气资源是未来世界油气资源开发的重要领域。海洋油气资源开发离不开海洋平台，钢质桩基导管架平台凭借自身的诸多优点而被广泛应用于海洋油气开发中。导管架安装过程中的调平作业是影响导管架平台海上安装质量的关键环节之一，深水导管架调平需要一些特殊的机具，其中调平机具系统是调平作业所必需的专用液压机具，由于其能同时完成夹持和调平两项操作，对提高安装效率、降低海上安装成本具有重要作用。我国在该领域的研究还处于起步阶段，因此对其关键技术进一步研究以加快该装备的国产化进程具有现实意义。
本课题来源于中国海洋石油工程股份有限公司综合科研项目“深水导管架安装液压装具研发”。本文综述了海洋油气平台导管架调平作业系统的国内外应用现状，评述了该技术的发展和需要进一步研究的问题，针对调平机具系统的夹持和调平作业这两项关键工序，深入分析了其关键部件—夹持器的齿形夹爪参数、管桩承载能力及调平力的关系，给出了齿形爪参数确定方法，建立了表征齿形爪参数与调平力和管桩承载力关系的数学模型，构建了齿形爪优化的可视化仿真平台，进一步研究了便于工程应用的长管路调平提升系统数学模型简化方法及其同步控制技术。
本文根据夹持器齿形爪的受力状态，应用弹性理论推导了齿形爪截面内任意点的应力分量表达式，确定了较为合理的齿形爪结构。在此基础上，分析了齿形爪结构参数对调平力的影响，从齿形爪和管桩材料满足最大应力条件出发，提出了齿形爪结构参数的确定方法，为齿形爪系列化设计打下了基础。
针对齿形爪结构优化问题，采用一种数值模拟正交试验、支持向量机回归和改进遗传算法的综合优化方法。首先确定了数值模拟正交试验因素及各因素水平；其次根据不规则实体的多楔接触问题解法，利用ANSYS软件建立了齿形爪与导管桩夹持接触的有限元模型，以齿形爪与管桩间夹持力及其应力作为试验指标，将得到的不同因素水平组合的有限元分析结果作为训练样本，建立了夹持接触力、齿形爪应力和管桩应力的支持向量机回归模型，采用另外的预测样本对回归模型的预测效果进行了验证，结果证明了所建模型的合理性；最后以夹持接触力的回归模型为目标函数，以齿形爪和管桩应力的回归模型为约束函数，采用改进的遗传算法对齿形爪结构进行了优化，将优化结果与ANSYS分析结果进行了对比，结果表明两者误差小于1%。构建了齿形爪结构优化可视仿真平台，为实际工程应用提供了一种便捷设计方法。
在分析调平机具系统作业特点的基础上确定了系统管路布置形式，基于管路传输动力学理论，修正了长软管的线性摩擦模型，建立了考虑管路效应的长管路电液提升系统数学模型，分析了管路效应对系统动态特性的影响。为解决系统模型参数复杂与求解困难等问题，本着构建工程适用模型的思想，本文利用管路的质量-弹簧-阻尼动力学模型，提出了一种基于模型降阶法的快速建立长管路简化模型的方法，给出了简化模型公式，与原模型对比分析的结果表明所提出的简化模型与原模型有很高的近似度。
对并联长管路电液提升系统各通道间运动耦合问题，借鉴最少相关耦合轴数控制的基本思想建立了并联长管路环交叉耦合同步控制模型。提出了一种改进的Smith滑模预估控制方法，设计了跟踪误差控制器，并与一种改进的PID Smith预估控制器进行了比较，仿真结果表明所提出控制方法的有效性。采用滑模变结构控制方法设计了相邻两通道的同步误差控制器。将环交叉耦合控制与等同式同步控制进行了比较，结果表明了环交叉耦合控制方式应用于并联长管路电液提升系统同步控制的可行性和有效性。
Over the past decade, the practices of global large oil and gas field exploration show thatthe onshore oil and gas resources have reached a plateau, and its output growth has been closeto the peak, so that activities are turning to the sea and it will be a significant area of theworld’s oil and gas resource exploitation in the future. The offshore platforms are theessential equipment, among them the pile-supported steel jacket-type platform is widely used.Leveling jacket is a key step of platform installation. Leveling operation for deepwater jacketneeds some special tools, and leveling tool system is a specific hydraulic tool. Due to thegripping and leveling operations can be doing simultaneously, the tool is very important toimprove the installation efficiency and reduce cost. The studies are still in beginning stage inour country, so further research of the technique is necessary to speed up its nationalization.
The project roots in the comprehensive project of Offshore Oil Engineering Co. Ltd“hydraulic equipment development for deepwater jacket installation”. In this paper, theleveling operating system both at home and abroad are summarized, the research progress ofthat technique is reviewed, and the problems which need further studied are described.Aiming at two key technologies of leveling tools system, gripping and leveling, the internalrelations between the structural parameters of the gripper’s toothed gripping jaw and levelingforce and bearing capacity of steel pile are studied further in this paper, the method todetermine these parameters is obtained, the mathematical model describing those innerrelations is built, the optimization simulation platform for toothed gripping jaw is constructed,the simplified mathematical model of the electro-hydraulic executive system with longpipeline is researched, which is convenient to apply to engineering, and the synchronizationcontrol strategy of the parallel long pipeline leveling system is presented.
By analyzing force condition of the toothed gripping jaw, the stress componentsexpressions at any point in the tooth’s normal section are derived adopting elastic theory, anda reasonable structure is deduced from analysis results. On that basis, the effect of structureparameters on the leveling force is also discussed. And based on the thought of the toothedgripping jaw and pile materials meeting the greatest stress conditions, the methods that maybe used to determine the key parameters are given, which will make a foundation for theserial design of gripping jaw.
For structural optimization of the gripping jaw, a comprehensive optimization approachis presented, which incorporates the numerical simulation orthogonal experiment optimization method, the support vector machine regression and the improved geneticalgorithm. Firstly, the orthogonal experiment factors and their levels of numerical simulationare confirmed. Then according to the solution method for multiple wedges contact problem ofthe irregular entities, the finite element model of clamping contact between gripping jaw andpile is established by using ANSYS software, and the finite analysis results for different levelcombination of those factors are obtained on condition that contact pressure between grippingjaw and pile and their stresses are taken as the orthogonal experiment indexes. On that basis,the support vector machine regression models of contact pressure, gripping jaw stress andpile stress are set up, and the forecasting accuracy of regression model are verified by anotherprediction sample set, which shows that these models are validity. Using the regression modelof contact pressure as a target function and that of gripping jaw and pile as constraintfunctions, an optimal tooth structure of gripping jaw is obtained by adopting a kind ofimproved genetic algorithm, and the comparative result between optimal values andcalculated ones of ANSYS indicates that the error is less than1%. In addition, a visiblesimulation platform of structure optimization is designed for the toothed gripping jaw so as tooffer a convenient method for the engineering practice.
By analyzing leveling operation features, the pipeline arrangement form is determinedand a linear friction model of long hose is revised based on transmission pipeline dynamics.The leveling system mathematic model considering pipeline effect is derived and the effectson system dynamic characteristics are analyzed. To handle the problem that the model hasvery complex parameters and is difficult to solve, in line with the thought of constructing asuitable engineering model, this paper presents a fast modeling method of long pipeline byusing a spring-damper-mass model based on model reduction and the simplified formula isgiven. Compared with the original model, the simplified one has better approximation.
For the movement coupling between different channels of the leveling system with longpipelines in parallel, a circular cross-coupling synchronous control model is set up based onthe idea of the minimum number of correlative axis control. An improved Smith sliding modeprediction control method is proposed to design a tracking error controller and comparisonwith an improved PID Smith predictor indicates that the approach is effective. Thesynchronization error controller of two adjacent channels is designed by employing slidingmode variable structure control method. The results of comparison with an equalsynchronization control show that the synchronous control strategy used in the parallelleveling system with long pipelines is feasible and effective.
本课题来源于中国海洋石油工程股份有限公司综合科研项目“深水导管架安装液压装具研发”。本文综述了海洋油气平台导管架调平作业系统的国内外应用现状，评述了该技术的发展和需要进一步研究的问题，针对调平机具系统的夹持和调平作业这两项关键工序，深入分析了其关键部件—夹持器的齿形夹爪参数、管桩承载能力及调平力的关系，给出了齿形爪参数确定方法，建立了表征齿形爪参数与调平力和管桩承载力关系的数学模型，构建了齿形爪优化的可视化仿真平台，进一步研究了便于工程应用的长管路调平提升系统数学模型简化方法及其同步控制技术。
本文根据夹持器齿形爪的受力状态，应用弹性理论推导了齿形爪截面内任意点的应力分量表达式，确定了较为合理的齿形爪结构。在此基础上，分析了齿形爪结构参数对调平力的影响，从齿形爪和管桩材料满足最大应力条件出发，提出了齿形爪结构参数的确定方法，为齿形爪系列化设计打下了基础。
针对齿形爪结构优化问题，采用一种数值模拟正交试验、支持向量机回归和改进遗传算法的综合优化方法。首先确定了数值模拟正交试验因素及各因素水平；其次根据不规则实体的多楔接触问题解法，利用ANSYS软件建立了齿形爪与导管桩夹持接触的有限元模型，以齿形爪与管桩间夹持力及其应力作为试验指标，将得到的不同因素水平组合的有限元分析结果作为训练样本，建立了夹持接触力、齿形爪应力和管桩应力的支持向量机回归模型，采用另外的预测样本对回归模型的预测效果进行了验证，结果证明了所建模型的合理性；最后以夹持接触力的回归模型为目标函数，以齿形爪和管桩应力的回归模型为约束函数，采用改进的遗传算法对齿形爪结构进行了优化，将优化结果与ANSYS分析结果进行了对比，结果表明两者误差小于1%。构建了齿形爪结构优化可视仿真平台，为实际工程应用提供了一种便捷设计方法。
在分析调平机具系统作业特点的基础上确定了系统管路布置形式，基于管路传输动力学理论，修正了长软管的线性摩擦模型，建立了考虑管路效应的长管路电液提升系统数学模型，分析了管路效应对系统动态特性的影响。为解决系统模型参数复杂与求解困难等问题，本着构建工程适用模型的思想，本文利用管路的质量-弹簧-阻尼动力学模型，提出了一种基于模型降阶法的快速建立长管路简化模型的方法，给出了简化模型公式，与原模型对比分析的结果表明所提出的简化模型与原模型有很高的近似度。
对并联长管路电液提升系统各通道间运动耦合问题，借鉴最少相关耦合轴数控制的基本思想建立了并联长管路环交叉耦合同步控制模型。提出了一种改进的Smith滑模预估控制方法，设计了跟踪误差控制器，并与一种改进的PID Smith预估控制器进行了比较，仿真结果表明所提出控制方法的有效性。采用滑模变结构控制方法设计了相邻两通道的同步误差控制器。将环交叉耦合控制与等同式同步控制进行了比较，结果表明了环交叉耦合控制方式应用于并联长管路电液提升系统同步控制的可行性和有效性。
Over the past decade, the practices of global large oil and gas field exploration show thatthe onshore oil and gas resources have reached a plateau, and its output growth has been closeto the peak, so that activities are turning to the sea and it will be a significant area of theworld’s oil and gas resource exploitation in the future. The offshore platforms are theessential equipment, among them the pile-supported steel jacket-type platform is widely used.Leveling jacket is a key step of platform installation. Leveling operation for deepwater jacketneeds some special tools, and leveling tool system is a specific hydraulic tool. Due to thegripping and leveling operations can be doing simultaneously, the tool is very important toimprove the installation efficiency and reduce cost. The studies are still in beginning stage inour country, so further research of the technique is necessary to speed up its nationalization.
The project roots in the comprehensive project of Offshore Oil Engineering Co. Ltd“hydraulic equipment development for deepwater jacket installation”. In this paper, theleveling operating system both at home and abroad are summarized, the research progress ofthat technique is reviewed, and the problems which need further studied are described.Aiming at two key technologies of leveling tools system, gripping and leveling, the internalrelations between the structural parameters of the gripper’s toothed gripping jaw and levelingforce and bearing capacity of steel pile are studied further in this paper, the method todetermine these parameters is obtained, the mathematical model describing those innerrelations is built, the optimization simulation platform for toothed gripping jaw is constructed,the simplified mathematical model of the electro-hydraulic executive system with longpipeline is researched, which is convenient to apply to engineering, and the synchronizationcontrol strategy of the parallel long pipeline leveling system is presented.
By analyzing force condition of the toothed gripping jaw, the stress componentsexpressions at any point in the tooth’s normal section are derived adopting elastic theory, anda reasonable structure is deduced from analysis results. On that basis, the effect of structureparameters on the leveling force is also discussed. And based on the thought of the toothedgripping jaw and pile materials meeting the greatest stress conditions, the methods that maybe used to determine the key parameters are given, which will make a foundation for theserial design of gripping jaw.
For structural optimization of the gripping jaw, a comprehensive optimization approachis presented, which incorporates the numerical simulation orthogonal experiment optimization method, the support vector machine regression and the improved geneticalgorithm. Firstly, the orthogonal experiment factors and their levels of numerical simulationare confirmed. Then according to the solution method for multiple wedges contact problem ofthe irregular entities, the finite element model of clamping contact between gripping jaw andpile is established by using ANSYS software, and the finite analysis results for different levelcombination of those factors are obtained on condition that contact pressure between grippingjaw and pile and their stresses are taken as the orthogonal experiment indexes. On that basis,the support vector machine regression models of contact pressure, gripping jaw stress andpile stress are set up, and the forecasting accuracy of regression model are verified by anotherprediction sample set, which shows that these models are validity. Using the regression modelof contact pressure as a target function and that of gripping jaw and pile as constraintfunctions, an optimal tooth structure of gripping jaw is obtained by adopting a kind ofimproved genetic algorithm, and the comparative result between optimal values andcalculated ones of ANSYS indicates that the error is less than1%. In addition, a visiblesimulation platform of structure optimization is designed for the toothed gripping jaw so as tooffer a convenient method for the engineering practice.
By analyzing leveling operation features, the pipeline arrangement form is determinedand a linear friction model of long hose is revised based on transmission pipeline dynamics.The leveling system mathematic model considering pipeline effect is derived and the effectson system dynamic characteristics are analyzed. To handle the problem that the model hasvery complex parameters and is difficult to solve, in line with the thought of constructing asuitable engineering model, this paper presents a fast modeling method of long pipeline byusing a spring-damper-mass model based on model reduction and the simplified formula isgiven. Compared with the original model, the simplified one has better approximation.
For the movement coupling between different channels of the leveling system with longpipelines in parallel, a circular cross-coupling synchronous control model is set up based onthe idea of the minimum number of correlative axis control. An improved Smith sliding modeprediction control method is proposed to design a tracking error controller and comparisonwith an improved PID Smith predictor indicates that the approach is effective. Thesynchronization error controller of two adjacent channels is designed by employing slidingmode variable structure control method. The results of comparison with an equalsynchronization control show that the synchronous control strategy used in the parallelleveling system with long pipelines is feasible and effective.
引文
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