在役钻机井架使用安全性综合评价方法研究
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摘要
井架是石油钻机的重要组成部分,其安全性能直接关系到整套钻机系统的生产运行。对于井架这种复杂承载的空间钢结构,使用过程中经常存在拆装、运输、超载和腐蚀等各种因素的影响,且所受载荷具有随机性,发生损伤和破坏的潜在危险性较大,从而使结构安全受到威胁。更为严重的是,有些结构的重要部件一旦发生损伤,它的破坏程度将迅速发展,而在未及时发现的情况下可能会导致整个结构的毁坏,造成灾难性悲剧。为了保障生命财产安全,减少重大经济损失,同时也为了对服役钻机井架进行合理维修、减少维护费用,采取有效的技术手段及方法对在役钻机井架结构进行安全检测、健康诊断和安全评估尤为必要和迫切。因此,针对井架结构开展损伤诊断及性能评价方法的研究,建立安全评价体系,具有十分重要的理论意义及现实意义。
本文针对在役钻机井架使用安全性评价中涉及到的关键科学与技术问题进行了系统研究,主要研究内容和成果如下：
(1)对有损伤在役钻机井架数值分析方法进行了研究。以有限元方法为基础,借助于通用软件的分析能力,提出了描述在役钻机井架损伤因素和结构性能参数隐含关系的数值分析方法。通过对在役钻机井架存在的损伤进行分析,建立结构损伤模型,引入了损伤指标函数的概念,揭示了损伤对结构特性的影响,构建了有损伤井架结构的损伤数值计算模型,为进一步的模型修正和性能评价奠定了基础。
(2)以性能评价为目标,对钻机井架测试理论及方法进行了研究。针对钻机井架的结构形式和作业特点,从静力和动力角度阐述其测试理论和测试方法。首先,针对传统测试手段存在的不足,开发无线测试技术及系统,将其运用到钻机井架结构的安全检测上,从理论上剖析无线应力测试的原理,通过试验证实WiFi无线测试系统是可行的,能够为进一步的性能评价提供良好的基础数据；其次,详细分析了模态测试中若干试验参数,如激励方式、传感器位置以及频率分辨率等,推演了一种基于环境随机激励的结构试验模态识别的有效方法。基于此,探讨了测试过程中存在的信息不完备问题,并针对这一问题,给出了具体的解决方案。
(3)基于参数反演的思想,对在役钻机井架的模型修正方法进行了研究。首先阐述参数反演的基本思想和思路框架,综合考虑静态、模态参数,提出基于优化的有限元模型反演修正的方法。从灵敏度的物理意义出发,详细论述灵敏度分析方法,推演出一种适合工程应用的灵敏度分析方法,指出了结构的敏感参数；优化修正时以反映结构性能参数的残差最小作为目标函数,推导了目标函数的改进形式,反演优化问题借助于改进后的目标函数结合一阶随机搜索和遗传算法求解,使得反演计算效率有了明显提高,且计算精度可靠。以实验室井架模型为例验证了参数反演方法的可行性,并针对在役钻机井架的模型修正问题给出适于工程应用的解决策略,即多阶段模型反演修正方法、结合直接修正方法的模型局部反演方法和联合静动力分层次模型反演修正方法。
(4)从使用安全性的角度系统地分析了在役钻机井架的综合评价方法。提出了基于工程经验和参数反演的在役钻机井架使用安全性综合评价方法。对三个典型工程实例进行了结构性能评价,并分别验证了基于静态参数修正方法、基于模态参数修正方法和联合静动力指标分层次修正方法的有效性,为在役钻机井架的性能评价和状态评估提供了一种新思路。以API标准为主线,结合其中一个典型工程实例综合考虑极限载荷、起升工况和风载荷等特殊情况下结构使用安全性的分析方法,从而实现综合性能评价,为在役钻机井架作业的安全性提供了保障。
Derrick is an important part of oil rig, its safety performance is directly related to the operation of a complete set of rig system. As a kind of complex carrying space steel structure, derrick is ofen affected by many factors during using, for example, dismounting and mounting, transportation, overload and corrosion, etc. and the carried load is random. So the potential risk of injuries and destruction is very big, the safety of structures is threatened. More seriously, if some important parts have been damaged, its destruction degree will develop rapidly, quickly lead to the destruction of the whole structure and cause catastrophic tragedy. In order to ensure life and property security, reduce the great economic losses and repair in-service rig derrick reasonably and reduce maintenance costs, it is particularly necessary and urgent to take effective technical means and methods for the testing, health diagnosis and safety evaluation of in-service rig derrick. Therefore, it has very important theoretical significance and practical significance that study on the damage diagnosis and performance evaluation method is carried out to establish the safety evaluation system of derrick.
This paper studies the key scientific and technological problems about safety evaluation of in-service rig derrick. The main research contents and results are as follows:
(1) The numerical analysis method of in-service rig derrick with damage was studied. Using analysis platform based on finite element method, the numerical model analysis method that can describe the implicit relationship between damage factors and performance parameters of in-service rig derrick is put forward. Through analyzing damage and its mechanism, damage mathematical fomulas is established, the damage functions are introduced, the influence of damage on structure characteristics is revealed, consequent damage numerical models of in-service rig derrick are established, thereby the method of damage numerical simulation is proposed. The analysis offers foundation for further model updating and performance evaluation.
(2) The testing theory and method for performance evaluation of rig derrick is studied. According to the features and characters of rig derrick, the static and dynamic testing methods are explained. Firstly, aiming at the shortcomings of the traditional strain test, the wireless stress testing technology and system is developed, that can be used for safety testing of rig derrick. The principle of wireless stress test is theoretically analyzed. The efficiency and reliability of WiFi wireless test system is proved by the comparison test. It can provide good foundation data for further performance evaluation; Secondly, some testing parameters during modal test are discussed in detail, such as motivational pattern, sensor location and frequency resolution etc. A novel method about experimental modal parameters identification under ambient random excitation is deduced. Based on these, the problems and its solutions on the incomplete measuerments are discussed.
(3) The model updating method based on parameter inversion of rig derrick is studied. Firstly, the paper expounds the basic ideas and framework of parameter inversion. And then the inversion model updating method based on optimization is proposed, comprehensivly considering the static and modal parameters. A sensitivity analysis method suitable for practical engineering applications is deduced according to its physical meaning, then sensitivity parameters are accqured. The optimal updating function was established according to residual equation between test and theory parameters. Combined with first-order optimization algorithm and genetic algorithm, the improved objective function is proposed to solve this problem. Inversion calculation efficiency is obviously improved, and the computation precision is reliable. The inversion method has been verified by experimental analysis of derrick model. The solutions on model updating problem the in-service rig derrick suitable to engineering application are given, that is:multi-stage inversion model updating method, partial inversion model method combined with the direct updating and the static and dynamic hierarchical model updating method.
(4) From the point of view of the using safety, this paper systematically analyzes the comprehensive evaluation method of in-service rig derrick based on the empirical judgment and parameters inversion. Three typical engineering examples have been done the performance evaluation, and the result verified the availability of three kinds of updating methods, that is:the model updating method based on the static parameters, the model updating method based on the modal parameters and stratified updating method combined with static and dynamic index. It provides a new idea for the performance evaluation and the condition assessment of in-service rig derrick. API standard as the main line, considering comprehensively the particular situation of the ultimate load, hoisting condition and wind load, etc, the using safety of one typical engineering example is analysed so as to realize the comprehensive performance evaluation. It can provide the security for the operating safty of in-service rig derrick.
本文针对在役钻机井架使用安全性评价中涉及到的关键科学与技术问题进行了系统研究,主要研究内容和成果如下：
(1)对有损伤在役钻机井架数值分析方法进行了研究。以有限元方法为基础,借助于通用软件的分析能力,提出了描述在役钻机井架损伤因素和结构性能参数隐含关系的数值分析方法。通过对在役钻机井架存在的损伤进行分析,建立结构损伤模型,引入了损伤指标函数的概念,揭示了损伤对结构特性的影响,构建了有损伤井架结构的损伤数值计算模型,为进一步的模型修正和性能评价奠定了基础。
(2)以性能评价为目标,对钻机井架测试理论及方法进行了研究。针对钻机井架的结构形式和作业特点,从静力和动力角度阐述其测试理论和测试方法。首先,针对传统测试手段存在的不足,开发无线测试技术及系统,将其运用到钻机井架结构的安全检测上,从理论上剖析无线应力测试的原理,通过试验证实WiFi无线测试系统是可行的,能够为进一步的性能评价提供良好的基础数据；其次,详细分析了模态测试中若干试验参数,如激励方式、传感器位置以及频率分辨率等,推演了一种基于环境随机激励的结构试验模态识别的有效方法。基于此,探讨了测试过程中存在的信息不完备问题,并针对这一问题,给出了具体的解决方案。
(3)基于参数反演的思想,对在役钻机井架的模型修正方法进行了研究。首先阐述参数反演的基本思想和思路框架,综合考虑静态、模态参数,提出基于优化的有限元模型反演修正的方法。从灵敏度的物理意义出发,详细论述灵敏度分析方法,推演出一种适合工程应用的灵敏度分析方法,指出了结构的敏感参数；优化修正时以反映结构性能参数的残差最小作为目标函数,推导了目标函数的改进形式,反演优化问题借助于改进后的目标函数结合一阶随机搜索和遗传算法求解,使得反演计算效率有了明显提高,且计算精度可靠。以实验室井架模型为例验证了参数反演方法的可行性,并针对在役钻机井架的模型修正问题给出适于工程应用的解决策略,即多阶段模型反演修正方法、结合直接修正方法的模型局部反演方法和联合静动力分层次模型反演修正方法。
(4)从使用安全性的角度系统地分析了在役钻机井架的综合评价方法。提出了基于工程经验和参数反演的在役钻机井架使用安全性综合评价方法。对三个典型工程实例进行了结构性能评价,并分别验证了基于静态参数修正方法、基于模态参数修正方法和联合静动力指标分层次修正方法的有效性,为在役钻机井架的性能评价和状态评估提供了一种新思路。以API标准为主线,结合其中一个典型工程实例综合考虑极限载荷、起升工况和风载荷等特殊情况下结构使用安全性的分析方法,从而实现综合性能评价,为在役钻机井架作业的安全性提供了保障。
Derrick is an important part of oil rig, its safety performance is directly related to the operation of a complete set of rig system. As a kind of complex carrying space steel structure, derrick is ofen affected by many factors during using, for example, dismounting and mounting, transportation, overload and corrosion, etc. and the carried load is random. So the potential risk of injuries and destruction is very big, the safety of structures is threatened. More seriously, if some important parts have been damaged, its destruction degree will develop rapidly, quickly lead to the destruction of the whole structure and cause catastrophic tragedy. In order to ensure life and property security, reduce the great economic losses and repair in-service rig derrick reasonably and reduce maintenance costs, it is particularly necessary and urgent to take effective technical means and methods for the testing, health diagnosis and safety evaluation of in-service rig derrick. Therefore, it has very important theoretical significance and practical significance that study on the damage diagnosis and performance evaluation method is carried out to establish the safety evaluation system of derrick.
This paper studies the key scientific and technological problems about safety evaluation of in-service rig derrick. The main research contents and results are as follows:
(1) The numerical analysis method of in-service rig derrick with damage was studied. Using analysis platform based on finite element method, the numerical model analysis method that can describe the implicit relationship between damage factors and performance parameters of in-service rig derrick is put forward. Through analyzing damage and its mechanism, damage mathematical fomulas is established, the damage functions are introduced, the influence of damage on structure characteristics is revealed, consequent damage numerical models of in-service rig derrick are established, thereby the method of damage numerical simulation is proposed. The analysis offers foundation for further model updating and performance evaluation.
(2) The testing theory and method for performance evaluation of rig derrick is studied. According to the features and characters of rig derrick, the static and dynamic testing methods are explained. Firstly, aiming at the shortcomings of the traditional strain test, the wireless stress testing technology and system is developed, that can be used for safety testing of rig derrick. The principle of wireless stress test is theoretically analyzed. The efficiency and reliability of WiFi wireless test system is proved by the comparison test. It can provide good foundation data for further performance evaluation; Secondly, some testing parameters during modal test are discussed in detail, such as motivational pattern, sensor location and frequency resolution etc. A novel method about experimental modal parameters identification under ambient random excitation is deduced. Based on these, the problems and its solutions on the incomplete measuerments are discussed.
(3) The model updating method based on parameter inversion of rig derrick is studied. Firstly, the paper expounds the basic ideas and framework of parameter inversion. And then the inversion model updating method based on optimization is proposed, comprehensivly considering the static and modal parameters. A sensitivity analysis method suitable for practical engineering applications is deduced according to its physical meaning, then sensitivity parameters are accqured. The optimal updating function was established according to residual equation between test and theory parameters. Combined with first-order optimization algorithm and genetic algorithm, the improved objective function is proposed to solve this problem. Inversion calculation efficiency is obviously improved, and the computation precision is reliable. The inversion method has been verified by experimental analysis of derrick model. The solutions on model updating problem the in-service rig derrick suitable to engineering application are given, that is:multi-stage inversion model updating method, partial inversion model method combined with the direct updating and the static and dynamic hierarchical model updating method.
(4) From the point of view of the using safety, this paper systematically analyzes the comprehensive evaluation method of in-service rig derrick based on the empirical judgment and parameters inversion. Three typical engineering examples have been done the performance evaluation, and the result verified the availability of three kinds of updating methods, that is:the model updating method based on the static parameters, the model updating method based on the modal parameters and stratified updating method combined with static and dynamic index. It provides a new idea for the performance evaluation and the condition assessment of in-service rig derrick. API standard as the main line, considering comprehensively the particular situation of the ultimate load, hoisting condition and wind load, etc, the using safety of one typical engineering example is analysed so as to realize the comprehensive performance evaluation. It can provide the security for the operating safty of in-service rig derrick.
引文
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