【作者】 李明；

【导师】 熊青山； 张长生； 李学民；

【作者基本信息】 长江大学 ， 机械工程， 2013， 硕士

【摘要】 当前,柴油机是国内机械钻机的主要动力,由于柴油价格较高,因此,能否有效控制燃料成本就成为降低钻井成本的关键因素。天然气发动机使用价格低的天然气作为燃料,能将天然气机引入机械钻机作为动力设备,对于节省燃料成本、减少排放都具有重大意义。依据中石油集团公司“以LNG为气源的天然气发动机置换柴油发动机钻井试验项目”的安排,为确保该项目在各大油田的推广应用和顺利实施,由渤海钻探第一钻井公司、济南柴油机股份有限公司、海南福山油田联合进行“天然气机驱动机械钻机技术研究与应用项目”的试验,以此检验天然气机是否满足钻井工况要求,在钻井现场能否逐步替代柴油机的可行性,并通过试验达到对该天然气发动机系统进行不断的完善和优化的目的。通过研究天然气机功率与钻井作业负荷的匹配以及天然气机选型,根据天然气机转速特性,设计传动模块,研究天然气机带载与钻井工况适应问题,对天然气机控制系统进行改进,解决并车功率分配问题,结合天然气机的动态特性改变钻井操作习惯,制定安全操作规范确保现场应用天然气的生产、人身和设备安全。选定具有典型代表的老45J钻机进行现场工业化试验,采用2台济柴产2000型天然气发动机置换2台柴油机,机房动力设备采取了2台气机+1台柴油机的组合动力方式,为了确保并车的平稳性,使用减速比为1.732的减速箱代替1.536的柴油机减速箱,经过3口井的现场试验,对比柴油机和天然气发动机的动态特性,检验了天然气发动机作为机械钻机的动力设备方面存在的优势和不足。本项目自立项以来,先进行现场调研,初步选定济柴2000型天然气机作为动力机型,这是充分考虑天然气机的技术风险性和液化天然气的供应范围问题后做出的选择,在现场不使用天然气机的时候可以方便的使用原有2000型柴油机,现场具有替换性。对原有的传动模块重新设计,使用耦合器输出动力,代替原有的万向轴输出动力。耦合器输出动力平稳,提高抗负荷波动能力。重新设计了传动比,针对天然气机的动力输出曲线,重新计算优化泵冲的传动比。对原有的天然气机控制系统进行改进,使用数字显示的转速表,功率分配更加均衡。并能实现远程监视机组运行状态和远程控制启停等功能。将原皮带直接传动的散热风扇,改为耦合器传动,并采用温度控制,能够更好的控制机体温度,提高燃烧效率。降低风扇转速,减小风扇噪音,增大风扇迎风面积,提高风量。简化排气管消音器支撑机构,将原来的单独支撑,修改为消音器与水箱一体的结构,安装快捷安全。将天然气机工作转速由原来的1350-1400RPM,提高至1400-1450RPM,可提升功率50-80KW,提升功率储备有利适应钻井时的冲击载荷。在现场试验阶段,针对天然气机的不足进行了必要的整改和优化,解决并车问题和并车带载时功率分配问题,调整天然气机灵敏度和稳定性以适应钻井施工现场的特殊要求；制定了适合现场实际的操作规范。最终完成了在1个钻井队进行了3口井的试验,摸索出天然气机在机械钻机上的使用经验。本次研究与应用解决了天然气机用于钻机的最佳性能参数的优选,在改造投入最低、功率配比最合理的前提下,分析济南柴油机股份有限公司所生产各型天然气机性能特点,确定实验研究机型；通过现场工业试验,优化机组的性能参数,提高对钻井工况的适应性；在改动工作量最少、投入最低的指导原则下,制定传动系统改造方案,并结合现场试验情况进行方案优化；结合天然气机的工作特点,结合钻井的实际工况,摸索出天然气机在机械钻机上的使用规律,修订完善操作规范,适应确保天然气机与钻井工况的需要,确保作业安全、经济、平稳、可靠。通过本次研究和现场应用,天然气发动机参与运行了3口井钻井的全过程和全工况,证明2000型天然气发动机可以代替原有的柴油发动机进行钻井各种工况的作业。从功率上讲,单台2000型天然气发动机完全可以取代单台柴油机。天然气发动机的抗突变负荷能力基本满足钻井各工况的要求,但是负荷特性比较软,在瞬时启动大负荷(启动泥浆泵)的情况下,速降最大瞬时值在15%左右,而且稳定时间较长,在试验过程中通过调整稳定性已得到改善。天然气发动机存在两台发动机并车运行时负荷分配不均的现象,易出现某台发动机超负荷,在试验过程中将天然气机的燃气消耗量作为反馈信号传送到控制系统进行比较,解决了并车时负荷分配不均的问题。天然气发动机的燃料是LNG,控制系统比柴油机更加先进,因此,必须采取相应的安全技术手段,降低在井场上上使用的风险,同时需要对操作人员进行专业知识培训和安全操作规程的教育。通过在50522队试验应用天然气发动机进行钻井作业,在试验阶段采集的数据分析,同等功率下天然气发动机比柴油机节省燃料费用27%,减少一氧化碳排放17%,碳氢化物排放6%,氮氧化物排放21%。更多还原

【Abstract】 At present, the diesel engine is the main driving force of domestic mechanical rig, because the price of diesel is higher, therefore, the ability to effectively control the cost of fuel has become a key factor in reducing drilling costs. Low price of natural gas engines using natural gas as a fuel, natural gas can introduce mechanical rig machine as power equipment, for the save fuel costs and reduce emissions are of great significance.According to CNPC" LNG as gas source gas engine displacement diesel engine drilling pilot project " arrangements, in order to ensure that the project in the major field of application and the smooth implementation of the first by the Bohai Drilling Drilling Company, Jinan Diesel Engine Co., company, Hainan Fushan Oilfield joint " gas-drive mechanical rig technology research and application projects," the pilot, in order to test gas drilling machine meets the conditions required in the drilling site could gradually replace diesel feasibility, and through trial met the gas engine system for continuous improvement and optimization purposes.By studying the natural gas drilling machine power and load matching and gas machinery selection, based on machine speed characteristics of natural gas, transmission module design, research gas machine with load adjustment problems with drilling conditions for gas control system improved to resolve and power allocation problem, combined with the change in the dynamics of natural gas drilling machine operating practices, to develop safe working practices to ensure that the production of natural gas field applications, personal and equipment safety.Selected45J has a typical representative of the old industrial test rigs on site, using two sets JICHAI production2000natural gas engine replacement two diesel engines, power equipment took2+1air-powered diesel engine combination, and in order to ensure and stationary vehicle, the use of the speed reduction ratio of1.732instead of1.536diesel engine gearbox gear box, after three field test wells, diesel and natural gas engines compare the dynamic characteristics of the gas engine as a mechanical test rig that exist in a power plant strengths and weaknessesSince the project inception, the first on-site investigation, initially selected JICHAI2000natural gas as a power machine model, which is sufficient to consider the technical risks of natural gas engines and liquefied natural gas supply problems range choices made in the field do not use natural gas machine when you can easily use the original2000diesel engine.The original drive modules redesigned using coupler output power, instead of the original universal shaft output power. Stable power output coupler, the load fluctuations and improve resistance. Redesigned the transmission ratio for natural gas engines power output curve, recalculate optimized pump stroke gear ratio. The original gas control system to improve, with digital display tachometer, power distribution more balanced. And can achieve remote monitoring and remote control unit running start and stop functions. The original direct drive fan belt, instead coupler transmission, and using temperature control, to better control body temperature, improve combustion efficiency.Reduce fan speed, reducing fan noise and increase fan frontal area, improve air flow. Exhaust muffler simplified support mechanism, the original individual support, modified muffler with integrated tank structure, installation fast and safe. Natural gas machine operating speed from the original1350-1400RPM, increased to1400-1450RPM, can increase power50-80KW, enhance power reserve favorable impact loads while drilling adaptIn the field test phase, for the lack of natural gas machine made the necessary rectification and optimization, problem solving and car and truck with load and power allocation problem, adjust the sensitivity and stability of gas machine drilling site to accommodate the special requirements; developed for live actual practices. Finally completed in a drilling crew conducted three test wells, and explore natural gas in the mechanical rig machine user experience.The research and application of machine is used to solve the natural gas rig preferred parameters for optimum performance, the minimum investment in the transformation of the power ratio of the most reasonable under the premise of Jinan Diesel Engine Co., Ltd. produces various types of gas machine performance characteristics that determine experimental study models; through the field of industrial test and optimize unit performance parameters to improve working conditions for drilling adaptability; at least workload changes, the lowest investment guidelines, to develop transmission system rehabilitation programs, combined with the field test conducted optimization; Combined gas machine working characteristics, combined with the drilling of the actual working conditions, and explore the natural gas engines used in the mechanical rig laws, revised and improved practices to adapt to ensure that natural gas drilling conditions of the machine and the need to ensure operational safety, economy, stable, reliable.The passing of this Ci research and field applications, natural gas engine involved in running for3wells the drilling of the whole process and the total working conditions, prove that2000type natural gas engine can instead of the original diesel engine carry out well drilling various working conditions jobs. From a power perspective, a single2000natural gas engine can fully replace a single engine. Natural gas engines’s anti-mutation load capacity basically meet the needs well drilling of each requirements of working conditions, but the load characteristics is quite soft, during instantaneous startup large load (startup mud pump) in the case, downhill the maximum instantaneous value of the at around15%, moreover stabilization time representing an long, during the trial process through the adjusting stability is been improved.The presence of natural gas engines and vehicles running two engines uneven load distribution, an engine prone to overload, during the test drive gas consumption of natural gas as a feedback signal to the control system compares solved and car when the problem of uneven load distribution. Gas engine fuel is LNG, the control system more advanced than the engine therefore, must take appropriate safety techniques to reduce the risk of the use of the well field, while the need for operator training and expertise of personnel safety procedures education.By50,522teams testing applications for drilling natural gas engines, the data collected during the pilot phase analysis, the same power than gas engines diesel fuel cost savings of27%, reduce carbon monoxide emissions17%,6%of hydrocarbon emissions, nitrogen oxide emissions21%.更多还原