Simulation test device and method for gas production single well hydraulic control system

Abstract

The invention discloses a simulation test device and method for a gas production single well hydraulic control system, a first controller receives a field simulation signal given by a second controller, an interlocking action instruction is sent to a field valve according to the configuration logic of the first controller, and the second controller receives the interlocking action instruction sent by the first controller. The data processing module interacts with the first controller and the second controller, obtains all instrument signals, control instructions and on-site valve state changes, records and archives the instrument signals, the control instructions and the on-site valve state changes, and automatically generates a test report. The output port of the first controller is connected with the energy storage structure, and the output end of the energy storage structure interacts with the second controller to achieve energy storage control. A simulated gas production single well platform is adopted, and comprehensive analogue simulation is provided for a single well instrument and an executing mechanism. Functions and performance of the hydraulic control system are comprehensively tested in an off-line simulation mode, system problems are found and solved before installation, and safety risks caused by logic errors or controller hardware problems are avoided.

Description

Technical Field

[0001] This invention belongs to the field of natural gas development technology and relates to a simulation test device and method for a gas production single-well hydraulic control system. Background Technology

[0002] Each gas production well is equipped with a three-stage hydraulic safety valve system: a downhole safety valve, a main safety valve, and a wing safety valve. The valves are opened by high-pressure hydraulic oil supplied by the hydraulic mechanism of the hydraulic control cabinet, and closed by spring reset when the hydraulic pressure is lost. The system is equipped with instruments such as oil pressure, casing pressure of each layer, pressure after first-stage throttling, pressure after second-stage throttling, wellhead temperature, temperature after first-stage throttling, temperature after second-stage throttling, single-well flow meter, and combustible gas detector.

[0003] The gas production single-well hydraulic control system, commonly referred to as the hydraulic control cabinet on-site, consists of a PLC system and a hydraulic mechanism. The PLC collects all instrument parameters and automatic control valve statuses at the gas production wellhead and automatically controls the wellhead automatic control valves. The interlocking shut-in logic includes: 1) High pressure alarm after secondary throttling at the wellhead, interlocking and closing the main safety valve and wing safety valve (commonly known as well shut-in); 2) Low pressure and high pressure drop rate alarms simultaneously after secondary throttling at the wellhead, the system judges this as a pipeline rupture and triggers interlocking shut-in; 3) Fusible plug melting in the gas production tree (in case of fire, high temperature melts the fusible plug), interlocking and closing the main safety valve, wing safety valve, and downhole safety valve. This is a mechanical interlock and does not require PLC signal acquisition or well shut-in signal issuance; 4) Local ESD button interlocking shut-in at the hydraulic control cabinet; 5) Combustible gas alarm interlocking shut-in at the well site; 6) Remote well shut-in from the main control room.

[0004] Currently, the testing of wellhead hydraulic control systems by various manufacturers is divided into two processes: pre-shipment testing and post-installation system integration testing. First, pre-shipment testing involves testing each signal channel individually to ensure the controller's input and output signal channels are normal and the wiring within the cabinet is correct. Second, on-site system integration testing involves: first, calibrating the wiring to ensure the correctness of each control loop; second, establishing connections by sending AI signals (4-20mA) or DI signals to each loop at the field instrument end, and checking the received signals at the controller end to ensure they match the field signals; third, sending AO and DO signals at the controller end, and checking the received signals at the field end to ensure they match the controller signals; and finally, testing each interlocking logic with the instruments and actuators to ensure each interlocking logic operates correctly as designed.

[0005] The limitations of the existing single-well hydraulic control system commissioning test are: (1) It can only be carried out after the gas well site process facilities are completed and the hydraulic control system is installed on site. If problems occur during the test, it will take time to solve them on site, which will affect the production time of the single well; (2) Testing the new hydraulic control system with field instruments and actuators poses a safety risk. If there are problems with the control logic or hydraulic control system hardware, it may cause damage to the instruments and automatic actuators, or cause process safety accidents. Summary of the Invention

[0006] The purpose of this invention is to address the limitations of existing single-well hydraulic control system commissioning and testing technologies, which may cause damage to instruments and automatic actuators. This invention provides a simulation testing device and method for a gas production single-well hydraulic control system.

[0007] To achieve the above objectives, the present invention employs the following technical solution:

[0008] The present invention proposes a simulation test device for a gas production single-well hydraulic control system, comprising a first controller, a second controller, a first and second digital display, a second and second digital display, and a data processing module;

[0009] The output signal of the second controller is converted and isolated by the first and second digital display meters and then sent to the input channel of the first controller to simulate field instrument signals; the output signal of the first controller is converted and isolated by the second digital display meters and then sent to the input channel of the second controller as a command signal reception; both the first controller and the second controller are connected to the data processing module to realize data processing; the output port of the first controller is connected to an energy storage structure, and the output end of the energy storage structure interacts with the second controller.

[0010] Preferably, the data processing module includes a processor;

[0011] The processor communicates with the second controller via a network switch to set test parameters, send test commands to the second controller, and collect feedback signals received by the second controller; the first controller receives the processor's commands via the network switch and issues interlocking action commands to the field valves.

[0012] Preferably, the processor, the second controller, and the first controller are all connected to the network switch via communication cables.

[0013] Preferably, the output port of the first controller is connected to a first safety valve, a second safety valve, and a third safety valve. One end of the first safety valve, one end of the second safety valve, and one end of the third safety valve are all connected to the hydraulic system, and the other ends of the first safety valve, the second safety valve, and the third safety valve are all connected to the energy storage structure.

[0014] Preferably, the first safety valve, the second safety valve, and the third safety valve are all connected to the hydraulic system via hydraulic lines, and the first safety valve, the second safety valve, and the third safety valve are all connected to the energy storage structure via hydraulic lines.

[0015] Preferably, the first safety valve, the second safety valve, and the third safety valve are all connected to the first controller via signal cables.

[0016] Preferably, the energy storage structure includes a first energy storage device, a second energy storage device, and a third energy storage device;

[0017] The first energy storage device is connected to the first safety valve, the second energy storage device is connected to the second safety valve, and the third energy storage device is connected to the third safety valve.

[0018] Preferably, a first pressure transmitter, a second pressure transmitter, and a third pressure transmitter are respectively provided between the second controller and the first energy storage device, the second energy storage device, and the third energy storage device.

[0019] Preferably, the first pressure transmitter, the second pressure transmitter, and the third pressure transmitter all communicate with the second controller via signal cables.

[0020] The present invention proposes a testing method for a simulation testing device for a gas production single-well hydraulic control system, comprising:

[0021] The second controller sends an output signal, which is then converted and isolated by the first and second multi-display meters before being sent to the input channel of the first controller.

[0022] After receiving the signal from the first and second digital display meters, the first controller outputs the signal, which is then converted and isolated by the second digital display meter before being sent to the input channel of the second controller. The second controller then responds after receiving the instruction signal from the second digital display meter.

[0023] During the signal transmission and reception process, a data processing module is used to record all instrument signals and control commands exchanged between the first controller and the second controller, and to monitor the energy storage status of the energy storage structure.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] This invention proposes a simulation testing device for a gas production single-well hydraulic control system. A first controller receives field simulation signals from a second controller and issues interlocking action commands to the field valves according to the configuration logic of the first controller. The second controller then receives the interlocking action commands from the first controller. A data processing module interacts with both the first and second controllers, acquiring, recording, and archiving all instrument signals, control commands, and field valve status changes, and automatically generating a test report. The output port of the first controller is connected to an energy storage structure, and the output of the energy storage structure interacts with the second controller to achieve energy storage control. This invention uses a simulated gas production single-well platform to provide comprehensive simulation of the single-well instruments and actuators. It can simultaneously provide instrument input simulation signals to the hydraulic control system, receive output commands from the hydraulic control system, and execute corresponding actions; it can perform multi-signal joint testing; and it can automatically record all signal transmissions and action execution during the test process and automatically generate a test report. By using offline simulation, the functions and performance of the hydraulic control system are comprehensively tested, allowing system problems to be identified and resolved before installation. After passing the test, on-site installation and commissioning can be carried out, shortening the on-site commissioning and testing time and eliminating the risk of process safety problems caused by logic errors or controller hardware issues during commissioning and testing. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a structural diagram of the simulation test device for the gas production single-well hydraulic control system of the present invention.

[0028] The system includes: a first controller 1, a second controller 2, a processor 3, a network switch 4, a first and second multi-display meter 5-1, a second and second multi-display meter 5-2, a hydraulic system 6, a first safety valve 7-1, a second safety valve 7-2 and a third safety valve 7-3, a first pressure transmitter 8-1, a second pressure transmitter 8-2, a third pressure transmitter 8-3, a first accumulator 9-1, a second accumulator 9-2, a third accumulator 9-3, a status indicator light 10, a signal cable 11, a hydraulic pipeline 12, and a communication cable 13. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0030] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0031] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0032] In the description of the embodiments of the present invention, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0033] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0034] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0035] The present invention will now be described in further detail with reference to the accompanying drawings:

[0036] This invention proposes a simulation and testing device for a gas production single-well hydraulic control system, such as... Figure 1 As shown, it includes a first controller 1, a second controller 2, a first and second display table 5-1, a second and second display table 5-2, and a data processing module;

[0037] The output signal of the second controller 2 is converted and isolated by the first and second display meters 5-1 and then sent to the input channel of the first controller 1 to simulate field instrument signals; the output signal of the first controller 1 is converted and isolated by the second display meter 5-2 and then sent to the input channel of the second controller 2 as a command signal; both the first controller 1 and the second controller 2 are connected to the data processing module to realize data processing; the output port of the first controller 1 is connected to an energy storage structure, and the output end of the energy storage structure interacts with the second controller 2.

[0038] The data processing module includes a processor 3; the processor 3 communicates with the second controller 2 via a network switch 4 to set test parameters, issue test commands to the second controller 2, and collect feedback signals received by the second controller 2; the first controller 1 receives commands from the processor 3 via the network switch 4 and issues interlocking commands to the field valves. The processor 3, the second controller 2, and the first controller 1 are all connected to the network switch 4 via communication cables.

[0039] The output port of the first controller 1 is connected to a first safety valve 7-1, a second safety valve 7-2, and a third safety valve 7-3. One end of the first safety valve 7-1, one end of the second safety valve 7-2, and one end of the third safety valve 7-3 are all connected to the hydraulic system 6. The other ends of the first safety valve 7-1, the second safety valve 7-2, and the third safety valve 7-3 are all connected to the energy storage structure. The first safety valve 7-1, the second safety valve 7-2, and the third safety valve 7-3 are all connected to the hydraulic system 6 via hydraulic lines 12, and the first safety valve 7-1, the second safety valve 7-2, and the third safety valve 7-3 are all connected to the energy storage structure via hydraulic lines 12. The first safety valve 7-1, the second safety valve 7-2, and the third safety valve 7-3 are all connected to the first controller 1 via signal cables 11. The energy storage structure includes a first energy storage unit 9-1, a second energy storage unit 9-2, and a third energy storage unit 9-3. The first energy storage unit 9-1 is connected to the first safety valve 7-1, the second energy storage unit 9-2 is connected to the second safety valve 7-2, and the third energy storage unit 9-3 is connected to the third safety valve 7-3. A first pressure transmitter 8-1, a second pressure transmitter 8-2, and a third pressure transmitter 8-3 are respectively provided between the second controller 2 and the first energy storage unit 9-1, the second energy storage unit 9-2, and the third energy storage unit 9-3. The first pressure transmitter 8-1, the second pressure transmitter 8-2, and the third pressure transmitter 8-3 all communicate with the second controller 2 via a signal cable 11.

[0040] The simulation test device for the single-well hydraulic control system of this gas production facility will be described in detail below with reference to the accompanying drawings, such as... Figure 1 As shown, Zone I is the hydraulic control cabinet device area to be tested, and Zone II is the device area of ​​the present invention. Zone I includes a first controller 1, a hydraulic system 6, a first safety valve 7-1, a second safety valve 7-2, and a third safety valve 7-3. Zone II includes a second controller 2, a first and second multi-display meter 5-1, a second and second multi-display meter 5-2, a status indicator light 10, a first pressure transmitter 8-1, a second pressure transmitter 8-2, a third pressure transmitter 8-3, a hydraulic pipeline 12, a first accumulator 9-1, a second accumulator 9-2, a third accumulator 9-3, a processor 3, a signal cable 11, and a communication cable 13.

[0041] The AO signal of the second controller 2 of the test system is converted and isolated by the first and second multi-display tables 5-1, and then sent to the AI ​​channel of the first controller 1 of the liquid control cabinet system.

[0042] The AO signal from the first controller 1 of the liquid control cabinet system is converted and isolated by the second multi-display meter 5-2 and then sent to the AI ​​channel of the second controller 2 of the test system.

[0043] The second controller 2 of the simulation test system sends an AO signal (4-20mA) to simulate the field instrument signal (4-20mA). It is first sent to the first and second digital display meters 5-1. The parameter value corresponding to the signal value (e.g., 10Mpa) is displayed on the screen of the first and second digital display meters 5-1. The first and second digital display meters 5-1 then forward the 4-20mA signal to the AI ​​input terminal of the first controller 1 of the hydraulic control system. This is equivalent to the first controller 1 acquiring the field instrument signal.

[0044] The first controller 1 sends an AO signal (4-20mA) to the second multi-display meter 5-2. The second multi-display meter 5-2 displays the parameter value corresponding to the signal value (e.g., 50% valve opening) on ​​its screen. At the same time, the second multi-display meter 5-2 forwards this signal to the AI ​​input terminal of the second controller 2 of the simulation test system as a command signal.

[0045] The first and second display tables 5-1 and 5-2 not only display instrument signal values ​​and command signal values, but also have isolation functions, which isolate the power supply of the first controller 1 of the hydraulic control system I from the power supply of the second controller 2 of the simulation test system II, thus avoiding signal distortion caused by differences in power grounding and voltage.

[0046] The processor 3 communicates with the second controller 2 of the test system through the switch 4, sets test parameters on the operator station computer, sends test commands to the second controller 2, and collects the feedback signals received by the second controller 2.

[0047] The first controller 1 receives the field simulation signal from the second controller 2 and issues an interlock action command to the field valve according to the configuration logic of the first controller 1. Then, the second controller 2 receives the interlock action command issued by the first controller 1 and makes corresponding status indications according to the panel indicator lights on the process status indicator board 10.

[0048] Processor 3 records and archives all instrument signals, control commands, and field valve status changes that interact between the first controller 1 of the hydraulic control system and the second controller 2 of the simulation test system, and automatically generates test reports.

[0049] Hydraulic system 6 has three hydraulic oil output lines. Two low-pressure hydraulic oil output lines provide hydraulic power to the main safety valve and wing safety valve of the gas production tree, and one high-pressure hydraulic oil output line provides hydraulic power to the downhole safety valve of the gas production tree. These three hydraulic oil output lines are connected to three hydraulic accumulators 9-1, 9-2, and 9-3 of the simulation test system, respectively. The hydraulic accumulators 9-1, 9-2, and 9-3 simulate the main safety valve, wing safety valve, and downhole safety valve at the wellhead. Pressure transmitters 8-1, 8-2, and 8-3 detect the hydraulic oil pressure in the accumulators. When the hydraulic oil pressure detected by pressure transmitters 8-1 / 8-2 / 8-3 reaches the opening pressure of the corresponding hydraulic safety valve (main safety valve, wing safety valve, downhole safety valve), the hydraulic safety valve is considered to be open. When the hydraulic oil pressure is 0, the hydraulic safety valve is considered to be closed.

[0050] A wellhead process flow and instrument valve status display area is set up on the control panel of the simulation test system, which centrally displays wellhead instrument parameters, hydraulic control system output command parameters, and wellhead valve status indicators in real time, so that the test process can be displayed intuitively.

[0051] The simulation testing system designed in this invention can be used by hydraulic control system manufacturers to check whether the control logic and performance of each execution unit (component) of the hydraulic control system meet the design expectations before the product leaves the factory, ensuring that the product meets the design or user requirements before leaving the factory; it can also be used for functional and performance testing of the hydraulic control system after delivery and before installation, to ensure that the received product meets the on-site functional and performance requirements.

[0052] The present invention proposes a testing method for a simulation testing device of a gas production single-well hydraulic control system, comprising the following steps:

[0053] The second controller 2 sends an output signal, which is then converted and isolated by the first and second multi-display meters 5-1 before being sent to the input channel of the first controller 1.

[0054] After receiving the signal from the first and second display meters 5-1, the first controller 1 outputs the signal, which is then converted and isolated by the second and second display meters 5-2 before being sent to the input channel of the second controller 2. The second controller 2 responds after receiving the instruction signal from the second and second display meters 5-2.

[0055] During the signal transmission and reception process, a data processing module is used to record all instrument signals and control commands exchanged between the first controller 1 and the second controller 2, and to monitor the energy storage status of the energy storage structure.

[0056] The simulation and testing device for a single-well hydraulic control system for gas production proposed in this invention has the following advantages:

[0057] 1) Compared with the traditional hydraulic control system, which is installed and then tested on-site, this invention can complete all functional and performance tests before the hydraulic control system is installed on-site, which can greatly improve the efficiency of on-site testing, shorten the on-site commissioning and testing time, and thus shorten the production preparation time of gas production wells;

[0058] 2) Compared with traditional single-point and single-channel PLC testing, this invention can perform multi-point linkage complex logic testing, which is more practical;

[0059] 3) This invention overcomes the limitations of the technical level and experience of on-site technicians, making the testing process more standardized and the test results more comprehensive, accurate and effective;

[0060] 4) This invention automatically records test results and automatically generates test reports, making the process and results more objective and accurate;

[0061] 5) This invention allows for testing of the hydraulic control system in a laboratory (workshop), overcoming the process safety risks associated with on-site commissioning and testing, and thus providing greater safety.

[0062] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A simulation and testing device for a gas production single-well hydraulic control system, characterized in that, It includes a first controller (1), a second controller (2), a first binary display (5-1), a second binary display (5-2), and a data processing module; The output signal of the second controller (2) is converted and isolated by the first and second display meters (5-1) and then sent to the input channel of the first controller (1) to simulate field instrument signals; the output signal of the first controller (1) is converted and isolated by the second display meter (5-2) and then sent to the input channel of the second controller (2) as a command signal; both the first controller (1) and the second controller (2) are connected to the data processing module to realize data processing; the output port of the first controller (1) is connected to an energy storage structure, and the output end of the energy storage structure interacts with the second controller (2).

2. The simulation and testing device for a gas production single-well hydraulic control system according to claim 1, characterized in that, The data processing module includes a processor (3); The processor (3) communicates with the second controller (2) through the network switch (4) to set test parameters, send test instructions to the second controller (2), and collect feedback signals received by the second controller (2); the first controller (1) receives instructions from the processor (3) through the network switch (4) and sends interlocking action instructions to the field valve.

3. The simulation and testing device for a gas production single-well hydraulic control system according to claim 2, characterized in that, The processor (3), the second controller (2) and the first controller (1) are all connected to the network switch (4) via communication cables.

4. The simulation and testing device for a gas production single-well hydraulic control system according to claim 1, characterized in that, The output port of the first controller (1) is connected to a first safety valve (7-1), a second safety valve (7-2), and a third safety valve (7-3). One end of the first safety valve (7-1), one end of the second safety valve (7-2), and one end of the third safety valve (7-3) are all connected to the hydraulic system (6). The other end of the first safety valve (7-1), the other end of the second safety valve (7-2), and the other end of the third safety valve (7-3) are all connected to the energy storage structure.

5. The simulation and testing device for a gas production single-well hydraulic control system according to claim 4, characterized in that, The first safety valve (7-1), the second safety valve (7-2), and the third safety valve (7-3) are all connected to the hydraulic system (6) through hydraulic lines (12), and the first safety valve (7-1), the second safety valve (7-2), and the third safety valve (7-3) are all connected to the energy storage structure through hydraulic lines (12).

6. The simulation and testing device for the gas production single-well hydraulic control system according to claim 4, characterized in that, The first safety valve (7-1), the second safety valve (7-2), and the third safety valve (7-3) are all connected to the first controller (1) via a signal cable (11).

7. The simulation and testing device for a gas production single-well hydraulic control system according to claim 4, characterized in that, The energy storage structure includes a first energy storage unit (9-1), a second energy storage unit (9-2), and a third energy storage unit (9-3); The first energy storage device (9-1) is connected to the first safety valve (7-1), the second energy storage device (9-2) is connected to the second safety valve (7-2), and the third energy storage device (9-3) is connected to the third safety valve (7-3).

8. The simulation and testing device for a gas production single-well hydraulic control system according to claim 7, characterized in that, A first pressure transmitter (8-1), a second pressure transmitter (8-2), and a third pressure transmitter (8-3) are respectively provided between the second controller (2) and the first energy storage device (9-1), the second energy storage device (9-2), and the third energy storage device (9-3).

9. The simulation and testing device for a gas production single-well hydraulic control system according to claim 8, characterized in that, The first pressure transmitter (8-1), the second pressure transmitter (8-2), and the third pressure transmitter (8-3) all communicate with the second controller (2) via a signal cable (11).

10. A test method for a simulation test device for a gas production single-well hydraulic control system, characterized in that, The simulation and testing device for the gas production single-well hydraulic control system according to any one of claims 1 to 9 includes: The output signal is sent by the second controller (2), and after being converted and isolated by the first and second multi-display meters (5-1), the output signal is sent to the input channel of the first controller (1); After receiving the signal from the first two-dimensional display (5-1), the first controller (1) outputs the signal after it is converted and isolated by the second two-dimensional display (5-2) and then sends it to the input channel of the second controller (2). The second controller (2) responds after receiving the instruction signal from the second two-dimensional display (5-2). During the signal transmission and reception process, a data processing module is used to record all instrument signals and control commands exchanged between the first controller (1) and the second controller (2), and to monitor the energy storage status of the energy storage structure.

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