Fluid control valve performance test system capable of realizing oil-gas-water three-phase mixed flow

Abstract

The invention relates to the technical field of petroleum engineering equipment testing, and discloses a fluid control valve performance testing system capable of realizing oil-gas-water three-phase mixed flow, comprising: a liquid supply unit for providing a liquid medium with adjustable pressure and flow, the liquid medium comprising water, oil or an oil-water mixture, the liquid supply unit comprises a plunger pump and a stirring tank; and the gas supply unit is used for providing a gas medium with adjustable pressure and flow, and the gas supply unit comprises nitrogen equipment and an adjustable safety valve. Under the condition that any instrument is not disassembled, the calibration branch is switched to through the calibration switching valve group. The known P-Q characteristic of the standard resistance piece is used for reversely calculating the system deviation under the current working condition, and a linear regression correction coefficient is generated through an error correction module in the control unit. The system can eliminate systematic errors caused by sensor drift and fluid medium change in real time, and the confidence coefficient of test data is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of petroleum engineering equipment testing technology, specifically to a fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water. Background Technology

[0002] Fluid control valves are key devices used to regulate downhole gas-liquid flow during oil and gas extraction. Their core function is to automatically identify natural gas and water and adaptively adjust the pressure differential and flow rate based on the gas-liquid mixing ratio. To ensure their reliability in the complex downhole environment, rigorous simulation tests are required on the surface.

[0003] Existing testing equipment often has limited functionality and is easily affected by environmental factors (such as temperature-induced gas volume changes and pump efficiency fluctuations), leading to significant systematic errors in test data. Traditional testing methods typically rely on a single testing station, lacking real-time reference, making it difficult to determine whether data anomalies during testing stem from valve performance or system fluctuations. Therefore, there is an urgent need for a testing system that integrates online reference calibration and can precisely control media parameters. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a fluid control valve performance testing system capable of achieving three-phase mixing of oil, gas, and water, thus solving the problems mentioned in the background art.

[0005] This invention provides the following technical solution: a fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water, comprising: A liquid supply unit for providing a liquid medium with adjustable pressure and flow rate, the liquid medium including water, oil or an oil-water mixture, the liquid supply unit including a plunger pump and a stirring tank; A gas supply unit for providing a gas medium with adjustable pressure and flow rate, the gas supply unit including a nitrogen device and an adjustable safety valve; A fluid control unit is connected between the liquid supply unit, the gas supply unit, and the test fixture unit to control the flow direction, mixing ratio, and system back pressure of the medium. The test fixture unit is used to fix the control valve of the fluid under test and provides a test flow path; A standard reference calibration unit is arranged in parallel with the test fixture unit. The standard reference calibration unit is equipped with a standard resistance component with known flow resistance characteristics, which is used to perform online verification of the system flow resistance and sensor accuracy before testing. The testing and detection unit includes a third pressure gauge, a fourth pressure gauge, a liquid flow meter, a gas flow meter, and a temperature monitoring device arranged at key nodes in the flow path; The control and data acquisition unit is electrically connected to the test and detection unit and the fluid control unit, and is used to acquire test data and control valve action; The fluid control unit also includes a back pressure regulating valve group located on the system return main pipeline, which is used to cooperate with the plunger pump or nitrogen equipment to establish the high-pressure test condition of the system.

[0006] Preferably, the test and detection unit is arranged as follows: the pressure gauges include at least a first pressure gauge located at the outlet of the liquid supply unit, a second pressure gauge located at the outlet of the gas supply unit, and a third and a fourth pressure gauge located at both ends of the common inlet and outlet of the test fixture unit and the standard reference calibration unit; the liquid flow meter is installed in the liquid supply pipeline with an accuracy of not less than 0.1 ml / min; the gas flow meter is installed in the gas supply pipeline; and the temperature monitoring device is installed on the common pipeline near the third pressure gauge to monitor the temperature of the fluid entering the test fixture unit or the standard reference calibration unit in real time.

[0007] Preferably, the input end of the manifold valve group in the fluid control unit is connected to the liquid supply unit and the gas supply unit respectively, and the manifold valve group is provided with liquid diversion pipeline and gas diversion pipeline inside; the manifold valve group includes a pure water control valve, a pure gas control valve, a mixed flow inlet valve and a mixed flow outlet valve connected to the diversion pipeline, as well as a one-way valve group located before the gas-liquid junction point. It also includes a calibration switching valve assembly, which is configured at the inlet of the test fixture unit and the standard reference calibration unit, for selectively connecting the test flow path or the calibration flow path; the back pressure regulating valve assembly is arranged after the confluence outlet of the calibration switching valve assembly, including at least one high-pressure remote control throttle valve, for applying variable resistance to the fluid flowing through the test fixture unit or the standard reference calibration unit to regulate the system pressure.

[0008] Preferably, the system further includes a foam generator; one branch of the liquid diversion pipeline and one branch of the gas diversion pipeline merge at a gas-liquid junction, and the mixing inlet valve is located after the gas-liquid junction; the foam generator is connected between the outlet of the mixing inlet valve and the inlet of the mixing outlet valve, and is used to mix the input liquid medium and gas medium to form a gas-liquid mixed fluid.

[0009] Preferably, the standard resistance element in the standard reference calibration unit is a standard long-diameter nozzle or a standard venturi tube; the standard resistance element has a calibrated discharge coefficient to provide a stable differential pressure-flow rate reference relationship.

[0010] Preferably, the mixing tank in the liquid supply unit is equipped with a variable frequency stirring motor and a circulation pipeline to maintain the emulsified suspension state of the oil-water mixture.

[0011] Preferably, the control and data acquisition unit includes a processor and a memory storing a computer program. When the processor executes the computer program, it performs the following steps: receiving the measured differential pressure data generated when the standard reference calibration unit is working, comparing it with the theoretical standard data, generating a correction coefficient based on a linear regression algorithm, and using the correction coefficient to compensate the sensor readings in the subsequent test fixture unit test process in real time.

[0012] Preferably, the system further includes a safety interlock protection mechanism; the safety interlock protection mechanism is configured such that when the pressure value monitored by the test detection unit exceeds a preset safety threshold, the plunger pump is automatically stopped and the valve of the gas supply unit is closed, while the safety valve is triggered to release pressure.

[0013] The present invention has the following beneficial effects: Without disassembling any instruments, the system is switched to the calibration branch via the calibration switching valve assembly. Utilizing the known PQ characteristics of standard resistance components, the system deviation under the current operating conditions is calculated backwards, and a linear regression correction coefficient is generated through the error correction module in the control unit. This enables the system to eliminate systematic errors introduced by sensor drift and changes in the fluid medium in real time, significantly improving the confidence level of the test data.

[0014] A common detection node design is adopted, where the third and fourth pressure gauges simultaneously serve both the test fixture unit and the standard reference calibration unit. This topology ensures that the control valve under test and the standard resistance component are compared under the same pressure sensing system and the same temperature monitoring environment. This design eliminates individual accuracy differences introduced by using two different sets of sensors, minimizing measurement uncertainty through hardware arrangement.

[0015] The one-way valve assembly effectively prevents high-pressure gas from flowing back into the liquid pipeline, ensuring system safety; the back pressure regulating valve assembly located in the return main pipe makes the establishment of system pressure no longer solely dependent on the pump load, achieving relative decoupling of flow regulation and pressure control, and can accurately simulate the downhole constant high pressure condition of 35MPa.

[0016] Employing a flow conversion method based on the real gas law (PV=ZnRT), this method automatically calculates the compressibility factor of nitrogen under current high-pressure conditions based on real-time monitored pressure and temperature. This allows for the accurate back-calculation of the gas-liquid integral under the target condition into the standard setpoint of the gas mass flow controller. This solves the problem of proportioning errors caused by significant volume changes in gas under different pressures, ensuring the realism of the simulated operating conditions.

[0017] When the monitored pressure exceeds the preset safety threshold, the system can respond in milliseconds, automatically cut off the power source and trigger the safety valve to release pressure, effectively preventing the risk of high-pressure pipeline rupture and ensuring the safety of test personnel and equipment. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall process flow of the present invention.

[0019] 10. Liquid supply unit; 11. Plunger pump; 12. Mixing tank; 13. First pressure gauge; 14. Liquid flow meter; 20. Gas supply unit; 21. Nitrogen equipment; 22. Safety valve; 23. Second pressure gauge; 24. Gas flow meter; 30. Fluid control unit; 31. Manifold valve assembly; 311. Pure water control valve; 312. Mixed flow inlet valve; 313. Mixed flow outlet valve; 314. Pure gas control valve; 32. Calibration switching valve assembly; 321. Inlet switching valve; 322. Outlet switching valve; 33. Foam generator; 34. Back pressure regulating valve assembly; 40. Test fixture unit; 41. Control valve for the fluid under test; 50. Standard reference calibration unit; 51. Standard resistance component; 60. Test and detection unit; 61. Third pressure gauge; 62. Fourth pressure gauge; 63. Temperature monitoring device; 70. Control and data acquisition unit. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] A performance testing system for a fluid control valve capable of achieving three-phase mixing of oil, gas, and water includes: a liquid supply unit 10 for providing a liquid medium with adjustable pressure and flow rate, the liquid medium including water, oil, or an oil-water mixture; the liquid supply unit 10 includes a plunger pump 11 and a mixing tank 12; a gas supply unit 20 for providing a gas medium with adjustable pressure and flow rate; the gas supply unit 20 includes a nitrogen device 21 and an adjustable safety valve 22; a fluid control unit 30 connected between the liquid supply unit 10, the gas supply unit 20, and the test fixture unit 40 for controlling the flow direction, mixing ratio, and system back pressure of the medium; the test fixture unit 40 for fixing the fluid control valve 41 under test and providing a test flow path; and a standard reference calibration sheet. The standard reference calibration unit 50 is arranged in parallel with the test fixture unit 40. The standard reference calibration unit 50 is equipped with a standard resistance component 51 with known flow resistance characteristics, which is used to perform online verification of the system flow resistance and sensor accuracy before testing. The test and detection unit 60 includes a third pressure gauge 61, a fourth pressure gauge 62, a liquid flow meter 14, a gas flow meter 24 and a temperature monitoring device 63 arranged at key nodes in the flow path. The control and data acquisition unit 70 is electrically connected to the test and detection unit 60 and the fluid control unit 30, which is used to collect test data and control valve actions. The fluid control unit 30 also includes a back pressure regulating valve group 34 located on the system return main pipeline, which is used to cooperate with the plunger pump 11 or the nitrogen equipment 21 to establish the high-pressure test condition of the system.

[0022] In a preferred embodiment, the test detection unit 60 is arranged as follows: the pressure gauges include at least a first pressure gauge 13 located at the outlet of the liquid supply unit 10, a second pressure gauge 23 located at the outlet of the gas supply unit 20, and a third pressure gauge 61 and a fourth pressure gauge 62 located at both ends of the common inlet and outlet of the test fixture unit 40 and the standard reference calibration unit 50; the liquid flow meter 14 is installed in the liquid supply pipeline with an accuracy of not less than 0.1 ml / min; the gas flow meter 24 is installed in the gas supply pipeline; and the temperature monitoring device 63 is installed on the common pipeline near the third pressure gauge 61 to monitor the temperature of the fluid entering the test fixture unit 40 or the standard reference calibration unit 50 in real time.

[0023] Liquid supply unit 10: Employs a 3DP-120 high-pressure three-plunger pump 11 with a rated discharge pressure of 40MPa and a theoretical discharge capacity of 200L / min. The plunger pump 11 is connected to a frequency converter, allowing precise control of the output flow rate by adjusting the motor frequency. The mixing tank 12 has a volume of 2m³ and is equipped with a variable frequency stirring motor and a bottom circulation pump. The bottom circulation pump is connected to the mixing tank 12 via an external circulation pipeline, forming a closed-loop circulation system used to maintain the emulsified suspension state of the oil-water mixture.

[0024] Gas supply unit 20: Nitrogen equipment 21 uses a high-pressure nitrogen cylinder group to work with a gas booster pump, with an output pressure range of 0-40MPa.

[0025] Foam generator 33: A mixing device that can shear the gas-liquid two-phase flow into a uniform foam flow is used to ensure the uniformity of the fluid entering the test fixture.

[0026] Fluid control unit 30: The main pipe diameter of the system is DN25.

[0027] Liquid diversion pipeline: The pipeline at the outlet of the liquid supply unit 10 is divided into two branches. The first branch is connected to the calibration switching valve group 32 via the pure water control valve 311; the second branch is connected to the gas-liquid junction via the check valve.

[0028] Gas splitting pipeline: The pipeline at the outlet of the gas supply unit 20 is divided into two branches. The first branch is connected to the calibration switching valve group 32 via the pure gas control valve 314; the second branch is connected to the gas-liquid junction via the check valve.

[0029] Merging point and mixing branch: The second branch of the liquid splitting pipeline and the second branch of the gas splitting pipeline merge at a gas-liquid merging point. After the merging point, the mixing inlet valve 312, the foam generator 33 and the mixing outlet valve 313 are connected in series, and finally lead to the calibration switching valve group 32.

[0030] One-way valve assembly: The two one-way valves located on the second branch of the liquid diversion pipeline and the second branch of the gas diversion pipeline respectively constitute a one-way valve assembly. Located before the gas-liquid junction, it effectively prevents gas-liquid cross-flow and backflow under high pressure conditions.

[0031] The calibration switching valve group 32 consists of two high-pressure three-way ball valves: an inlet switching valve 321 and an outlet switching valve 322. The common input terminal of the inlet switching valve 321 is connected to the main pipe after the convergence of the three branch lines: pure water line, pure gas line, and mixed flow line.

[0032] Back pressure regulating valve assembly 34: Installed on the common return pipeline after the outlet switching valve 322, it uses a multi-stage orifice plate throttle valve in conjunction with a high-pressure needle valve to precisely control the system back pressure, which is adjustable from 0-35MPa, ensuring stable pressure under test conditions. Test detection unit 60: First pressure gauge 13: Installed on the pipeline between the outlet of plunger pump 11 and the diversion point to monitor the pump outlet pressure.

[0033] Second pressure gauge 23: Installed at the outlet of the gas booster pump to monitor the gas supply pressure.

[0034] Liquid flow meter 14: A high-precision Coriolis mass flow meter with an accuracy of 0.1 ml / min is selected and installed on the liquid supply main pipe.

[0035] Gas flow meter 24: A thermal gas mass flow meter is selected and installed on the gas supply main pipe.

[0036] The third pressure gauge 61 and temperature monitoring device 63 are installed on the main pipeline before the inlet switching valve 321 of the calibration switching valve group 32 to monitor the fluid pressure and temperature entering the test / calibration unit in real time.

[0037] Fourth pressure gauge 62: Installed on the main pipeline after outlet switching valve 322, before back pressure regulating valve group 34.

[0038] In a preferred embodiment: the input end of the manifold valve group 31 in the fluid control unit 30 is connected to the liquid supply unit 10 and the gas supply unit 20 respectively, and the manifold valve group 31 is provided with a liquid diversion pipeline and a gas diversion pipeline; the manifold valve group 31 includes a pure water control valve 311, a pure gas control valve 314, a mixed flow inlet valve 312 and a mixed flow outlet valve 313 connected to the diversion pipeline, as well as a one-way valve group located before the gas-liquid junction point; the calibration switching valve group 32 is configured at the inlet of the test fixture unit 40 and the standard reference calibration unit 50, and is used to selectively connect the test flow path or the calibration flow path; the back pressure regulating valve group 34 is arranged after the junction outlet of the calibration switching valve group 32, and includes at least one high-pressure remote control throttle valve, which is used to apply variable resistance to the fluid flowing through the test fixture unit 40 or the standard reference calibration unit 50 to regulate the system pressure.

[0039] In a preferred embodiment, the system further includes a foam generator 33; one branch of the liquid diversion line and one branch of the gas diversion line merge at a gas-liquid junction, and a mixing inlet valve 312 is located after the gas-liquid junction; the foam generator 33 is connected between the outlet of the mixing inlet valve 312 and the inlet of the mixing outlet valve 313 for mixing the input liquid medium with the gas medium to form a gas-liquid mixed fluid.

[0040] In a preferred embodiment: the standard resistance element 51 in the standard reference calibration unit 50 is a standard long-diameter nozzle or a standard venturi tube; the standard resistance element 51 has a calibrated discharge coefficient to provide a stable differential pressure-flow rate reference relationship.

[0041] Two branches, branch A and branch B, are set between the inlet switching valve 321 and the outlet switching valve 322 of the calibration switching valve group 32 to construct a dual-branch parallel topology that is physically independent but fluid logic switchable. The two branches are switched through the calibration switching valve group 32 and share the front-end fluid source and the back-end back pressure regulation and metering instrument, thereby achieving the design purpose of using the same sensor to measure the valve under test and the standard parts.

[0042] Branch A, Test Fixture Unit 40: Serves as the test channel for the product under test, and includes an upstream rectifier pipe section, a hydraulic automatic clamping device, and a downstream straight pipe section. The hydraulic automatic clamping device is equipped with replaceable sealing adapter rings, which can be adapted to control valves 41 of different pipe diameters under test, enabling rapid loading and unloading and zero-leakage sealing under high-pressure conditions.

[0043] Branch B, Standard Reference Calibration Unit 50: Serving as the physical reference channel for system accuracy, it is arranged in parallel with Branch A. Internally, a standard long-diameter nozzle (51) is rigidly mounted via a flange as a standard resistance component. This nozzle is manufactured according to GB / T2624 (or ISO 5167) standards, made of 316L stainless steel, with a throat diameter d=5.00mm (which can be replaced according to the flow range), and calibrated by a national legal metrology institution, with an outflow coefficient C=0.992 and an expanded uncertainty better than 0.5%. The existence of this branch allows the system to perform "actual flow calibration" of the combined measurement error of the pressure and flow sensors at any time by switching the flow path without disassembling the instruments.

[0044] In a preferred embodiment: the mixing tank 12 in the liquid supply unit 10 is equipped with a variable frequency stirring motor and a circulation pipeline to maintain the emulsified suspension state of the oil-water mixture; the plunger pump 11 is a high-pressure three-plunger pump, and the output flow is controlled by a frequency converter.

[0045] In a preferred embodiment: the control and data acquisition unit 70 includes a processor and a memory storing a computer program. When the processor executes the computer program, it performs the following steps: receiving the measured differential pressure data generated when the standard reference calibration unit 50 is working, comparing it with the theoretical standard data, generating a correction coefficient based on a linear regression algorithm, and using the correction coefficient to compensate the sensor readings in the subsequent test fixture unit 40 test process in real time.

[0046] In a preferred embodiment, the system further includes a safety interlock protection mechanism. The safety interlock protection mechanism is configured such that when the pressure value monitored by the test detection unit 60 exceeds a preset safety threshold, the plunger pump 11 is automatically stopped and the valve of the gas supply unit 20 is closed, while the safety valve 22 is triggered to release pressure.

[0047] The safety interlock protection mechanism specifically includes an error correction module, integrated into the data acquisition unit. Its working logic is as follows: a. Collect the measured pressure difference ΔP_meas of the standard resistance component 51 at the standard flow rate Q_std.

[0048] b. Calculate the theoretical pressure difference ΔP_theo.

[0049] c. Use the linear correction model: P_corrected = K * P_raw + B.

[0050] d. Correction factor K = ΔP_theo / ΔP_meas, offset B is usually set to 0, zero point is calibrated.

[0051] e. In subsequent tests, the software automatically multiplies all pressure sensor readings by K for compensation.

[0052] Safety interlock: The system pressure threshold is set to 38 MPa. Once the pressure sensor detects overpressure, the control program immediately executes the following interlocking actions: The pump 11 was shut down by cutting off the power supply to the frequency converter. Send a command to close the main gas valve and pure gas control valve 314 of the gas supply unit 20; The safety valve 22 is triggered to physically relieve pressure.

[0053] A performance testing method for a fluid control valve capable of achieving three-phase mixing of oil, gas, and water includes the following steps: S1: Preparations before testing: Model the speed and flow rate calibration of plunger pump 11, and connect and pressure test the system pipelines; S2: Online reference calibration, control the fluid to enter the standard reference calibration unit 50, use the back pressure regulating valve group 34 to establish the standard pressure condition, record the pressure difference data of the standard resistance element 51, and verify the measurement accuracy of the system; S3: Divided medium test, switch the fluid into the test fixture unit 40, and perform pure water condition test, pure gas condition test and gas-liquid mixed flow condition test in sequence. S4: Data processing, plotting the flow curves of the fluid control valve 41 under different media and pressures, comparing them with the flow curves of standard valves, and analyzing the gas-liquid identification capability and flow regulation performance of the fluid control valve.

[0054] The specific operation of step S2 is as follows: close the inlet valve of the test fixture unit 40 and open the inlet valve of the standard reference calibration unit 50; adjust the back pressure regulating valve group 34 to make the system reach the preset calibration pressure; set a set of standard flow rates, record the pressure difference value and flow rate value collected by the test detection unit 60, and compare them with the theoretical characteristic curve of the standard resistance component 51; if the deviation is within the preset range, the system status is determined to be qualified and proceed to step S3; if the deviation exceeds the preset range, the liquid flow meter 14 or pressure gauge parameters are compensated by a correction coefficient.

[0055] The specific operation of step S3 is as follows: S31: Pure water test: Open the pure water control valve 311, maintain the system pressure constant by adjusting the back pressure regulating valve group 34, adjust the pump flow rate in descending order, and record the inlet and outlet pressure difference data of the fluid control valve 41 under different flow rates; S32: Pure gas test: Open the pure gas control valve 314, and under constant back pressure, adjust the nitrogen flow rate in descending order and record the pressure difference data; S33: Gas-liquid mixed flow test: Open the mixed flow inlet valve 312 and the mixed flow outlet valve 313. According to the set gas-liquid integral number GVF value, use the gas state equation to convert the gas volume flow rate under the working condition into the standard mass flow rate. Adjust the output of the liquid supply unit 10 and the gas supply unit 20 to achieve the target working condition after mixing. Record the pressure difference data.

[0056] To eliminate systematic errors, the following steps should be taken before formal testing: Step S1: Pre-test preparation and pump modeling The pump pressure was stabilized at 10 MPa, and the frequency of the frequency converter was adjusted from 10 Hz to 50 Hz in 5 Hz increments. A linear regression equation for "frequency-flow rate" was established using the weighbridge method: Q = 3.84 * f - 1.2, with a correlation coefficient R^2 > 0.999.

[0057] Step S2: Specific operations for online reference verification Switching flow path: Control the calibration switching valve group 32 to close the flow path to the test fixture unit 40 and open the flow path to the standard reference calibration unit 50 through the inlet switching valve 321.

[0058] Set standard operating conditions: Set pump flow rate Q_set=100L / min.

[0059] Establish back pressure: Adjust the back pressure regulating valve group 34 to stabilize the reading of the fourth pressure gauge 62 at 15MPa.

[0060] Data acquisition: Read the values ​​of the third pressure gauge 61 and the fourth pressure gauge 62 to obtain the measured pressure difference ΔP_meas.

[0061] Comparison and verification: The theoretical pressure difference was calculated according to the standard nozzle formula ΔP_theo=(ρ / 2)*(Q / (C*A))^2 of standard resistance component 51.

[0062] Judgment and correction: If |ΔP_meas-ΔP_theo| / ΔP_theo≤1%, the system is deemed qualified and automatically proceeds to step S3; if the error is >1%, the system software automatically generates a correction coefficient K=ΔP_theo / ΔP_meas and compensates for the pressure reading in subsequent tests.

[0063] Step S3: Specific operation of the media testing: After verification, switch the calibration switching valve group 32 to branch A where the test fixture unit 40 is located, and perform the following tests: Pure water medium test corresponds to S31 Adjust the back pressure regulating valve group 34 to maintain the system pressure at 20MPa, and gradually reduce the pump flow rate from 180L / min to 20L / min. Record the difference between the third pressure gauge 61 and the fourth pressure gauge 62, and plot the "pure water pressure difference - flow rate" curve.

[0064] Pure gas medium test corresponds to S32 Using nitrogen gas testing, the gas supply flow rate was gradually reduced from 500 Nm³ / h, and the data was recorded.

[0065] Gas-liquid mixed flow test corresponds to S33 Objective: To verify the response of the fluid control valve 41 to different gas contents of GVF.

[0066] Parameter calculation: Under the condition of target GVF=90%, the test pressure is assumed to be P=20MPa, the temperature T=25℃, and the nitrogen compressibility factor Z≈1.05.

[0067] Operating gas flow rate calculation: Based on the total flow rate Q_total and GVF, calculate the required operating gas flow rate Q_g_act = Q_total * GVF.

[0068] Standard condition flow conversion: Using the real gas state equation PV=ZnRT, calculate the standard condition setpoint required for the gas flow controller MFC: Q_g_std=Q_g_act*(P / P_std)*(T_std / T)*(1 / Z).

[0069] Operation: Open the mixed-flow inlet valve 312 and the mixed-flow outlet valve 313, adjust the pump output liquid flow rate, and adjust the gas flow controller output Q_g_std. The fluids are combined through the check valve and then enter the foam generator 33 for shearing and mixing before entering the valve to be tested. Record the pressure difference after stabilizing for 60 seconds.

[0070] The system is equipped with a standard reference calibration unit 50, the core of which is a standard resistance element 51 with known and stable flow resistance characteristics. Fluid is introduced into this unit through a calibration switching valve group 32, and the real-time pressure difference of the fluid flowing through the standard nozzle is collected using a third pressure gauge 61 and a fourth pressure gauge 62. Since the geometric dimensions of the standard nozzle are fixed and the discharge coefficient has been calibrated by the National Institute of Metrology, the system can calculate the theoretical standard PQ pressure difference-flow characteristic data under the current fluid medium, such as a gas-liquid mixture, and at the current temperature and pressure, based on Bernoulli's equation. This measured data reflects the comprehensive state of the system's sensors and fluid properties, serving as a real-time reference to verify the measurement deviations of the pressure transmitter and flow meter, thereby eliminating system errors caused by changes in fluid properties and sensor drift.

[0071] The foam generator 33 is designed for unstable flow patterns such as slug flow and laminar flow that are prone to occur in multiphase flow of oil, gas, and water. It receives the input liquid and gas and provides a mixing space, allowing the gas and liquid phases to coexist in physical space and form a mixed fluid output. The mixing effect is created inside the pipeline by the fluid's own flow energy, ensuring that the fluid medium entering the valve under test is in a mixed state, thereby obtaining effective test data.

[0072] The topological advantages of the common detection node: By employing a third pressure gauge 61 and a fourth pressure gauge 62 to simultaneously serve both the test fixture unit 40 and the standard reference calibration unit 50, a comparative measurement topology based on the same physical sensor is constructed. This design eliminates zero-point drift and linearity errors caused by individual accuracy differences due to the use of different sensors, ensuring the consistency of the measured data and calibration data on the measurement reference.

[0073] Emergency Response Plan Overpressure protection: When the system pressure exceeds 38MPa, safety valve 22 will automatically open to relieve pressure.

[0074] Leakage handling: If the pressure drop rate is detected to exceed 0.5 MPa / s, the ESD emergency shutdown will be automatically triggered.

[0075] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0076] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended technical solutions and their equivalents.

Claims

1. A fluid control valve performance testing system capable of achieving three-phase mixing of oil, gas, and water, characterized in that, include: A liquid supply unit (10) is used to provide a liquid medium with adjustable pressure and flow rate, the liquid medium including water, oil or oil-water mixture, the liquid supply unit (10) including a plunger pump (11) and a stirring tank (12). A gas supply unit (20) is used to provide a gas medium with adjustable pressure and flow rate. The gas supply unit (20) includes a nitrogen device (21) and an adjustable safety valve (22). A fluid control unit (30) is connected between the liquid supply unit (10), the gas supply unit (20) and the test fixture unit (40) to control the flow direction, mixing ratio and system back pressure of the medium. The test fixture unit (40) is used to fix the control valve (41) of the fluid to be tested and to provide a test flow path; The standard reference calibration unit (50) is arranged in parallel with the test fixture unit (40). The standard reference calibration unit (50) is equipped with a standard resistance component (51) with known flow resistance characteristics, which is used to verify the system flow resistance and sensor accuracy online before testing. The test and detection unit (60) includes a third pressure gauge (61), a fourth pressure gauge (62), a liquid flow meter (14), a gas flow meter (24), and a temperature monitoring device (63) arranged at key nodes of the flow path. The control and data acquisition unit (70) is electrically connected to the test and detection unit (60) and the fluid control unit (30) and is used to acquire test data and control valve action; The fluid control unit (30) also includes a back pressure regulating valve group (34) located on the system return main pipeline, which is used to cooperate with the plunger pump (11) or nitrogen equipment (21) to establish the high pressure test condition of the system.

2. The fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water according to claim 1, characterized in that, The test and detection unit (60) is arranged as follows: the pressure gauges include at least a first pressure gauge (13) arranged at the outlet of the liquid supply unit (10), a second pressure gauge (23) arranged at the outlet of the gas supply unit (20), and a third pressure gauge (61) and a fourth pressure gauge (62) arranged at both ends of the common inlet and outlet of the test fixture unit (40) and the standard reference calibration unit (50); the liquid flow meter (14) is installed in the liquid supply pipeline with an accuracy of not less than 0.1 ml / min; the gas flow meter (24) is installed in the gas supply pipeline; the temperature monitoring device (63) is installed on the common pipeline near the third pressure gauge (61) for real-time monitoring of the fluid temperature entering the test fixture unit (40) or the standard reference calibration unit (50).

3. The fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water according to claim 1, characterized in that, The input end of the manifold valve group (31) in the fluid control unit (30) is connected to the liquid supply unit (10) and the gas supply unit (20) respectively. It is provided with a liquid diversion pipeline and a gas diversion pipeline inside. The manifold valve group (31) includes a pure water control valve (311), a pure gas control valve (314), a mixed flow inlet valve (312) and a mixed flow outlet valve (313) connected to the diversion pipeline, as well as a one-way valve group located before the gas-liquid junction. It also includes a calibration switching valve assembly (32), which is configured at the inlet of the test fixture unit (40) and the standard reference calibration unit (50) for selectively connecting the test flow path or the calibration flow path; the back pressure regulating valve assembly (34) is arranged after the confluence outlet of the calibration switching valve assembly (32), and includes at least one high-pressure remote control throttle valve for applying variable resistance to the fluid flowing through the test fixture unit (40) or the standard reference calibration unit (50) to regulate the system pressure.

4. The fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water according to claim 3, characterized in that, The system also includes a foam generator (33); one branch of the liquid diversion pipeline and one branch of the gas diversion pipeline merge at a gas-liquid junction, and the mixed flow inlet valve (312) is located after the gas-liquid junction; the foam generator (33) is connected between the outlet of the mixed flow inlet valve (312) and the inlet of the mixed flow outlet valve (313) for mixing the input liquid medium with the gas medium to form a gas-liquid mixed fluid.

5. The fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water according to claim 1, characterized in that, The standard resistance element (51) in the standard reference calibration unit (50) is a standard long-diameter nozzle or a standard venturi tube; the standard resistance element (51) has a calibrated discharge coefficient to provide a stable differential pressure-flow rate reference relationship.

6. The fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water according to claim 1, characterized in that, The mixing tank (12) in the liquid supply unit (10) is equipped with a variable frequency stirring motor and a circulation pipeline to maintain the emulsified suspension state of the oil-water mixture.

7. The fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water according to claim 1, characterized in that, The control and data acquisition unit (70) includes a processor and a memory storing a computer program. When the processor executes the computer program, it performs the following steps: receiving the measured differential pressure data generated when the standard reference calibration unit (50) is working, comparing it with the theoretical standard data, generating a correction coefficient based on the linear regression algorithm, and using the correction coefficient to compensate the sensor readings in the subsequent test fixture unit (40) test process in real time.

8. The fluid control valve performance testing system capable of realizing three-phase mixing of oil, gas, and water according to claim 1, characterized in that, The system also includes a safety interlock protection mechanism; the safety interlock protection mechanism is configured such that when the pressure value monitored by the test detection unit (60) exceeds the preset safety threshold, the plunger pump (11) is automatically stopped and the valve of the gas supply unit (20) is closed, and the safety valve (22) is triggered to release pressure.

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