An experimental device and method for FPSO natural gas pipeline leakage

Abstract

The present application belongs to the technical field of petrochemical safety engineering, and relates to a kind of FPSO natural gas pipeline leakage experimental device and method, comprising: power circulation module, control module, data acquisition module and leakage module;Power circulation module is connected with leakage module, for circulating pipeline in experimental device into natural gas, and make natural gas circulate in circulating pipeline;Leakage module, including several different shapes of pipeline, for replacing and adjusting pipeline combination according to experimental needs;Control module is connected with leakage module, for adjusting the working pressure and natural gas flow in leakage module;Data acquisition module is used for collecting environmental parameters, gas flow and flammable gas in leakage module, and the collected data are analyzed to obtain pipeline leakage information.It can simulate pipeline leakage under a variety of different leakage conditions, adjust the simulated leakage amount of pipeline, and more accurately evaluate and improve the leakage response measures.

Description

Technical Field

[0001] This invention relates to a test apparatus and method for leak testing of FPSO (Floating Production Storage and Offloading) natural gas pipelines, belonging to the field of petroleum and chemical safety engineering technology. Background Technology

[0002] Deep-sea exploration is extremely challenging, and offshore gas fields are characterized by high pressure, large gas volumes, and demanding development technologies. FPSOs, as an emerging technology and equipment in the offshore oil industry, are increasingly attracting global attention.

[0003] High-flow-rate natural gas processing units mainly include natural gas compression, natural gas mercury removal, natural gas dehydration, natural gas desalination, and natural gas dehydrocarbon removal. Different processing technologies use different equipment and pipeline layouts. Various types of pipeline equipment are numerous and complexly distributed, and there are mutual obstructions between equipment and pipelines. The characteristics and mechanisms of natural gas leaks under different operating conditions and at different stages are very different and complex. Once an oil and gas leak occurs, it can easily cause chain reactions such as fires and explosions, posing a significant threat to personnel, property, and the environment.

[0004] Given the current large-scale engineering application of FPSOs in China, research on FPSO pipeline leakage risk analysis is slow, which is detrimental to the long-term development of the offshore oil industry. To ensure the operational safety and reliability of FPSOs, it is necessary to assess and study their pipeline leakage conditions. However, existing experimental equipment cannot completely and accurately simulate real leakage scenarios and lacks automatic control and precise measurement capabilities. Summary of the Invention

[0005] To address the aforementioned problems, the present invention aims to provide an experimental apparatus and method for FPSO natural gas pipeline leakage, which can simulate pipeline leakage in FPSO high-flow natural gas processing units under various leakage conditions. By simulating different leakage scenarios, leakage response measures can be more accurately evaluated and improved.

[0006] To achieve the above objectives, the present invention proposes the following technical solution: an FPSO natural gas pipeline leakage test device, comprising: a power circulation module, a control module, a data acquisition module, and a leakage module; the power circulation module is connected to the leakage module and is used to introduce natural gas into the circulation pipeline of the test device and circulate the natural gas in the circulation pipeline; the leakage module includes several pipes of different shapes, used to replace and adjust the pipe combination according to experimental needs; the control module is connected to the leakage module and is used to adjust the working pressure and natural gas flow rate in the leakage module; the data acquisition module is used to collect environmental parameters, gas flow rate, and combustible gas in the leakage module, and analyze the collected data to obtain pipeline leakage information.

[0007] Furthermore, the leakage module includes at least three detachable pipe sections of different shapes, one of which is a detachable straight pipe section, one of which is a detachable eccentric reducing pipe section, and one of which is a detachable U-shaped pipe section, with the three detachable pipe sections connected in parallel.

[0008] Furthermore, the control module includes a pressure reducing valve, a manual ball valve, an electric regulating valve, and an electric valve. The pressure reducing valve is used to regulate the pressure of natural gas to the working pressure required for the experiment, and the manual ball valve, the electric regulating valve, and the electric valve are used to control the flow rate of natural gas in the pipeline.

[0009] Furthermore, the electric regulating valve includes a first electric regulating valve and a second electric regulating valve. The first electric regulating valve is installed on the pipeline between the power circulation module and the leakage module. By adjusting the opening of the first electric regulating valve, the leakage hole diameter is simulated or the leakage hole radius and shape are changed to create accident conditions with different leakage rates, thereby obtaining the changes in flow rate and environmental parameters in the pipeline system caused by different leakage rates under the same pressure and flow conditions in the pipeline.

[0010] Furthermore, the manual ball valve includes a first manual ball valve and a second manual ball valve, with the first manual ball valve installed on the detachable straight pipe section; the circulation pipeline includes two venting branches, one of which is equipped with the second electric regulating valve, and the other branch is equipped with the second manual ball valve.

[0011] Furthermore, the power circulation module includes a natural gas storage cylinder and a circulation fan. The natural gas is connected to the circulation pipeline through the pressure reducing valve to provide the natural gas required for the experiment. The circulation fan is installed on the circulation pipeline to generate airflow and transport the natural gas to the leakage module.

[0012] Furthermore, the data acquisition module includes a pressure transmitter, a temperature transmitter, a gas flow meter, a micro-flow controller, a point-type infrared combustible gas detector, and a data processing unit. The pressure transmitter, temperature transmitter, and gas flow meter are used to measure the pressure, temperature, and flow rate changes of the gas flow inside the pipeline before and after the leak. The micro-flow controller is used to accurately measure the leakage amount at the leak point. The point-type infrared combustible gas detector is used to select the optimal probe arrangement method by testing arrays at different installation positions. The data processing unit is used to acquire data from the pressure transmitter, temperature transmitter, gas flow meter, micro-flow controller, and point-type infrared combustible gas detector, and generate curves and reports for each detection data.

[0013] Furthermore, the pressure transmitter, temperature transmitter, and gas flow meter are all in two sets, one set is located at the input end of the leakage module, and the other set is located at the output end of the leakage module. The micro flow controller is located on the venting branch equipped with the second electric regulating valve. The pressure transmitter, temperature transmitter, gas flow meter, micro flow controller, point-type infrared combustible gas detector, first electric regulating valve, and second electric regulating valve are all communicatively connected to the data processing unit.

[0014] This invention discloses a method for FPSO natural gas pipeline leakage testing, employing the FPSO natural gas pipeline leakage testing apparatus described in any of the above-mentioned claims, comprising the following steps: obtaining the flow rate, pressure, and temperature of the experimental pipeline in the leakage module under normal operating conditions at different stable pipeline flow rates; simulating accident conditions under different leakage orifice radii by adjusting the opening of the first electric regulating valve; collecting signals from the pressure transmitter and sending them to the data processing unit, which analyzes the signals from the pressure transmitter, and if a negative pressure wave signal is present, it is considered that the natural gas pipeline is leaking; readjusting the opening of the first electric regulating valve to change the leakage rate of the natural gas pipeline, and obtaining the changes in flow rate and pressure in the pipeline caused by different leakage rates under the same pressure and flow conditions; replacing different experimental pipelines and repeating the above steps until all experimental pipelines are exhausted, simulating the changes in flow rate and pressure in the pipeline before and after leakage under different pipeline flow rates and leakage flow rates for the same length of experimental pipeline segment in different leakage scenarios.

[0015] Furthermore, before the experiment begins, an airtightness test is required to measure the airtightness of the connected circulation pipeline, locate any leaks, and repair them until the pipeline is airtight.

[0016] The present invention has the following advantages due to the adoption of the above technical solutions:

[0017] 1. The solution in this invention provides an experimental device that can simulate different leakage scenarios, with high experimental reliability and accuracy, and can more realistically evaluate and improve FPSO pipeline leakage response measures.

[0018] 2. The device in this invention has an automatic control function, which realizes precise control and automated operation of the experimental process through the regulating valve, thereby improving the stability and repeatability of the experiment.

[0019] 3. The data acquisition module in this invention can accurately measure the changes in temperature, pressure, and flow rate of the airflow inside the pipeline before and after the leak, and accurately measure the leakage amount at the leak point, providing comprehensive experimental data support and realizing comprehensive monitoring and analysis of the leakage process.

[0020] 4. The detachable leakage module design in this invention facilitates the setup and modification of experiments, adapts to different leakage scenarios, and increases the flexibility and scalability of experiments. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of a pipeline leakage test device in one embodiment of the present invention.

[0022] Figure 2 This is a schematic diagram of the array of installation positions of the combustible gas detectors in a leakage module according to an embodiment of the present invention.

[0023] Figure 3 This is a flowchart of a pipeline leakage test method in one embodiment of the present invention.

[0024] Figure label:

[0025] 1-Natural gas storage cylinder; 2-Pressure reducing valve; 3-Circulating fan; 4-Gas flow meter; 5-First electric regulating valve; 6-Temperature transmitter; 7-Pressure transmitter; 8-First manual ball valve; 9-Straight pipe section; 10-Eccentric reducing section; 11-U-shaped pipe section; 12-Micro flow controller; 13-Second electric regulating valve; 14-Second manual ball valve; 15-Electric valve; 16-Data processing unit; 17-Point-type infrared combustible gas detector. Detailed Implementation

[0026] To enable those skilled in the art to better understand the technical solutions of the present invention, the present invention is described in detail through specific embodiments. However, it should be understood that the specific embodiments are provided only for a better understanding of the present invention and should not be construed as limiting the present invention. In the description of the present invention, it should be understood that the terminology used is for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0027] To address the slow pace of research on FPSO pipeline leakage risk analysis in existing technologies, which fails to ensure the operational safety and reliability of FPSOs, this invention proposes an experimental device and method for FPSO natural gas pipeline leakage. Natural gas is introduced into the circulation pipeline via a power circulation module. Leakage modules installed on the circulation pipeline are combined with various pipeline shapes according to experimental needs to simulate accident conditions with different leakage rates based on different leak hole radii and shapes. The device obtains the changes in flow rate and environmental parameters in the pipeline system caused by different leakage rates under the same pressure and flow conditions. A data acquisition module collects the pressure of the leakage modules to determine whether a leak has occurred in the experimental pipeline and the leakage rate. This invention provides an experimental device capable of simulating different leakage scenarios, with high experimental reliability and accuracy. It can more realistically evaluate and improve FPSO pipeline leakage response measures. It has automatic control functions, achieving precise control and automated operation of the experimental process through regulating valves, improving the stability and repeatability of the experiment. The following detailed description of the invention, with reference to the accompanying drawings, illustrates the invention in detail through embodiments.

[0028] Example 1

[0029] This embodiment discloses an FPSO natural gas pipeline leakage test apparatus, such as Figure 1 As shown, it includes: a power cycle module, a control module, a data acquisition module, and a leakage module.

[0030] The power circulation module is connected to the leakage module via a circulation pipeline. The power circulation module includes a natural gas storage cylinder and a circulation fan 3. The natural gas storage cylinder 1 stores the natural gas required for the experiment and is used to supply natural gas to the circulation pipeline of the experimental setup, allowing the natural gas to circulate within the pipeline. Natural gas is connected to the circulation pipeline via a pressure reducing valve 2 to provide the necessary natural gas for the experiment. The circulation fan 3 is installed on the circulation pipeline to generate airflow, delivering the natural gas to the leakage module. The power circulation module is connected to the leakage module via the circulation pipeline, ensuring a continuous supply of airflow.

[0031] The leakage module comprises several pipes of different shapes, allowing for replacement and adjustment of pipe combinations as needed for experiments. The module includes at least three detachable pipe sections of different shapes: a detachable straight pipe section 9, a detachable eccentric reducer section 10, and a detachable U-shaped pipe section 11, connected in parallel. These pipe sections are designed to simulate different leakage scenarios for experimental and research purposes. Simulating different leak hole diameters, shapes, and other parameters creates accident conditions with varying leakage rates, allowing for the acquisition of changes in flow rate, pressure, and temperature in the pipeline system under the same pressure and flow conditions. This comprehensively evaluates the leakage response capability of the pipeline system. The leakage module is connected to a control module and a data acquisition module at both ends, enabling dynamic leakage experiments.

[0032] The control module is connected to the leakage module and is used to adjust the working pressure and natural gas flow rate in the leakage module, and to simulate different leakage conditions in the leakage module. The control module includes a pressure reducing valve 2, a manual ball valve, an electric regulating valve, and an electric valve 15. The pressure reducing valve 2 is used to adjust the natural gas pressure to the working pressure required for the experiment. The manual ball valve, the electric regulating valve, and the electric valve 15 are used to control the on / off of the gas flow and control the flow rate of natural gas in the pipeline to achieve precise control of the experimental conditions.

[0033] The data acquisition module is used to collect environmental parameters, gas flow rate, and flammable gas data from the leak module, and to analyze the collected data to obtain pipeline leak information.

[0034] In this embodiment, the electric regulating valve includes a first electric regulating valve 5 and a second electric regulating valve 13. The first electric regulating valve 5 is installed on the pipeline between the power circulation module and the leakage module. By adjusting the opening of the first electric regulating valve 5, the leakage orifice diameter is simulated, or the radius and shape of the leakage orifice are changed to create accident conditions with different leakage rates, thereby obtaining the changes in flow rate and environmental parameters in the pipeline system caused by different leakage rates under the same pressure and flow conditions. The manual ball valve includes a first manual ball valve 8 and a second manual ball valve 14. The first manual ball valve 8 is installed on the detachable straight pipe section 9. The circulation pipeline includes two venting branches, one of which is equipped with the second electric regulating valve 13, and the other branch is equipped with the second manual ball valve 14.

[0035] The data acquisition module includes a pressure transmitter 7, a temperature transmitter 6, a gas flow meter 4, a micro flow controller 12, a point-type infrared combustible gas detector 17, and a data processing unit 16. The pressure transmitter 7, temperature transmitter 6, and gas flow meter 4 are used to measure the pressure, temperature, and flow rate changes of the gas flow inside the pipeline before and after the leak. The micro flow controller 12 is used to accurately measure the leakage amount at the leak point. The point-type infrared combustible gas detector 17, in this embodiment, has four units, which are used to select a reasonable and optimal probe arrangement method by testing different installation position arrays. The data processing unit 16 is used to acquire data from the pressure transmitter 7, temperature transmitter 6, gas flow meter 4, micro flow controller 12, and point-type infrared combustible gas detector 17, and generate curves and reports for each detection data, so as to further analyze and evaluate the data.

[0036] In this embodiment, the pressure transmitter 7, temperature transmitter 6, and gas flow meter 4 are all in two sets. One set is located at the input end of the leakage module, and the other set is located at the output end of the leakage module. The micro flow controller 12 is located on the venting branch equipped with the second electric regulating valve 13. The pressure transmitter 7, temperature transmitter 6, gas flow meter 4, micro flow controller 12, point-type infrared combustible gas detector 17, first electric regulating valve 5, and second electric regulating valve 13 are all communicatively connected to the data processing unit 16. The arrangement of the point-type infrared combustible gas detector 17 is as follows: Figure 2 As shown.

[0037] During the experiment, the power circulation module provided the required natural gas and gas flow, the control module controlled the gas pressure and flow rate by adjusting valves and switches, and the data acquisition module monitored and recorded changes in gas temperature, pressure, and flow rate, as well as the leakage amount at the leak point, in real time. Through data collection and analysis, pipeline leakage under different leakage scenarios can be accurately assessed, providing a scientific basis for improving and optimizing pipeline leakage response measures.

[0038] This embodiment provides a reliable, accurate, and controllable pipeline leakage testing apparatus for a high-flow-rate FPSO natural gas processing unit, capable of precisely controlling experimental conditions and providing reliable measurement data. By using this apparatus for leakage testing, it is possible to better understand and improve the pipeline's leakage response capabilities, enhance system safety and reliability, and it has broad application prospects.

[0039] Example 2

[0040] Based on the same inventive concept, this embodiment discloses a method for testing FPSO natural gas pipeline leakage, employing any of the aforementioned FPSO natural gas pipeline leakage testing apparatus, such as... Figure 3 As shown, it includes the following steps:

[0041] Natural gas enters the test pipeline section after passing through electric valve 15 and manual valve. Various instruments are installed at the beginning, end, and intermediate points of the test section to collect data, including pressure, temperature, and flow rate at the starting point; pressure and flow rate at the end point; and sensors at intermediate points (near leak points). Compressed gas, after passing through the test pipeline section, enters the air compressor cooler and is then discharged back to the storage tank. Before the experiment begins, an airtightness test is conducted. The airtightness of the connected circulation pipeline is measured to locate and repair any leaks until the pipeline is completely airtight.

[0042] S1 acquires data on parameters such as flow rate, pressure, and temperature of the experimental pipeline in the leakage module under normal cyclic operating conditions at different stable pipeline flow rates.

[0043] S2 simulates accident conditions with different leakage hole radii by adjusting the opening degree of the first electric regulating valve 5 according to the experimental requirements.

[0044] S3 acquires signals from pressure transmitter 7 and sends them to data processing unit 16. Data processing unit 16 analyzes the signals from pressure transmitter 7; if a negative pressure wave signal is present, it indicates a natural gas pipeline leak. Pressure transmitter 7 can sense pressure changes in the gas pipeline and convert these changes into electrical signals. When a leak occurs, due to changes in gas flow velocity, a negative pressure wave signal is generated in the pipeline. The pressure sensor captures these fluctuations and converts them into electrical signals. Data processing unit 16 records and processes the signals generated by the pressure sensor. Data acquisition unit converts the analog signals output by the pressure sensor into digital signals and transmits them to a computer. Data processing software on the computer can analyze, visualize, and save the signals.

[0045] S4 readjusts the opening of the first electric regulating valve 5 to simulate different leakage rates under different parameters such as the radius and shape of the leakage hole; this causes the leakage rate of the natural gas pipeline to change, and obtains the changes in flow and pressure in the pipeline caused by different leakage rates under the same pressure and flow conditions.

[0046] S5 Replace different experimental pipes and repeat the above steps S1-S4 until all experimental pipes are exhausted. Simulate the changes in flow rate and pressure in the pipe before and after leakage under different pipeline flow rates and leakage flow rates for the same length of experimental pipe section under different leakage scenarios.

[0047] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific embodiments of the present invention. Any modifications or equivalent substitutions that do not depart from the spirit and scope of the present invention should be covered within the protection scope of the claims of the present invention. The above content is only a specific embodiment of this application, but the protection scope of this application is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be covered within the protection scope of this application. Therefore, the protection scope of this application should be determined by the protection scope of the claims.

Claims

1. A method for testing leaks in an FPSO natural gas pipeline, characterized in that, The FPSO natural gas pipeline leakage test device used includes: a power circulation module, a control module, a data acquisition module, and a leakage module; The power circulation module is connected to the leakage module and is used to introduce natural gas into the circulation pipeline of the experimental device and circulate the natural gas in the circulation pipeline. The leakage module includes several pipes of different shapes, which can be replaced and adjusted according to experimental needs; The control module is connected to the leakage module and is used to adjust the working pressure and natural gas flow rate in the leakage module. The data acquisition module is used to collect environmental parameters, gas flow rate and flammable gas in the leakage module, and analyze the collected data to obtain pipeline leakage information. The control module includes a pressure reducing valve, a manual ball valve, an electric regulating valve, and an electric valve. The pressure reducing valve is used to regulate the pressure of natural gas to the working pressure required for the experiment. The manual ball valve, the electric regulating valve, and the electric valve are used to control the flow rate of natural gas in the pipeline. The electric regulating valve includes a first electric regulating valve and a second electric regulating valve. The first electric regulating valve is installed on the pipeline between the power circulation module and the leakage module. By adjusting the opening of the first electric regulating valve, the leakage hole diameter is simulated or the leakage hole radius and shape are changed to create accident conditions with different leakage rates. The changes in flow rate and environmental parameters in the pipeline system caused by different leakage rates under the same pressure and flow conditions are obtained. The method includes the following steps: Obtain the flow rate, pressure, and temperature of the experimental pipeline in the leakage module under normal operating conditions at different stable pipeline flow rates; By adjusting the opening of the first electric regulating valve, accident conditions under different leakage hole radii are simulated; The signal from the pressure transmitter is collected and sent to the data processing unit. The data processing unit analyzes the signal from the pressure transmitter. If a negative pressure wave signal is present, it is considered that the natural gas pipeline is leaking. The opening of the first electric regulating valve was adjusted again to change the leakage rate of the natural gas pipeline, and the changes in flow and pressure in the pipeline caused by different leakage rates were obtained under the same pressure and flow conditions. Replace different experimental pipes and repeat the above steps until all experimental pipes are exhausted. Simulate the changes in flow rate and pressure in the pipe before and after the leakage occurs under different pipeline flow rates and leakage flow rates for the same length of experimental pipe section under different leakage scenarios.

2. The FPSO natural gas pipeline leakage test method as described in claim 1, characterized in that, The leakage module includes at least three detachable pipe sections of different shapes, one of which is a detachable straight pipe section, one of which is a detachable eccentric reducing pipe section, and one of which is a detachable U-shaped pipe section. The three detachable pipe sections are connected in parallel.

3. The FPSO natural gas pipeline leakage test method as described in claim 2, characterized in that, The manual ball valve includes a first manual ball valve and a second manual ball valve. The first manual ball valve is installed on the detachable straight pipe section. The circulation pipeline includes two venting branches, one of which is equipped with the second electric regulating valve, and the other branch is equipped with the second manual ball valve.

4. The FPSO natural gas pipeline leakage test method as described in claim 3, characterized in that, The power circulation module includes a natural gas storage cylinder and a circulation fan. The natural gas storage cylinder is connected to the circulation pipeline through the pressure reducing valve to provide the natural gas required for the experiment. The circulation fan is installed on the circulation pipeline to generate airflow and transport the natural gas to the leakage module.

5. The FPSO natural gas pipeline leakage test method as described in claim 4, characterized in that, The data acquisition module includes a pressure transmitter, a temperature transmitter, a gas flow meter, a micro-flow controller, a point-type infrared combustible gas detector, and a data processing unit. The pressure transmitter, temperature transmitter, and gas flow meter are used to measure the pressure, temperature, and flow rate changes of the gas flow inside the pipeline before and after a leak. The micro-flow controller is used to accurately measure the leakage amount at the leak point. The point-type infrared combustible gas detector is used to select the optimal probe arrangement method by testing arrays at different installation positions. The data processing unit is used to acquire data from the pressure transmitter, temperature transmitter, gas flow meter, micro-flow controller, and point-type infrared combustible gas detector, and generate curves and reports for each detection data.

6. The FPSO natural gas pipeline leakage test method as described in claim 5, characterized in that, The pressure transmitter, temperature transmitter, and gas flow meter are all in two sets, one set is located at the input end of the leakage module, and the other set is located at the output end of the leakage module. The micro flow controller is located on the venting branch equipped with the second electric regulating valve. The pressure transmitter, temperature transmitter, gas flow meter, micro flow controller, point-type infrared combustible gas detector, first electric regulating valve, and second electric regulating valve are all communicatively connected to the data processing unit.

7. The FPSO natural gas pipeline leakage test method as described in claim 1, characterized in that, Before the experiment begins, an airtightness test is required. The airtightness of the connected circulation pipeline is measured to find any leaks and repair them until the pipeline is airtight.

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