A valve load testing system

Abstract

The present invention discloses a valve load testing system. The disclosed test system includes a working pump, a main test pipeline and a branch test pipeline; the main pipeline inlet is connected to the working pump; the test branch pipeline inlet and outlet are respectively connected to the main test pipeline through connecting pipelines, and valves are installed on each connecting pipeline; the test branch pipeline inlet is also connected to a ball-delivery pipeline, and the outlet is also connected to a ball-receiving pipeline, and a switchable mechanism is installed at the inlet of the ball-delivery pipeline and the outlet of the ball-receiving pipeline. The test system of the present invention is designed with a pressure source module, a main test pipeline and a branch test pipeline, which can flexibly test various loads of the valve; the test system of the present invention can complete the assessment test of various oil pipeline valves such as switch valves, regulating valves, water hammer pressure relief valves and other safety valves, cleaning ball valves, etc. under different working conditions.

Description

Technical Field

[0001] The invention relates to a valve working performance testing technology, and in particular to a multifunctional valve load simulation test system. Background Art

[0002] If the regulating valves, various on-off valves, water hammer pressure relief valves and other safety valves and other main pipeline valves used in oil pipelines, especially the newly developed and designed valve products, can complete the relevant performance assessment and verification tests of the valve products through the test system before formal installation and use, it will greatly reduce the failure rate of the products when they are put into use, effectively ensure the safe and reliable operation of the oil pipeline, and reduce economic losses.

[0003] At present, due to the lack of a multifunctional test system that can fully simulate the load conditions of valves in actual use, various valves in long-distance pipelines such as refined oil and crude oil can only complete conventional factory sealing tests or ordinary static load tests before they are put into use. For newly developed valve products, especially valve products for oil pipelines with complex structures, it is impossible to conduct sufficient structural performance assessment and verification tests during the development stage. Once a valve product that has not been comprehensively tested fails after it is put into use, it will lead to serious consequences such as oil leakage or pipeline suspension, causing huge economic losses and even possible safety accidents. Summary of the invention

[0004] In view of the defects or shortcomings of the prior art, an object of the present invention is to provide a valve load testing system.

[0005] To this end, the valve load testing system provided by the present invention comprises:

[0006] Working pump;

[0007] A test main line, wherein the test main line is provided with an inlet and an outlet, and a first installation position for a valve to be tested is reserved between the inlet and the outlet of the test main line, and a flow meter and a regulating valve are installed on the main line; the inlet of the main line is connected to a working pump;

[0008] A test branch pipeline is provided with an inlet and an outlet, and a second installation position for a valve to be tested is reserved between the inlet and the outlet of the test branch pipeline, and a pressure gauge is installed on the branch pipeline; the inlet and outlet of the test branch pipeline are respectively connected to the test main pipeline through connecting pipelines, and a switch valve is installed on each connecting pipeline; the inlet of the test branch pipeline is also connected to a ball-delivering pipeline, and the outlet is also connected to a ball-receiving pipeline, and switchable mechanisms are installed at the inlet of the ball-delivering pipeline and the outlet of the ball-receiving pipeline.

[0009] Furthermore, the test system of the present invention also includes a pipe cleaner, which is placed into the test branch pipeline from the inlet of the ball-launching pipeline.

[0010] Preferably, the inner diameter of the test branch pipeline is the same as the inner diameter of the passage in the second tested valve; the inner diameters of the test main pipeline and the connecting pipeline are both smaller than the inner diameter of the test branch pipeline; the inner diameters of the ball serving pipeline and the ball receiving pipeline are both larger than the inner diameter of the test branch pipeline; the outer diameter of the pipe cleaner is larger than the inner diameter of the test branch pipeline.

[0011] Furthermore, the working pump includes at least one low-pressure pump and at least one high-pressure pump connected in series.

[0012] Preferably, the test system of the present invention also includes a side pipeline, the inlet of which is arranged on the test main pipeline and upstream of the test branch pipeline inlet, and a regulating valve is installed on the side pipeline for auxiliary regulation of pressure and flow on the test system pipeline.

[0013] Optionally, the switchable mechanism uses a quick-opening blind plate.

[0014] Optionally, the inlet of the test branch pipeline, the ball-delivering pipeline and the corresponding side connecting pipeline are connected via a pipeline tee, and the outlet of the branch pipeline, the ball-receiving pipeline and the corresponding side connecting pipeline are connected via a pipeline tee.

[0015] Furthermore, a pressure transmitter is installed on the test main pipeline, and the pressure transmitter monitors the pressure value of the pipeline in real time and feeds back to the central control room to help monitor the pressure condition value of the test system.

[0016] Furthermore, a ball collecting cage is provided in the ball collecting pipeline near the switch mechanism.

[0017] Compared with the prior art, the technical solution of the present invention has the following innovative features and beneficial effects:

[0018] (1) The test system of the present invention is designed with a pressure source module, a main test pipeline and a branch test pipeline, which can flexibly test various loads of the valve. Furthermore, the system pressure source is a combination of a front low-pressure pump + a rear high-pressure pump in series, and the front low-pressure pump and the rear high-pressure pump can be a single unit or multiple units as needed, which can provide the test system with different pressure / different flow test medium conditions to meet the actual use conditions of various test valves.

[0019] (2) The test system of the present invention can be used to complete the actual working condition assessment test of various oil pipeline valves such as on-off valves, regulating valves, water hammer pressure relief valves and other safety valves, pigging ball valves, etc. The valve performance can be fully assessed before the valve is put into operation to avoid huge losses caused by failures during operation.

[0020] (3) The test system of the present invention is used to simulate loads to analyze various dynamic load curves such as pressure and flow characteristics of valves under actual working conditions, and compare them with the theoretical numerical simulation results to correct or optimize the theoretical numerical calculation model and parameter settings. Product performance verification or optimization design is performed based on the test data to improve the performance reliability of the product after it is put into use. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic diagram of the structure of the valve load testing system of the present invention;

[0022] Figure 2 Schematic diagram of the structure of the simulation test system of the cleaning ball valve of Example 2 under specified load conditions. DETAILED DESCRIPTION

[0023] Unless otherwise specified, the terms described herein are understood according to common understanding in the relevant field.

[0024] The valve loads that can be tested by the test system of the present invention mainly refer to the working pressure, pressure / flow regulation characteristics, ball passing reliability, impurity resistance (i.e., the sealing performance of the pipe cleaning ball valve and the amount of impurities retained in the valve after a certain number of pipe cleaning impurities are completed), water hammer working conditions and other key valve performance indicators or pipeline important working condition parameters of various valves, which are used to assess the main working performance of various valves. The test system of the present invention can fully assess and verify the various index performances of various oil pipeline valves, and the various test data obtained can be used as comparative data for the theoretical numerical simulation calculation of valves; it can also carry out the commissioning assessment and verification test before the oil pipeline valves are put into use, to ensure the reliability of the formal installation and use of the product. Taking various valves in the long-distance oil pipeline as an example, the test system of the present invention can be used to test: the action test or life test of various switch valves under the set pressure working condition load; the pressure regulation characteristic test and flow regulation characteristic test of various regulating valves; the ball passing ability test and impurity resistance test of the pipe cleaning ball valve in the pipe cleaning system; it can also be widely used for the key indicator assessment of the return seat pressure test, the opening and closing pressure accuracy test, and the simulated pipeline water hammer working condition of the safety valve, and fully verify the use performance of the valve.

[0025] The first valve to be tested in the present invention refers to a valve that needs to test the working pressure, pressure / flow regulation characteristics and other related loads; the second valve to be tested mainly refers to a valve that needs to test the ball passing capacity, anti-impurity capacity and other related responsibilities. According to the actual valve load to be tested, the valve to be tested is installed in the reserved first valve to be tested installation position or / and the second valve to be tested installation position, and a common valve is installed in the reserved installation position where no valve is required to be installed to achieve the test circuit closure at the corresponding position.

[0026] The regulating valve described in the present invention is used to adjust the pressure or / flow on the corresponding pipeline, and the switch valve is suitable for controlling the opening and closing of the corresponding pipeline. The installation positions of the regulating valves, switch valves, flow meters and other components installed on each pipeline in the system are determined based on the realization of their respective functions. The present invention does not limit the installation positions of each on the corresponding pipeline unless otherwise specified.

[0027] The switchable mechanism of the present invention is used to realize the rapid opening and closing of the test branch. In the specific scheme, a quick opening blind plate can be selected.

[0028] In order to prevent the pipe cleaning device from violently hitting the quick-opening blind plate at the ball collecting barrel and damaging the equipment and to ensure smooth ball collection, a ball collecting cage with a squirrel-cage structure can be installed at the end of the ball collecting barrel.

[0029] In order to meet the wide range of requirements for test pressure and flow, the working pump in some specific implementation schemes of the test system of the present invention can be composed of a reasonable number of low-pressure pumps and high-pressure pumps connected in series. The number of low-pressure pumps and high-pressure pumps can be single or multiple depending on the working conditions required for the test.

[0030] In order to better obtain the test structure, on the basis of the scheme of the present invention, the inner diameter of the test branch pipeline can also be determined according to the inner diameter of the passage inside the valve to be tested; the inner diameters of the two connecting pipelines and the test main pipeline are smaller than the inner diameter of the passage inside the valve to be tested (or the inner diameter of the test branch pipeline), and the two are within a reasonable difference range. In engineering, one specification is generally smaller. For example, the inner diameter specification of the valve to be tested is DN200, and the inner diameters of the connecting pipeline and the test main pipeline are DN150. At the same time, the inner diameters of the launching pipeline and the receiving pipeline are larger than the inner diameter of the test branch pipeline, and the two are also within a reasonable difference range. In engineering, they are generally larger than one specification. For example, if the inner diameter of the test branch pipeline is DN200, the inner diameters of the launching pipeline and the receiving pipeline are DN250; and, the diameter of the pipe cleaner is larger than the inner diameter of the test branch pipeline (that is, the diameter of the pipe cleaner is about 5% larger than the inner diameter of the test branch pipeline) to achieve the sealing effect of the interference fit of the pipe cleaner. The pressure on the left side of the pipe cleaner will gradually increase until the pressure difference force on both sides of the pipe cleaner is greater than its own movement resistance, pushing the pipe cleaner to move.

[0031] Embodiment 1:

[0032] like Figure 1 As shown, the test system of this embodiment is connected by a working pump 1, a test main pipeline 3, a test branch pipeline 5 and related valves, wherein:

[0033] The inlet of the test main pipeline 3 is connected to the working pump 1, and a water reservoir 4 is provided at the outlet. The inlet and outlet of the test branch pipeline 5 are respectively connected to the main pipeline through a connecting pipeline 6, and the inlet of the test branch pipeline is also connected to a ball-delivery pipeline 7, and the outlet is connected to a ball-receiving pipeline 8. At the same time, the inlet of the ball-delivery pipeline 7 and the outlet of the ball-receiving pipeline 8 are respectively installed with a switchable mechanism, specifically a quick-opening blind plate 9;

[0034] A pump outlet regulating valve 2 is installed at the outlet of the working pump; a first valve installation position 3-0 to be tested is provided on the test main pipeline 3, and a flow meter 3-1, a pressure gauge 3-3, a pressure transmitter 3-2 and a system end regulating valve 3-4 are installed on the pipeline; a second valve installation position 5-0 to be tested is provided on the test branch pipeline 5, and an exhaust stop valve 5-1 is installed on the pipeline; pressure gauges 5-2 are installed on both the ball delivery pipeline 7 and the ball receiving pipeline 8; and switch valves 6-1 are installed on the two connecting pipelines 6. Among them:

[0035] The working pump 1 provides the medium pressure source for the entire test system; the pump outlet regulating valve 2 is used to adjust the initial pressure of the pipeline system; the pressure transmitter 3-2 is installed at the pressure measuring point of the test pipeline, and feeds back the pressure signal to the control system through the cable; the flow meter 3-1 is used to monitor the flow value of the test system; the pressure gauge 3-3 is installed at the pipeline measuring point according to the test needs, which is convenient for the operator to monitor the pipeline pressure on site; the regulating valve 3-4 can maintain the pressure at the end of the test system pipeline; the water reservoir 4 is the storage place for the test medium, providing recyclable medium for the test system.

[0036] In the preferred solution, an exhaust stop valve 5-1 is also installed on the test branch pipeline 5, and the exhaust stop valve 5-1 is used to control the pipeline to empty the gas in the pipeline between the pig in the ball launching tube and the valve to be tested, so as to complete the ball launching smoothly;

[0037] In a further solution, the test main pipeline of the system is connected to the working pump by a side pipeline 11, a regulating valve 11-1 is installed on the side pipeline, and a water reservoir is provided at the outlet of the side pipeline. The regulating valve 11-1 is used to adjust the pressure and flow condition values ​​required for the test.

[0038] During the test, the valve to be tested is installed according to the test requirements. Figure 1 The 3-0 or 5-0 position shown is used to assess the performance of the valve. When the tested valve is installed in the 3-0 position, the branch line is cut off by the switch valve of the test branch line, and the test branch line does not work. The load test of the tested valve is completed only by the test main line. Specifically, the life test of the valve under dynamic load conditions and the performance assessment test of various control valves for pressure regulation or flow regulation can be tested. When the tested valve is installed in the 5-0 position, the ball receiving and sending performance, ball passing performance and impurity resistance performance of the valve can be tested.

[0039] A specific test example: When the valve to be tested is a flow control valve, the valve to be tested is installed at Figure 1 At position 3-0 on the test main line, adjust the pressure and flow on the main line to achieve the test conditions required for the test (the specific conditions are determined according to the working performance or design parameters of the valve to be tested); then adjust the valve opening of the tested valve (100%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10%, 0%), test and record the pressure and flow values ​​of the back-end test system of the tested valve at different openings (specifically, they can be read through the test data on the pressure transmitter 3-2 and the control valve 3-4); then summarize the data to produce a regulation characteristic curve of flow rate changing with valve opening, and compare it with the results of theoretical numerical simulation calculations as a basis for verifying or optimizing the design parameters of the flow control valve.

[0040] Embodiment 2:

[0041] Another specific test example, such as Figure 2 As shown, the valve under test is a pigging ball valve 12, which is installed at Figure 1 The 5-0 position is shown, and at the same time, a manual valve is installed at the 3-0 position; then the ball passing reliability of the cleaning ball valve 12 under the specified working conditions is tested, and it can also be used to assess the anti-impurity performance of the cleaning ball valve.

[0042] In this test example, combined with Figure 1 and 2 As shown, the ball-launching pipeline, the inlet end of the test branch pipeline and the connecting pipeline of the corresponding end are connected by a pipeline tee, and the ball-receiving pipeline, the outlet of the test branch pipeline and the connecting pipeline of the corresponding end are also connected by a pipeline tee. The inlet of the ball-launching pipeline and the outlet of the ball-receiving pipeline are installed with quick-opening blind plates, and a pipe cleaner 10 is placed in the ball-launching pipeline 7 and the ball-receiving pipeline 8. Specifically, the pipe cleaner 10 is placed into the inlet end of the test branch pipeline through the ball-launching pipeline end, wherein the pipe cleaner 10 is the "ball" described in the ball-passing test, which is used to push impurities in the pipeline to complete the ball-passing test, specifically the ball-launching test or the ball-receiving test; the function of the quick-opening blind plate at the ball-launching end is to be able to quickly open and close the blind plate flange, so as to facilitate opening the ball-launching barrel and installing the pipe cleaner to the ball-launching position; the function of the quick-opening blind plate at the ball-receiving end is to be able to quickly open and close the blind plate flange, so as to facilitate opening the ball-receiving barrel and taking out the pipe cleaner after the ball-receiving test is completed.

[0043] In a more preferred solution, a squirrel cage is installed at the end of the ball collecting cylinder to assist in buffering and complete the ball collecting process of the system.

[0044] Based on the above scheme, the working pump can be formed by a front low-pressure pump 1-1 and a rear high-pressure pump 1-2 connected in series. The front pump provides low pressure and high flow, and the rear pump provides high pressure. The front pump or the rear pump can be a single unit or a combination of multiple units according to the test conditions. Different combination test conditions from low pressure to high pressure, from large flow to small flow can be provided, such as a flow range of ≤700m 3 / h, the pressure range is 0-10MPa, to meet different test requirements. The working parameters of high and low pressure pumps are determined according to the performance parameters of the tested valve. For example, the performance parameters of the low pressure pump are to provide low pressure and high flow, where the pressure is 0.5MPa and the flow can reach 2000m 3 / h; the performance parameters of the high-pressure pump are high pressure and low flow, pressure 5MPa, flow value 500m 3 / h.

[0045] Based on the above solution, another preferred solution is: determine the inner diameter of the test branch pipeline 5 according to the inner diameter of the passage in the tested valve, that is, Figure 2 The inner diameter of the pipeline directly connected to the inlet and outlet of the tested valve is the same as the inner diameter of the passage inside the tested valve; the inner diameters of the two connecting pipelines 6 and the test main pipeline 3 are both smaller than the inner diameter of the passage inside the tested valve, and the inner diameter specification of the tested valve is DN200, and the inner diameters of the connecting pipeline and the test main pipeline are DN150; at the same time, the inner diameters of the ball-issuing pipeline and the ball-receiving pipeline are larger than the inner diameter of the test branch pipeline, among which the inner diameter of the test branch pipeline is DN200, and the inner diameters of the ball-issuing pipeline and the ball-receiving pipeline are DN250; and the diameter of the pipe cleaner is larger than the inner diameter of the test branch pipeline.

[0046] The test system of this embodiment can test the alignment of the inlet, valve disc flow channel, valve core flow channel and valve outlet of the tested valve; it can also test the ability of the valve to resist impurities. In the specific test, the ball passing reliability test (testing the alignment of the valve inlet, valve disc flow channel, valve core flow channel and valve outlet) of the tested pig ball valve under different pipeline load pressures is divided into three parts: pressure regulation, ball delivery and ball collection, as follows:

[0047] (1) Pipeline pressure regulation

[0048] Close the left switch valve 6-1, open the manual valve at position 3-0, start the low-pressure pump and the high-pressure pump, adjust the main line pressure to 1.0MPa through the pump outlet regulating valve 1-2 (and the bypass regulating valve 11-1), and adjust the pressure before the regulating valve 3-4 to 1.0MPa through the regulating action of the regulating valve 3-4. The system flow is about 560m 3 / h. The main pipeline pressure and flow rate during the test are designed and determined by the actual working parameters of the tested pigging ball valve 12;

[0049] (2) Serving stage

[0050] Open the quick-opening blind plate 9 at the ball end, put the pig into the downstream side of the pipeline tee, and close the quick-opening blind plate on this side;

[0051] Then open the quick-open blind plate 9 at the ball receiving end, put the squirrel cage into the ball receiving tube and close to the quick-open blind plate, and close the quick-open blind plate after putting the squirrel cage into it;

[0052] Then open the cleaning ball valve 12, and then open the switch valves 6-1 on the two connecting pipelines at the same time, and slowly close the manual valve at the 3-0 position in the main pipeline. Under the sealing effect of the pig's interference, the pressure on the left side of the pig will gradually increase until the pressure difference on both sides of the pig is greater than its own movement resistance, pushing the pig to move through the cleaning ball valve 12 to complete the pipeline ball launch operation;

[0053] (3) Receiving the ball

[0054] The pig continues to move to the pig ball valve 12. If the pig ball valve inlet, valve disc flow channel, valve core flow channel and valve outlet are aligned, the pig passes through the valve inlet, valve disc flow channel, valve core flow channel and valve outlet of the pig ball valve 12 in sequence, that is, the pig passes through the valve flow channel smoothly, thereby detecting the alignment of the four positions; otherwise, the flow channel in the valve is not aligned, and the valve does not have the pig ball passing performance;

[0055] After the pipe cleaner passes through the pipe cleaning ball valve 12, it reaches the ball collecting cylinder (squirrel cage position) at the end of the branch pipeline. At this time, (if there is a bypass pipeline, fully open the bypass regulating valve 11-1), close the manual valve installed at the 3-0 position and the left connecting pipeline switch valve 6-1 in turn, and fully open the regulating valve 3-4, and use the pipeline where the right connecting pipeline switch valve 6-1 is located to release the medium pressure of the ball collecting and sending cylinder pipeline. When the pressure gauge reading at the ball collecting cylinder end is zero, close the pipe cleaning ball valve; open the quick-opening blind plate at the ball collecting end, take out the pipe cleaner, and complete the pipeline ball collecting operation.

[0056] During the process, the bypass regulating valve 11-1 can be used to adjust the medium pressure of the pipeline after the pump outlet regulating valve. The bypass terminal pipeline is connected to the water reservoir to adjust the working conditions of the overall test loop. The main adjustment parameters include pressure and flow.

[0057] In the above work, the post-high pressure pump is used to achieve the high pressure working condition required by the pipeline system. The function of the pressure transmitter 3-2 is to feed back the pressure value of the measuring point to the central control room to achieve real-time monitoring of the system working pressure.

[0058] By adjusting the pump outlet regulating valve (and the bypass manual regulating valve), the main line pressure is adjusted to 2.0MPa, 3.0MPa, 4.0MPa, and 5MPa in turn; repeat the above-mentioned pipeline pressure regulation, ball serving and ball receiving operation processes.

[0059] By analyzing the test results, the minimum pressure difference (such as about 0.21MPa) for the pig to move can be obtained. The 12-way pig ball valve operates smoothly and can pass the ball reliably under different pressure conditions, which can verify the reliability of the tested valve product.

[0060] When testing the valve's ability to resist impurities, on the basis of the above method, put impurities (such as iron slag, mud, welding slag, oil impurities, etc.) at the front end of the pig to test whether the valve can pass the ball in the presence of impurities. In addition, after the ball passing process is completed, open and close the pig ball valve several times to test whether the valve can still be reliably closed with zero leakage. After that, disassemble the valve, measure the residual pig impurities in the valve, check the valve seat sealing surface, and further qualitatively and quantitatively analyze the valve's ability to resist impurities.

Claims

1. A valve load testing system, characterized in that: include: Working pump; A test main line, wherein the test main line is provided with an inlet and an outlet, and a first installation position for a valve to be tested is reserved between the inlet and the outlet of the test main line, and a flow meter and a regulating valve are installed on the test main line; the inlet of the test main line is connected to a working pump; A test branch pipeline, the test branch pipeline is provided with an inlet and an outlet, and a second valve installation position to be tested is reserved between the inlet and the outlet of the test branch pipeline, and a pressure gauge is installed on the branch pipeline; the inlet and the outlet of the test branch pipeline are respectively connected to the test main pipeline through connecting pipelines, and a switch valve is installed on each connecting pipeline; the inlet of the test branch pipeline is also connected to a ball-delivery pipeline, and the outlet is also connected to a ball-receiving pipeline, and a switch mechanism is installed at the inlet of the ball-delivery pipeline and the outlet of the ball-receiving pipeline; It also includes a side pipeline, the inlet of which is arranged on the test main pipeline and upstream of the inlet of the test branch pipeline. A regulating valve is installed on the side pipeline to assist in regulating the pressure and flow on the test system pipeline; it also includes a pipe cleaner, which is placed into the test branch pipeline from the inlet of the ball-issuing pipeline; the inner diameter of the test branch pipeline is the same as the inner diameter of the passage in the second tested valve; the inner diameter of the test main pipeline and the inner diameter of the connecting pipeline are both smaller than the inner diameter of the test branch pipeline; the inner diameter of the ball-issuing pipeline and the inner diameter of the ball-receiving pipeline are both larger than the inner diameter of the test branch pipeline; the outer diameter of the pipe cleaner is larger than the inner diameter of the test branch pipeline.

2. The valve load testing system according to claim 1, characterized in that: The working pump comprises at least one low-pressure pump and at least one high-pressure pump connected in series.

3. The valve load testing system according to claim 1, characterized in that: The switch mechanism uses a quick-opening blind plate.

4. The valve load testing system according to claim 1, characterized in that: The inlet of the test branch pipeline, the ball-delivering pipeline and the corresponding side connecting pipeline are connected through a pipeline tee, and the outlet of the test branch pipeline, the ball-receiving pipeline and the corresponding side connecting pipeline are connected through a pipeline tee.

5. The valve load testing system according to claim 1, characterized in that: A pressure transmitter is installed on the test main pipeline, which monitors the pressure value of the pipeline in real time and feeds back to the central control room to help monitor the pressure condition value of the test system.

6. The valve load testing system according to claim 1, characterized in that: A ball collecting cage is provided in the ball collecting pipeline near the switch mechanism.

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