Blowout preventer control system testing method and system based on hardware-in-loop

Abstract

The invention provides a blowout preventer control system testing method and system based on hardware-in-the-loop, the system at least comprises an upper computer used for establishing a blowout preventer simulation model and a real-time simulation machine, and the real-time simulation machine is used for operating the blowout preventer simulation model and receiving a control instruction from a blowout preventer control system. According to the method, the control instruction is sent to the blowout preventer simulation model, the output result of the blowout preventer simulation model is obtained according to the control instruction, and the output result is fed back to the blowout preventer control system to determine whether the control function test of the blowout preventer control system is qualified, so that the function test of the blowout preventer control system can be completed in a laboratory, the test period can be shortened, and the test efficiency can be improved. In addition, field safety accidents can be avoided, the test safety is improved, the work intensity and cost of field test are reduced through the use of the blowout preventer simulation model, fault simulation can be realized through the modification of the model, the test result is more comprehensive, and the test convenience is improved.

Description

Technical Field

[0001] The invention relates to the field of oil production equipment, and in particular to a blowout preventer control system testing method and system based on hardware-in-the-loop. Background Art

[0002] Deep-sea oil and gas development places extremely high demands on the safety and reliability of offshore oil drilling and production technology. BOPs, as important infrastructure for deep-sea oil and gas operations, are used to close the wellhead during oil testing, well repair, and well completion operations to prevent wellhead gushing. The BOP control system is an electro-hydraulic device used to control the action of the BOP, including a hydraulic system and an electrical control system. It can control the BOP to quickly close the wellhead when high-pressure oil and gas appear to prevent blowout accidents.

[0003] Since the operation of BOP and BOP control system is related to the safety of offshore oil and gas production, it is necessary to test the BOP and BOP control system before putting them into actual oil and gas operations.

[0004] Traditional methods for testing BOPs include building a test pool in a factory, placing the BOP in the test pool, and using a water pump to pressurize the pool to simulate the actual application environment. There is also a method of transporting the equipment to the ocean with suitable sea conditions for testing. These methods all have problems such as low testing efficiency, high labor intensity, high cost investment, and difficulty in fault simulation.

[0005] Traditional BOP control system testing methods mainly include factory testing and field testing. These methods are not only time-consuming and costly, but also difficult to fully cover performance verification under various complex working conditions and extreme environments.

[0006] Therefore, there is a need for a test solution for the blowout preventer control system that can complete the test of the blowout preventer control system in the laboratory, shorten the test cycle, improve the test efficiency, and have a more comprehensive test effect. Summary of the invention

[0007] An object of the present application is to provide a blowout preventer control system testing method and system based on hardware-in-the-loop, so as to solve the problems of long test cycle, low test efficiency and incomplete test effect existing in the blowout preventer control system testing in the prior art.

[0008] To achieve the above objectives, some embodiments of the present application provide a blowout preventer control system testing method based on hardware-in-the-loop, the method comprising:

[0009] Establishing a blowout preventer control system test system for testing the blowout preventer control system, the blowout preventer control system test system at least includes a host computer and a real-time simulator for establishing a blowout preventer simulation model, the real-time simulator is used to run the blowout preventer simulation model and receive control instructions from the blowout preventer control system, and obtain output results of the blowout preventer simulation model according to the control instructions, and feed the output results back to the blowout preventer control system, so that the blowout preventer control system test system determines whether the control function test of the blowout preventer control system is qualified;

[0010] The control functions of the blowout preventer control system are tested based on the blowout preventer control system test system. The control functions include pressure charging control function, pressure replenishment control function, shear control function and system alarm function.

[0011] Furthermore, the output results include pressure data, flow data and displacement data.

[0012] Furthermore, the method further comprises:

[0013] A blowout preventer simulation model is established according to the blowout preventer control system under test and the model information of the corresponding blowout preventer, where the model information includes the model and parameters.

[0014] Furthermore, a blowout preventer simulation model is established, including:

[0015] Establish component simulation models for components in the blowout preventer;

[0016] Use preset parameters, simulation steps and solvers to simulate and test the BOP simulation model composed of multiple component simulation models;

[0017] When the simulation test results do not meet the preset characteristic conditions, the parameters of the blowout preventer simulation model are iteratively optimized until the simulation test results meet the preset characteristic conditions;

[0018] The blowout preventer simulation model that meets the preset characteristic conditions is determined as the final blowout preventer simulation model.

[0019] Furthermore, after the BOP simulation model is established, it also includes:

[0020] Compile the blowout preventer simulation model into computer real-time language code;

[0021] Transfer the computer real-time language code to the real-time simulator for execution.

[0022] Furthermore, the pressure control function of the BOP control system is tested, including:

[0023] The BOP control system sends a pressurization opening command to the real-time simulator;

[0024] The real-time simulator starts the hydraulic pump simulation element and opens the accumulator isolation valve simulation element according to the pressure-charging start instruction, so that the pressure data in the blowout preventer simulation model increases;

[0025] The real-time simulator obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0026] When the pressure data reaches the preset pressure threshold, it is detected that the blowout preventer control system outputs a pressurization stop command, and the pressure indicating device of the blowout preventer control system is in a triggered state, determining that the pressurization control function test of the blowout preventer control system is qualified.

[0027] Furthermore, the pressure relief control function of the BOP control system is tested, including:

[0028] The real-time simulator obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0029] When the pressure data is lower than the preset pressure lower limit threshold, it is detected that the blowout preventer control system outputs a pressure charging start command, and the low pressure indicating device of the blowout preventer control system is in a triggered state, and it is determined that the low pressure control function test of the blowout preventer control system is qualified, and the pressure charging control function includes a low pressure control function and a high pressure control function;

[0030] When the pressure data is higher than the preset upper pressure threshold, it is detected that the blowout preventer control system outputs a pressurization stop command, and the high-pressure indication device of the blowout preventer control system is in a triggered state, and it is determined that the high-pressure control function test of the blowout preventer control system is qualified;

[0031] When both the low-pressure control function and the high-pressure control function are tested and qualified, it is determined that the pressure replenishment control function test of the blowout preventer control system is qualified.

[0032] Furthermore, the shear control function of the BOP control system was tested, including:

[0033] The BOP control system sends a shear-on command to the real-time simulator and sets the shear indicator device to a trigger state;

[0034] The real-time simulation machine switches the reversing valve simulation element to the shearing working position according to the shearing opening instruction, so that the simulated high-pressure oil passes through the reversing valve simulation element to reach the opening cavity of the actuator simulation element, and pushes the actuator simulation element to shear;

[0035] The real-time simulation machine obtains the displacement data collected by the displacement sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0036] When it is detected that the displacement data reaches a preset displacement threshold and the shear indicating device of the blowout preventer control system is in a shear completion state, it is determined that the shear control function test of the blowout preventer control system is qualified.

[0037] Furthermore, the system alarm function of the BOP control system is tested, including:

[0038] The BOP control system sends a pressure relief command to the real-time simulator and sets the pressure relief indicator device to a trigger state;

[0039] The real-time simulator controls the pressure relief valve simulation element to open according to the pressure relief instruction, so that the pressure data in the blowout preventer simulation model decreases;

[0040] The real-time simulator obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0041] When the pressure data reaches the preset alarm pressure threshold, it is detected that the alarm indication device of the blowout preventer control system is in a triggered state and the sound alarm device is in a triggered state, and it is determined that the system alarm function test of the blowout preventer control system is qualified.

[0042] Some embodiments of the present application also provide a blowout preventer control system test system based on hardware-in-the-loop, the system comprising:

[0043] Host computer, used to establish the BOP simulation model;

[0044] The real-time simulator is used to run the blowout preventer simulation model and receive control instructions from the blowout preventer control system, and obtain the output results of the blowout preventer simulation model according to the control instructions, and feed the output results back to the blowout preventer control system so that the test system can determine whether the control function test of the blowout preventer control system is qualified.

[0045] Compared with the prior art, the solution provided in the present application establishes a blowout preventer control system test system for testing a blowout preventer control system, the system at least comprising a host computer and a real-time simulator for establishing a blowout preventer simulation model, the real-time simulator being used to run the blowout preventer simulation model and receive control instructions from the blowout preventer control system, and to obtain the output result of the blowout preventer simulation model according to the control instruction, and to feed back the output result to the blowout preventer control system so that the system determines whether the control function test of the blowout preventer control system is qualified; based on the blowout preventer control system test system, the control function of the blowout preventer control system is tested, the control functions include a pressure charging control function, a pressure replenishing control function, a shear control function and a system alarm function, so that the functional test of the blowout preventer control system can be completed in the laboratory, the test cycle can be shortened, the test efficiency can be improved, on-site safety accidents can be avoided, the test safety can be improved, the work intensity and cost of on-site testing can be reduced by using the blowout preventer simulation model, and fault simulation can be achieved by modifying the model, so that the test results are more comprehensive and the convenience of testing can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Other features, objects and advantages of the present application will become more apparent by reading the detailed description of non-limiting embodiments made with reference to the following drawings:

[0047] Figure 1 A flowchart of a blowout preventer control system testing method based on hardware-in-the-loop is provided for some embodiments of the present application.

[0048] Figure 2 A structural schematic diagram of a blowout preventer control system test system provided for some embodiments of the present application.

[0049] Figure 3 A schematic structural diagram of a hardware-in-the-loop test cabinet is provided for some embodiments of the present application.

[0050] Figure 4 A structural schematic diagram of a real-time simulation machine provided for some embodiments of the present application. DETAILED DESCRIPTION

[0051] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0052] Here, the blowout preventer control system testing method based on hardware-in-the-loop according to an embodiment of the present application is suitable for use in a scenario where the control function of the blowout preventer control system is tested.

[0053] In this scenario, the BOP control system sends corresponding control instructions to the BOP according to the control function that needs to be tested. The BOP performs corresponding actions according to the received control instructions and feeds back the results of the actions to the BOP control system. The BOP control system performs subsequent control actions according to the feedback results, such as sending subsequent control instructions or displaying the current status of the BOP.

[0054] The blowout preventer control system testing method based on hardware-in-the-loop provided in the embodiment of the present application establishes a blowout preventer control system testing system for testing the blowout preventer control system, the system at least comprising a host computer and a real-time simulator for establishing a blowout preventer simulation model, the real-time simulator is used to run the blowout preventer simulation model and receive control instructions from the blowout preventer control system, and obtain the output result of the blowout preventer simulation model according to the control instruction, and feed the output result back to the blowout preventer control system, so that the system determines whether the control function test of the blowout preventer control system is qualified; based on the blowout preventer control system testing system, the control function of the blowout preventer control system is tested, and the control functions include a pressure charging control function, a pressure replenishing control function, a shear control function and a system alarm function, so that the function test of the blowout preventer control system can be completed in the laboratory, the test cycle can be shortened, the test efficiency can be improved, the on-site safety accidents can be avoided, the test safety can be improved, the work intensity and cost of on-site testing can be reduced by using the blowout preventer simulation model, and fault simulation can be realized by modifying the model, so that the test results are more comprehensive and the convenience of testing can be improved.

[0055] In some embodiments of the present application, the process of the blowout preventer control system testing method based on hardware in the loop is as follows: Figure 1 As shown, the method may include the following steps:

[0056] Step S101, establishing a blowout preventer control system test system for testing the blowout preventer control system.

[0057] Here, the blowout preventer control system is a hydraulic station including a variety of equipment, which may include but are not limited to motors, pumps, accumulators, relief valves, pressure reducing valves, solenoid valves, etc., and also includes some electrical control panels for controlling the switching of solenoid valves.

[0058] In some embodiments of the present application, the blowout preventer control system is tested using hardware-in-the-loop technology. The hardware-in-the-loop technology is used to simulate the actual working environment of the blowout preventer control system, and to test and verify the performance of the blowout preventer control system through real-time data and simulated signals. This technology simulates the actual working conditions of the blowout preventer in a laboratory environment through system modeling, and can realize blowout preventer fault simulation by processing the model and the signal, thereby improving the test efficiency of the blowout preventer control system and reducing the cost.

[0059] In some embodiments of the present application, the blowout preventer control system test system established based on hardware-in-the-loop technology includes at least a host computer and a real-time simulator. The host computer is used to establish a blowout preventer simulation model, and the real-time simulator is used to run the blowout preventer simulation model and receive control instructions from the blowout preventer control system, and obtain the output results of the blowout preventer simulation model according to the control instructions, and feed the output results back to the blowout preventer control system. The blowout preventer control system test system determines whether the control function test of the blowout preventer control system is qualified according to the corresponding control instructions and status information output by the blowout preventer control system.

[0060] In some embodiments of the present application, the output results of the blowout preventer simulation model may include but are not limited to the following data: pressure data, flow data, and displacement data. The pressure data is used to describe the current oil and gas pressure state of the blowout preventer, the flow data is used to describe the current oil and gas flow state of the blowout preventer, and the displacement data is used to describe the current displacement state of the blowout preventer.

[0061] Figure 2 The composition structure of the blowout preventer control system test system in some embodiments of the present application is shown, which includes a power supply, a host workstation (i.e., a host computer), an Ethernet switch, a hardware-in-the-loop test cabinet (including a real-time simulator) and a blowout preventer control system under test (i.e., a blowout preventer control system), wherein the power supply provides power to the hardware-in-the-loop test cabinet and the host workstation, the host workstation and the hardware-in-the-loop test cabinet realize data exchange through the Ethernet switch, and the hardware-in-the-loop test cabinet and the blowout preventer control system under test realize communication through the Ethernet switch.

[0062] Figure 3 The composition structure of a hardware-in-the-loop test cabinet in some embodiments of the present application is shown. The hardware-in-the-loop test cabinet may include a display screen, a test panel, a real-time simulator, and a power module. Figure 4 The composition structure of the real-time simulation machine in some embodiments of the present application is shown. The real-time simulation machine may include a simulation lower computer, an IO module and a communication module. The simulation lower computer is a hardware device including a computing CPU, an IO module interface, etc., which is used to run the blowout preventer simulation model to simulate the operation of the blowout preventer. The IO module is used to collect control instructions given by the control system of the blowout preventer under test, and send the pressure, flow, displacement and other states of the blowout preventer simulation model to the control system of the blowout preventer under test through the communication module to realize the detection of the control system. The test data is displayed on the display screen.

[0063] Here, the host workstation, Ethernet switch, real-time simulator communication module and the BOP control system under test can be connected through network cables, and each device can use the UDP communication protocol for real-time communication. The user activates the button on the operation panel of the BOP control system under test to send control instructions to the BOP simulation model. The control instructions of the BOP control system under test are output to the IO module of the real-time simulator. The BOP simulation model performs the corresponding actions, and the flow, pressure, displacement and other system state change data of the virtual BOP are output to the BOP control system and display screen under test through the IO module.

[0064] In some embodiments of the present application, a blowout preventer simulation model may be established based on the blowout preventer control system under test and the model information of the corresponding blowout preventer, where the model information may include but is not limited to the model and parameters, and the parameters may include but are not limited to mechanical parameters, electrical parameters, hydraulic parameters, and control parameters.

[0065] Here, the blowout preventer is composed of multiple parts, which may include but are not limited to: annular blowout preventer, semi-closed gate blowout preventer, fully closed gate blowout preventer, shear gate blowout preventer, etc. The blowout preventer can achieve shearing and sealing functions of different pipe diameters and drill strings according to different sizes. In addition, the parameters of each component of the hydraulic system of the blowout preventer control system and the parameters such as electrical control logic are related to the specific design. It can be understood that the sizes of the blowout preventer simulation models established according to different models and parameters of the blowout preventer control system are different, and there are differences in control pressure and closing time.

[0066] In some embodiments of the present application, establishing a blowout preventer simulation model may specifically include the following steps:

[0067] 1) Establish component simulation models for components in the blowout preventer;

[0068] 2) Use preset parameters, simulation step size and solver to simulate and test the BOP simulation model composed of multiple component simulation models;

[0069] 3) When the simulation test results do not meet the preset characteristic conditions, the parameters of the blowout preventer simulation model are iteratively optimized until the simulation test results meet the preset characteristic conditions;

[0070] 4) The blowout preventer simulation model that meets the preset characteristic conditions is determined as the final blowout preventer simulation model.

[0071] Here, after determining the model and parameters of the blowout preventer and the blowout preventer control system, the blowout preventer simulation model is established on the host computer. It can be understood that a variety of third-party software for establishing a blowout preventer simulation model can be pre-installed on the host computer, such as one-dimensional simulation software for modeling, software for generating real-time code, software for communicating with a real-time simulator, etc. The one-dimensional simulation software for modeling can be, for example, AMESim, SimulationX, etc., and its functions can include but are not limited to modeling, simulation, and generating C language code files, etc. The software for generating real-time code can be, for example, MATLAB / Simulink, etc., and its functions can include but are not limited to integrated model C language code files and real-time code generation, etc. The functions of the software for communicating with the real-time simulator can include but are not limited to: downloading the real-time code communication to the simulation lower computer of the real-time simulator, sending the control instructions to the real-time simulator for execution in real time, and viewing the running results of the real-time simulator, etc.

[0072] BOP includes a variety of hydraulic components, including but not limited to: hydraulic pump, oil tank, motor, safety valve, reversing valve, accumulator, hydraulic cylinder, sensor, etc. First, the required hydraulic components can be confirmed according to the hydraulic system schematic diagram of the BOP, and then the corresponding mathematical model can be established for each hydraulic component.

[0073] For example, the following mathematical model can be established for a hydraulic pump:

[0074] Q p =V p *n p

[0075] Among them, Q p is the hydraulic pump output flow, V p is the hydraulic pump displacement, n p is the hydraulic pump speed.

[0076] The following mathematical model is established for the reversing valve:

[0077]

[0078] Among them, q i is the flow rate of the four throttling sides of the reversing valve, C d is the flow coefficient, A i is the area of ​​the four throttling edges of the reversing valve, p1 and p2 are the pressures of the valve to the load, and p s and p t is the valve inlet and return oil pressure, and ρ is the hydraulic oil density.

[0079] The following mathematical model is established for the accumulator:

[0080]

[0081] Among them, P acc and V acc is the pressure and gas volume of the accumulator when it is working, P0 and V0 are the pre-charged gas pressure and initial volume of the accumulator, and n is the gas polynomial index.

[0082] The following mathematical model is established for the hydraulic cylinder:

[0083]

[0084] Among them, Q a , Q b is the flow rate of the rodless chamber and the rod chamber of the hydraulic cylinder, x p is the piston position, A and B are the areas of the two chambers of the hydraulic cylinder, and C ip and C ep is the internal leakage and external leakage coefficient, V a 、V b is the volume of the two chambers of the hydraulic cylinder, P a , P b is the pressure in the two chambers, β e is the bulk elastic modulus of the oil, m c is the piston mass, B c is the velocity damping coefficient, F l For the load force.

[0085] After the mathematical model of the components in the blowout preventer is established, a simulation model of the components is established according to the mathematical model of the components using one-dimensional simulation software, and a blowout preventer simulation model is formed by combining multiple component simulation models. After the blowout preventer simulation model is built, the blowout preventer simulation model is simulated and tested using preset parameters, simulation steps and solvers, and the simulation test results of the blowout preventer simulation model are analyzed to determine whether the simulation test results meet the preset characteristic conditions. If the preset characteristic conditions are not met, the parameters of the blowout preventer simulation model are iteratively optimized, and then the blowout preventer simulation model after parameter optimization is simulated and tested to analyze whether the newly obtained simulation test results meet the preset characteristic conditions. If the preset characteristic conditions are met, the simulation test is stopped, and the blowout preventer simulation model that meets the preset characteristic conditions is used as the final blowout preventer simulation model. The blowout preventer simulation model is a blowout preventer simulation model that can provide accurate feedback. If the preset characteristic conditions are still not met, the process of parameter optimization, simulation test and result analysis is repeated until the preset characteristic conditions are met.

[0086] Here, the blowout preventer simulation model is mainly used to simulate the hydraulic system of the blowout preventer, and the preset parameters can be the parameters of all hydraulic components in the blowout preventer, etc. The solver is used to calculate the simulation test results of the blowout preventer simulation model, which can be divided into two categories: variable step solver and fixed step solver. In some embodiments of the present application, a fixed step solver is used to calculate the simulation test results of the blowout preventer simulation model. The fixed step solver may include but is not limited to: Euler, Runge Kutta, etc.

[0087] In addition, it can be understood that the simulation step size can be set according to actual needs. For example, in order to ensure that the simulation is synchronized with the actual physical time, the simulation step size of the blowout preventer simulation model can be set to 0.1ms. The preset characteristic condition can be that the error between the simulation result and the actual blowout preventer operation result is less than a preset error threshold, and the error threshold can be, for example, a value between 5% and 10%.

[0088] In some embodiments of the present application, after the blowout preventer simulation model is established, the blowout preventer simulation model can also be compiled into a computer real-time language code, and the computer real-time language code can be transmitted to a real-time simulation machine for operation. Here, the blowout preventer simulation model can be compiled into a computer real-time language code file by a compiler in the one-dimensional simulation software, and the computer real-time language code file can be transmitted to the real-time simulation machine through an Ethernet switch.

[0089] In some embodiments of the present application, the process of establishing a blowout preventer control system test system and debugging it may include the following steps:

[0090] 1) Open the host computer, run the one-dimensional simulation modeling software, build a blowout preventer simulation model according to the blowout preventer hydraulic system schematic diagram, set the solver type and step size, and compile the obtained model file into a C language code file;

[0091] 2) Open MATLAB / Simulink software in the host computer, use S-function module to read the compiled C language code file, and build UDP communication interface to realize data communication between software and hardware;

[0092] 3) Connect the BOP control system to the IO module of the real-time simulator;

[0093] 4) Connect the host computer and the real-time simulator through the network, start the real-time simulator, open the RT-LAB software on the host computer, import the Simulink file into RT-LAB, compile and check whether there is an error, and download it to the real-time simulator after compilation for operation;

[0094] 5) Press the control button of the BOP control system and observe whether the output of the BOP simulation model in the real-time simulator changes accordingly to ensure smooth communication;

[0095] 6) Connect the IO module and display screen of the real-time simulator to ensure that the test data can be displayed normally;

[0096] 7) Determine whether the above steps meet the debugging requirements. If not, repeat the above process;

[0097] 8) Turn off the real-time simulator and host computer, and cut off the power supply.

[0098] Step S102: testing the control function of the blowout preventer control system based on the blowout preventer control system test system.

[0099] Here, the control functions of the blowout preventer control system may include but are not limited to a pressure charging control function, a pressure compensation control function, a shearing control function, and a system alarm function. The pressure charging control function controls the pressure of the blowout preventer to rise to a set value, and controls the hydraulic pump of the blowout preventer to stop working when the pressure rises to the set value. The pressure compensation control function controls the hydraulic pump to start charging when it is detected that the pressure of the blowout preventer is lower than the lower limit pressure, and controls the hydraulic pump to stop working when it is detected that the pressure rises to the upper limit pressure. The shearing control function controls the actuator of the blowout preventer to complete the action of the shear rod. The system alarm function triggers an alarm when it is detected that the manifold pressure of the blowout preventer control system exceeds the set alarm value.

[0100] In some embodiments of the present application, testing the pressure control function of the blowout preventer control system may include the following steps:

[0101] 1) The BOP control system sends a pressurization start command to the real-time simulator;

[0102] 2) The real-time simulator starts the hydraulic pump simulation element and opens the accumulator isolation valve simulation element according to the pressure-charging start instruction, so that the pressure data in the blowout preventer simulation model increases;

[0103] 3) The real-time simulator obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0104] 4) When the pressure data reaches the preset pressure threshold, the BOP control system test system detects that the BOP control system outputs a pressurization stop command and that the pressure indicating device of the BOP control system is in a triggered state, thereby determining that the pressurization control function test of the BOP control system is qualified.

[0105] Specifically, the user presses the hydraulic pump charging button in the blowout preventer control system to send a charging start command. After the IO module of the real-time simulation machine receives the charging start command, the hydraulic pump in the blowout preventer simulation model starts, outputs flow, the accumulator isolation valve opens, and the pressure in the blowout preventer simulation model begins to rise. The pressure sensor in the blowout preventer simulation model collects pressure data and sends the collected pressure data to the blowout preventer control system and the display through the IO module for display. When the pressure reaches the set pressure value, if the pressure indicator light of the blowout preventer control system lights up and the hydraulic pump stop command is output, it is determined that the charging control function test of the blowout preventer control system has passed.

[0106] In some embodiments of the present application, testing the pressure compensation control function of the blowout preventer control system may include the following steps:

[0107] 1) The real-time simulator obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0108] 2) When the pressure data is lower than the preset lower pressure threshold, it is detected that the blowout preventer control system outputs a pressurization start command, and the low pressure indication device of the blowout preventer control system is in a triggered state, and it is determined that the low pressure control function test of the blowout preventer control system is qualified, and the pressure compensation control function includes a low pressure control function and a high pressure control function;

[0109] 3) When the pressure data is higher than the preset upper pressure threshold, it is detected that the blowout preventer control system outputs a pressurization stop command, and the high-pressure indication device of the blowout preventer control system is in a triggered state, and it is determined that the high-pressure control function test of the blowout preventer control system is qualified;

[0110] 4) When both the low-pressure control function and the high-pressure control function have passed the test, determine that the pressure-boosting control function of the blowout preventer control system has passed the test.

[0111] Specifically, the pressure in the model is collected by the pressure sensor of the blowout preventer simulation model and sent to the blowout preventer control system through the IO module. When the blowout preventer control system collects a low pressure signal, it sends a hydraulic pump start command, and the low pressure indicator light comes on to indicate that the system is qualified. When the blowout preventer control system collects a high pressure signal, it sends a hydraulic pump stop command, and the high pressure indicator light comes on to indicate that the system is qualified.

[0112] In some embodiments of the present application, testing the shear control function of the blowout preventer control system may include the following steps:

[0113] 1) The BOP control system sends a shear-on command to the real-time simulator and sets the shear indication device to a trigger state;

[0114] 2) The real-time simulation machine switches the reversing valve simulation element to the shearing working position according to the shearing opening instruction, so that the simulated high-pressure oil passes through the reversing valve simulation element to reach the opening cavity of the actuator simulation element, pushing the actuator simulation element to shear;

[0115] 3) The real-time simulation machine obtains the displacement data collected by the displacement sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0116] 4) When it is detected that the displacement data reaches a preset displacement threshold and the shear indication device of the blowout preventer control system is in a shear completion state, it is determined that the shear control function test of the blowout preventer control system is qualified.

[0117] Specifically, the user presses the shear function button of the blowout preventer control system, the shear indicator light of the blowout preventer control system lights up, and the shear start instruction is transmitted to the blowout preventer simulation model through the switch and the IO module. After the blowout preventer simulation model receives the shear start instruction, the reversing valve in the blowout preventer simulation model switches to the shear working position, and the high-pressure oil passes through the reversing valve to the blowout preventer actuator opening chamber, pushing the actuator to achieve shearing. The pressure, flow, displacement and other parameter variables in the blowout preventer simulation model are collected by various sensors and sent to the blowout preventer control system for display. When the collected data of the blowout preventer displacement reaches 100% of the stroke, the shear function can be considered to be completed, and the shear indicator light of the blowout preventer control system goes out.

[0118] In some embodiments of the present application, testing the system alarm function of the blowout preventer control system may include the following steps:

[0119] 1) The BOP control system sends a pressure relief command to the real-time simulator and sets the pressure relief indication device to the trigger state;

[0120] 2) The real-time simulator controls the pressure relief valve simulation element to open according to the pressure relief instruction, so that the pressure data in the blowout preventer simulation model decreases;

[0121] 3) The real-time simulator obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system;

[0122] 4) When the pressure data reaches the preset alarm pressure threshold, it is detected that the alarm indication device of the blowout preventer control system is in a triggered state and the sound alarm device is in a triggered state, and it is determined that the system alarm function test of the blowout preventer control system is qualified.

[0123] Specifically, the user presses the pressure relief button of the blowout preventer control system to gradually reduce the manifold pressure, the pressure relief indicator light comes on, and the pressure relief command is transmitted to the blowout preventer simulation model through the switch and IO module to control the pressure relief valve to open. The pressure in the blowout preventer simulation model gradually decreases, and the pressure is collected by the pressure sensor and transmitted to the blowout preventer control system through the switch and IO module. When the pressure exceeds the alarm set pressure value, the alarm indicator of the blowout preventer control system should light up and the buzzer sounds an alarm.

[0124] If the BOP control system meets the above test process requirements, it means that the BOP control system is qualified, otherwise it is unqualified.

[0125] If the BOP control system test result fails, the failed test item will be recorded, and the BOP control system will be corrected and tested again until the test passes.

[0126] In summary, the solution provided in the present application establishes a blowout preventer control system test system for testing a blowout preventer control system, the system at least comprising a host computer and a real-time simulator for establishing a blowout preventer simulation model, the real-time simulator being used to run the blowout preventer simulation model and receive control instructions from the blowout preventer control system, and obtain the output result of the blowout preventer simulation model according to the control instruction, and feed the output result back to the blowout preventer control system, so that the system determines whether the control function test of the blowout preventer control system is qualified; based on the blowout preventer control system test system, the control function of the blowout preventer control system is tested, and the control functions include a charging control function, a compensating pressure control function, a shear control function and a system alarm function, so that the functional test of the blowout preventer control system can be completed in the laboratory, the test cycle can be shortened, the test efficiency can be improved, on-site safety accidents can be avoided, the test safety can be improved, the work intensity and cost of on-site testing can be reduced by using the blowout preventer simulation model, and fault simulation can be achieved by modifying the model, so that the test results are more comprehensive and the convenience of testing can be improved.

[0127] It should be noted that the present application can be implemented in software and / or a combination of software and hardware, for example, can be implemented using an application specific integrated circuit (ASIC), a general purpose computer or any other similar hardware device. In one embodiment, the software program of the present application can be executed by a processor to implement the steps or functions described above. Similarly, the software program of the present application (including relevant data structures) can be stored in a computer-readable recording medium, for example, a RAM memory, a magnetic or optical drive or a floppy disk and similar devices. In addition, some steps or functions of the present application can be implemented using hardware, for example, as a circuit that cooperates with a processor to perform each step or function.

[0128] In a typical configuration of the present application, the terminal and the network device each include one or more processors (CPU), input / output interface, network interface and memory.

[0129] The memory may include non-permanent storage in a computer-readable medium, random access memory (RAM) and / or non-volatile memory in the form of read-only memory (ROM) or flash RAM. The memory is an example of a computer-readable medium.

[0130] Computer readable media include permanent and non-permanent, removable and non-removable media that can be implemented by any method or technology to store information. Information can be computer readable instructions, data structures, program modules or other data. Examples of computer storage media include, but are not limited to, phase change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, read-only compact disk (CD-ROM), digital versatile disk (DVD) or other optical storage, magnetic cassettes, magnetic tape disk storage or other magnetic storage devices or any other non-transmission media that can be used to store information that can be accessed by a computing device. As defined herein, computer readable media does not include non-transitory media such as modulated data signals and carrier waves.

[0131] In addition, a part of the present application may be applied as a computer program product, such as a computer program instruction, which, when executed by a computer, can call or provide the method and / or technical solution according to the present application through the operation of the computer. The program instruction for calling the method of the present application may be stored in a fixed or removable recording medium, and / or transmitted through a data stream in a broadcast or other signal-bearing medium, and / or stored in a working memory of a computer device that runs according to the program instruction. Here, according to an embodiment of the present application, a device is included, the device including a memory for storing computer program instructions and a processor for executing program instructions, wherein, when the computer program instruction is executed by the processor, the device is triggered to run the method and / or technical solution based on the aforementioned multiple embodiments according to the present application.

[0132] It is obvious to those skilled in the art that the present application is not limited to the details of the above exemplary embodiments, and that the present application can be implemented in other specific forms without departing from the spirit or basic features of the present application. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-restrictive, and the scope of the present application is limited by the attached claims rather than the above description, so it is intended to include all changes that fall within the meaning and scope of the equivalent elements of the claims in the present application. Any figure mark in the claims should not be regarded as limiting the claims involved. In addition, it is obvious that the word "comprising" does not exclude other units or steps, and the singular does not exclude the plural. Multiple units or devices stated in the device claim can also be implemented by one unit or device through software or hardware. The words first, second, etc. are used to indicate names, and do not indicate any particular order.

Claims

1. A blowout preventer control system testing method based on hardware in the loop, characterized in that: The method includes: Establishing a blowout preventer control system test system for testing a blowout preventer control system, the blowout preventer control system test system at least comprising a host computer and a real-time simulator for establishing a blowout preventer simulation model, the real-time simulator being used to run the blowout preventer simulation model and receive control instructions from the blowout preventer control system, and obtaining output results of the blowout preventer simulation model according to the control instructions, and feeding back the output results to the blowout preventer control system, so that the blowout preventer control system test system determines whether the control function test of the blowout preventer control system is qualified; The control functions of the blowout preventer control system are tested based on the blowout preventer control system test system, and the control functions include a pressure charging control function, a pressure replenishing control function, a shearing control function and a system alarm function.

2. The method according to claim 1, characterized in that The output results include pressure data, flow data and displacement data.

3. The method according to claim 1, characterized in that The method further includes: The blowout preventer simulation model is established according to the blowout preventer control system under test and the model information of the corresponding blowout preventer, wherein the model information includes the model and parameters.

4. The method according to claim 3, characterized in that Establish a BOP simulation model, including: Establishing component simulation models for components in the blowout preventer; Using preset parameters, simulation step size and solver to perform simulation test on a blowout preventer simulation model composed of a plurality of component simulation models; When the simulation test result does not meet the preset characteristic condition, iteratively optimize the parameters of the blowout preventer simulation model until the simulation test result meets the preset characteristic condition; The blowout preventer simulation model that meets the preset characteristic conditions is determined as the final blowout preventer simulation model.

5. The method according to claim 4, characterized in that After the BOP simulation model is established, it also includes: Compiling the blowout preventer simulation model into computer real-time language code; The computer real-time language code is transmitted to the real-time simulation machine for execution.

6. The method according to claim 1, characterized in that Testing the pressure control function of the blowout preventer control system includes: The blowout preventer control system sends a pressurization opening instruction to the real-time simulator; The real-time simulation machine starts the hydraulic pump simulation element and opens the accumulator isolation valve simulation element according to the pressure-charging start instruction, so that the pressure data in the blowout preventer simulation model increases; The real-time simulation machine obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system; When the pressure data reaches a preset pressure threshold, it is detected that the blowout preventer control system outputs a pressurization stop command, and the pressure indicating device of the blowout preventer control system is in a triggered state, and it is determined that the pressurization control function test of the blowout preventer control system is qualified.

7. The method according to claim 1, characterized in that The pressure compensation control function of the blowout preventer control system is tested, including: The real-time simulation machine obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system; When the pressure data is lower than the preset pressure lower limit threshold, it is detected that the blowout preventer control system outputs a pressurization start instruction, and the low pressure indication device of the blowout preventer control system is in a triggered state, and it is determined that the low pressure control function test of the blowout preventer control system is qualified, wherein the pressure compensation control function includes a low pressure control function and a high pressure control function; When the pressure data is higher than the preset upper pressure threshold, it is detected that the blowout preventer control system outputs a pressurization stop command, and the high pressure indicating device of the blowout preventer control system is in a triggered state, and it is determined that the high pressure control function test of the blowout preventer control system is qualified; When both the low-pressure control function and the high-pressure control function are tested to be qualified, it is determined that the pressure compensation control function of the blowout preventer control system is tested to be qualified.

8. The method according to claim 1, characterized in that Testing the shear control function of the blowout preventer control system includes: The blowout preventer control system sends a shear-on instruction to the real-time simulator and sets the shear indication device to a trigger state; The real-time simulation machine switches the reversing valve simulation element to the shearing working position according to the shearing opening instruction, so that the simulated high-pressure oil passes through the reversing valve simulation element to reach the opening cavity of the actuator simulation element, and pushes the actuator simulation element to perform shearing; The real-time simulation machine obtains displacement data collected by the displacement sensor simulation element in the blowout preventer simulation model and sends the data to the blowout preventer control system; When it is detected that the displacement data reaches a preset displacement threshold and the shear indicating device of the blowout preventer control system is in a shear completion state, it is determined that the shear control function test of the blowout preventer control system is qualified.

9. The method according to claim 1, characterized in that: Testing the system alarm function of the blowout preventer control system includes: The blowout preventer control system sends a pressure relief instruction to the real-time simulator and sets the pressure relief indication device to a trigger state; The real-time simulation machine controls the pressure relief valve simulation element to open according to the pressure relief instruction, so that the pressure data in the blowout preventer simulation model decreases; The real-time simulation machine obtains the pressure data collected by the pressure sensor simulation element in the blowout preventer simulation model and sends it to the blowout preventer control system; When the pressure data reaches a preset alarm pressure threshold, it is detected that the alarm indication device of the blowout preventer control system is in a triggered state and the sound alarm device is in a triggered state, and it is determined that the system alarm function test of the blowout preventer control system is qualified.

10. A blowout preventer control system test system based on hardware in the loop, characterized in that: The system includes: Host computer, used to establish the BOP simulation model; The real-time simulator is used to run the BOP simulation model and receive control instructions from the BOP control system, and obtain output results of the BOP simulation model according to the control instructions, and feed the output results back to the BOP control system so that the test system determines whether the control function test of the BOP control system is qualified.

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