A test system for an electrically controlled throttle valve for managed pressure drilling

Abstract

The utility model discloses a kind of test systems of electric control throttle valve for pressure control drilling, including the pressure control module and back pressure module being set to both ends of the throttle valve to be tested, pressure control module left side is connected to high pressure pump module;High pressure pump module right end connects fluid circulation pipeline, upper end is connected to solid injection module, gas injection module is also accessed between high pressure pump module and pressure control module, gas injection module other end and fluid circulation pipeline are jointly accessed gas-liquid separation device, gas-liquid separation device is finally connected to the other end of back pressure module, form loop.This scheme solves the problem that general control pressure drilling throttle valve test method is difficult to simulate real downhole complex coupling condition, through the synergistic effect of high pressure pump module, pressure control module and back pressure module, simulate complex pressure environment on site, ensure the boundary condition, accuracy and safety of test.

Description

Technical Field

[0001] This utility model relates to the field of oil and gas exploration and development technology, and in particular to a testing system for an electrically controlled throttle valve used in pressure-controlled drilling. Background Technology

[0002] As oil and gas exploration and development targets increasingly shift towards deeper geological formations, high-temperature and high-pressure reservoirs, and areas with narrow safe density windows, traditional drilling techniques have significant limitations in addressing formation pressure sensitivity, easily inducing complex downhole situations such as well kicks and stuck pipe. These problems have become key technical bottlenecks restricting exploration and development efficiency and safety. Controlled pressure drilling, as an advanced drilling technology paradigm, provides an effective way to solve these challenges.

[0003] The core of controlled pressure drilling lies in its ability to dynamically and precisely control the wellbore pressure profile in a closed loop, enabling the drilling operation to adapt to the inherent safe pressure window of the formation. This technology significantly reduces the probability of complex drilling conditions such as lost circulation and overflows by managing the annular pressure profile. Its application not only helps optimize drilling cost structure, simplify operating procedures, and reduce non-productive time, but also ultimately improves the productivity and efficiency of oil and gas wells by protecting reservoir integrity.

[0004] However, conventional testing methods for throttle valves used in controlled-pressure drilling face significant challenges. The biggest drawback lies in the difficulty of simulating the complex coupled operating conditions in the field. Test benches typically use clean water or a single-base fluid, failing to reproduce the complex rheological properties and chemical corrosiveness of real mud environments containing high concentrations of abrasive solids, oil-based, or water-based drilling fluids. The dynamic erosion and wear effects of abrasive particles on the valve seat and valve core are difficult to simulate effectively on the test bench, leading to significant deviations between experimental results and actual operating conditions. Utility Model Content

[0005] To address the aforementioned technical problems, this utility model provides a testing system for an electrically controlled throttle valve used in pressure-controlled drilling.

[0006] This utility model is achieved using the following technical solution: A testing system for an electrically controlled throttle valve used in pressure-controlled drilling includes a pressure control module and a back pressure module disposed at both ends of the throttle valve under test. The left side of the pressure control module is connected to a high-pressure pump module; the right end of the high-pressure pump module is connected to a fluid circulation pipeline, and the upper end is connected to a solid injection module. A gas injection module is also connected between the high-pressure pump module and the pressure control module. The other end of the gas injection module and the fluid circulation pipeline are connected to a gas-liquid separation device. The gas-liquid separation device is finally connected to the other end of the back pressure module, forming a loop.

[0007] Specifically, it also includes control terminals that connect various modules of the system, enabling unified scheduling and control to achieve comprehensive and systematic control.

[0008] Specifically, the high-pressure pump module includes a high-pressure pump and a mud tank that provides liquid supply as a source. The bottom of the mud tank is also equipped with heating and cooling coils to control the fluid temperature.

[0009] Specifically, the solid injection module includes a solid addition device and a solid concentration monitoring sensor located at the rear end of the solid addition device. The solid addition device also includes a storage bin, a feeder, and a Venturi injector.

[0010] Specifically, the gas injection module includes a gas source, a gas pressurization device, and a mass flow controller that controls the gas flow rate and the injected gas flow rate, connected in sequence.

[0011] Specifically, the pressure control module is located at the inlet end of the throttle valve under test, and includes a pressure regulating valve, a pressure sensor, and a PID controller, which form a closed loop.

[0012] Specifically, the back pressure module is located at the outlet end of the throttle valve under test, and includes a second pressure sensor, a second PID controller, and a back pressure valve, which form a closed loop.

[0013] The beneficial effects of this utility model are as follows: Through the design of independent solid injection module and gas injection module, this utility model realizes functions such as simulating drilling fluid containing solid phase, simulating gas invasion conditions, quantitatively assessing erosion resistance performance, and verifying the stability of throttle valve control, solving the problem that the general control pressure drilling throttle valve test method is difficult to simulate the complex coupled conditions in real downhole; through the synergistic effect of high pressure pump system and pressure control and back pressure system, it simulates the complex pressure environment on site, ensuring the boundary conditions, accuracy and safety of the test. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0015] Figure 1 This is a test system architecture diagram of the electrically controlled throttle valve for pressure-controlled drilling in this embodiment of the present invention; The components are as follows: 1-High-pressure pump module; 101-Mud tank; 102-High-pressure pump; 2-Solid injection module; 201-Solid addition device; 202-Solid concentration monitoring sensor; 3-Gas injection module; 301-Gas source; 302-Gas pressurization device; 303-Mass flow controller; 4-Pressure control module; 401-Pressure regulating valve; 402-Pressure sensor one; 403-PID controller one; 5-Back pressure module; 501-Pressure sensor two; 502-Back pressure valve; 503-PID controller two; 6-Tested electric throttle valve; 7-Control terminal; 8-Gas-liquid separation device; 9-Fluid circulation pipeline. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0017] 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.

[0018] The following is in conjunction with the appendix Figure 1 The following describes some embodiments of the present invention in detail. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0019] This utility model proposes a testing system for electrically controlled throttle valves used in pressure-controlled drilling, such as... Figure 1 As shown, in a preferred embodiment, the system includes a fluid circulation pipeline 9, with a high-pressure pump module 1 connected to the left end of the fluid circulation pipeline 9, a solid injection module 2 connected to the upper end of the high-pressure pump module 1, a gas injection module 3 connected to the lower end of the high-pressure pump module 1, and pressure control and back pressure modules 4 and 5 and a throttle valve under test 6 connected to the right end of the high-pressure pump module 1. A gas-liquid separation system 8 is connected between the high-pressure pump module 1 and the back pressure module 5, and all modules are connected to a control terminal 7.

[0020] In this embodiment, the high-pressure pump module includes a mud tank 101 and a high-pressure pump 102. The mud tank 101, as the source of the high-pressure pump system, can store a sufficient volume of test fluid to provide a continuous and stable fluid supply to the high-pressure pump 102. Before or during the test, water / oil, viscosity modifiers, fluid loss reducers, and other materials can be added to the mud tank 101 in proportion to accurately prepare a drilling fluid simulation fluid that meets the test requirements. A heating / cooling coil is installed at the bottom of the mud tank to control the fluid temperature inside the tank, simulate the downhole temperature, and conduct high-temperature and high-pressure tests, maintaining consistent rheological properties of the drilling fluid simulation fluid during the experiment.

[0021] In one embodiment, the high-pressure pump 102 consists of a three-cylinder plunger pump and a variable frequency motor. The variable frequency motor drives the three-cylinder plunger pump through a reduction gearbox, thereby efficiently controlling the stroke frequency and output flow of the three-cylinder plunger pump. The three-cylinder plunger pump converts low-pressure fluid into high-pressure fluid through mechanical energy, providing power for the entire test circuit. In this embodiment, independent solid injection module 2 and gas injection module 3 are used to simulate extreme downhole conditions and verify the full-dimensional performance of the throttle valve. Existing technologies cannot accurately simulate complex downhole conditions, leading to an inability to accurately evaluate the dynamic pressure control effect of the electric throttle valve under actual conditions. This solution, through the configured solid injection module 2 and gas injection module 3, realistically simulates various complex conditions during the drilling process, ensuring that the tested electric throttle valve can obtain a true pressure control effect evaluation under different complex downhole conditions. Existing testing methods mostly use static pressure testing, lacking consideration for transient downhole pressure fluctuations, such as pumping / excitation pressure and sudden pressure changes in gas intrusion slug flow. This solution, through the high-pressure pump module 1 and a multi-stage plunger pump structure, can test transient pressure waveforms and accurately test the valve's dynamic response performance. This embodiment solves the problems of distorted simulation of operating conditions, insufficient dynamic pressure coverage, and lack of multiphase flow coupling in existing testing methods.

[0022] In this embodiment, the solid injection module 2 includes a solid addition device 201 and a solid concentration monitoring sensor 202 connected in sequence. The solid addition device 201 consists of a storage bin, a feeder, and a Venturi injector. Notably, the Venturi injector uses negative pressure to draw solids into the liquid flow, which can avoid the influence of pulses. The solid concentration monitoring sensor 202 uses an ultrasonic concentration meter, which inverts the particle concentration by measuring the attenuation rate of sound waves in the suspension. Compared with existing testing methods that often conduct pure liquid phase erosion or pure gas phase sealing tests separately, this method can uniformly inject solid particles into the drilling fluid simulation fluid at a set concentration and rate, simulating the downhole solid phase content and achieving a solid-liquid two-phase synergistic effect.

[0023] In this embodiment, the gas injection module 3 includes a gas source 301, a gas booster device 302, and a mass flow controller 303 connected in sequence. The gas source 301 provides the gas required for the test, such as nitrogen (N2), air, and methane (CH4), to simulate the influence of different gas components on the performance of the throttle valve. The gas booster device 302 uses a hydraulically driven booster pump, which uses hydraulic oil to push a piston to compress the gas. A proportional valve controls the booster ratio to raise the gas source pressure to the high pressure required for the test, simulating deep well gas intrusion or supercritical gas conditions, ensuring stable gas flow, and avoiding pressure fluctuations from affecting the throttle valve's adjustment accuracy. The mass flow controller 303 uses a thermal mass flow meter, which calculates the flow rate based on the cooling effect when the gas flows through a thermistor, enabling real-time monitoring of the gas mass flow rate and precise control of the gas injection rate. Compared with existing testing methods that often conduct separate pure liquid phase erosion or pure gas phase sealing tests, the gas injection module can simulate downhole gas intrusion or gas-filled drilling fluid conditions, verifying the throttle valve's pressure regulation capability, gas-liquid two-phase flow stability, and sealing performance in gas-containing fluids.

[0024] In this embodiment, the pressure control module 4 and the back pressure module 5 are located at the inlet and outlet ends of the tested electric throttle valve. The pressure control module 4 includes a pressure regulating valve 401, a pressure sensor 402, and a PID controller 403, which form a closed loop. The pressure regulating valve adjusts the wellhead back pressure to accurately reproduce the hydrostatic column pressure, circulating pressure loss, and transient pressure fluctuations during the drilling process. The back pressure module 5 includes a pressure sensor 501, a back pressure valve 502, and a PID controller 503, which also form a closed loop. During gas injection, a controllable back pressure is applied to prevent pressure runaway caused by gas expansion, verifying whether the valve can quickly balance the pressure of the gas-liquid two-phase flow. Furthermore, when the fluid level drops during simulated tripping, the dynamic following performance of the valve can be verified through back pressure compensation.

[0025] In this embodiment, the gas-liquid separation device 8 is located between the high-pressure pump module 1 and the back pressure module 5. The gas-liquid separation device 8 can safely and efficiently separate gas-liquid mixtures, ensuring the accuracy of test data, the safety of the equipment, and the compliance of the test environment.

[0026] Control terminal 7 undertakes core functions such as automated control, data acquisition, real-time monitoring, and intelligent analysis, and is a key component to ensure the accuracy, repeatability, and safety of testing.

[0027] This utility model provides a testing system for electrically controlled throttle valves used in pressure-controlled drilling, and its working process is as follows: Step 1: System Integration and Safety Preparation. Install the electric throttle valve in the simulated well control manifold and connect it to the high-pressure pump module, solids injection module, gas injection module, pressure control and back pressure module, gas-liquid separator, and computer control terminal. All pipeline flanges, electrical interfaces, and sensors must be strictly sealed.

[0028] Step 2: Static Function and Basic Verification. Start the system under low-pressure water medium and send opening commands via computer terminal, such as valve opening of 0%, 25%, 50%, 75%, 100%, etc. Check whether the valve movement is smooth and whether the valve position feedback signal matches the actual position in real time; test local / remote control switching and emergency shutdown response to verify whether the valve quickly returns to its preset failure mode when power is off or signal is interrupted; record the total stroke time to confirm whether it meets the design specifications.

[0029] Step 3: Data traceability and report generation. The entire process is recorded via computer terminal, including parameters such as valve command location, actual opening degree, upstream and downstream pressure, medium flow rate, gas phase ratio, and solid concentration corresponding to the timestamp; dynamic curves are generated, such as pressure-opening response curves and flow control deviation distribution curves; and a test report is output.

[0030] Through the above steps, this utility model achieves basic static functional testing of electrically controlled throttle valves for pressure-controlled drilling.

[0031] The following specific examples illustrate the testing of an electrically controlled throttle valve (electrically controlled throttle valve) using a test system for pressure-controlled drilling based on this solution: Example 1: Testing of a choke valve under simulated drilling fluid conditions containing solid phases in a real drilling environment. Specifically, the following steps are included: Step 1: System Integration and Safety Preparation. Install the electric throttle valve in the simulated well control manifold and connect all systems. Ensure all pipeline flanges, electrical interfaces, and sensors are strictly sealed.

[0032] Step 2: Steady-state erosion durability test. A stepped concentration operating mode is used. For example, at a 4% concentration, the valve opening is maintained at 50%, the pump pressure at 15 MPa, and the cycle is repeated for 6 hours. Every 30 minutes, the following are recorded: pressure difference before and after the valve; fluctuations in the valve position feedback signal; and the sealing leakage rate. At an 8% concentration, the test is conducted for 12 hours under the same conditions. At a 12% concentration, the test is shortened to a 2-hour limit test, with cavitation noise monitored in real time. After each stage, erosion pits on the valve seat / valve core surface are inspected using an endoscope, and the deformation of the sealing surface contour is compared using a 3D scan.

[0033] Step 3: Dynamically adjust the anti-clogging test using a low-opening challenge, such as at an 8% solids content: the valve is closed in steps from 70% to 30%, such as 10% per step, pausing for 2 minutes, and then parameters such as the deviation between the opening command and the actual position, and the magnitude of pressure differential changes are monitored. Alternatively, a pulse-type adjustment method can be used: the valve is reciprocated 500 times at a frequency of 1Hz between 40% and 60% opening, and the number of lag cycles is recorded.

[0034] Step 4: Verify the flow control accuracy using a variable concentration constant flow test method. For example, maintain the flow rate at 3 m³ / min and gradually increase the solids content (4%→8%→12%), record the valve opening adaptive adjustment curve, and calculate the flow control error. Alternatively, a variable flow rate disturbance rejection test method can be used. For example, at a solids content of 8%, cause a step change in pump displacement, measure the valve response time, and analyze the flow overshoot.

[0035] Step 5: Data traceability and report generation. The entire process is recorded via computer terminal, including parameters such as valve command location, actual opening degree, upstream and downstream pressure, medium flow rate, gas phase ratio, and solid concentration corresponding to the timestamp; dynamic curves are generated, such as pressure-opening response curves and flow control deviation distribution curves; and a test report is output.

[0036] Example 2: Throttling valve test under simulated downhole gas intrusion conditions in a real drilling environment. Specifically, the following steps are included: Step 1: System Integration and Safety Preparation. Install the electric throttle valve in the simulated well control manifold and connect all systems. Ensure all pipeline flanges, electrical interfaces, and sensors are strictly sealed.

[0037] Step 2: Steady-state gas-containing regulation test, opening control under different flow states: Bubble flow, valve opening is increased from 20% to 80% in steps, and the flow fluctuation rate is recorded at each opening; Slug flow, the opening is maintained at 50%, and the valve stem is observed to see if high-frequency vibration is induced by bubble collapse; the flow meter reading deviation caused by the gas phase is measured; Slug flow, the valve oscillates at a frequency of 0.5Hz between 30% and 70% opening, and the position tracking accuracy under alternating liquid / gas plug impact is verified.

[0038] Step 3: Transient gas inrush response test, simulating well kick conditions, such as setting the initial state as GVF=15%, valve opening 60%, and downstream pressure 15MPa; then allowing the gas injection module to increase GVF to 35% within 3 seconds. Then monitor whether the valve automatically closes to 40% within 2 seconds; the time it takes for the downstream pressure to drop from the peak to 15±0.5MPa; and the critical liquid carrying rate when the gas phase passes through the throttle orifice, etc.

[0039] Step 4: Data traceability and report generation. The entire process is recorded via computer terminal, including parameters such as valve command location, actual opening degree, upstream and downstream pressure, medium flow rate, gas phase ratio, and solid concentration corresponding to the timestamp; dynamic curves are generated, such as pressure-opening response curves and flow control deviation distribution curves; and a test report is output.

[0040] Example 3: Throttling valve test under simulated dynamic pressure conditions Specifically, the following steps are included: Step 1: System Integration and Safety Preparation. Install the electric throttle valve in the simulated well control manifold and connect all systems. Ensure all pipeline flanges, electrical interfaces, and sensors are strictly sealed.

[0041] Step 2: Step pressure disturbance test. The gas injection unit rapidly increases the gas volume within 2 seconds, creating a sudden pressure surge upstream to simulate a sudden well kick. Valve dynamic response: The computer terminal immediately sends a pressure control command to maintain downstream pressure, triggering the valve to automatically adjust its opening.

[0042] Step 3: Slope pressure change test to simulate gradual pressure change: The downstream pressure is increased or decreased at a constant rate using the back pressure module. Valve tracking verification: A target pressure curve is set on the computer terminal, and the valve adjusts its opening in real time according to the PID algorithm; the deviation curve between the actual pressure and the target pressure is monitored, and the average tracking error throughout the process is calculated; it is observed whether the valve exhibits hysteresis due to changes in flow regime.

[0043] Step 4: Alternating load disturbance test to simulate pump interference: Flow fluctuations are created by periodically changing the displacement of a high-pressure pump. Valve anti-interference capability: The valve is required to maintain stable downstream pressure during sudden flow changes; the pressure fluctuation range is recorded, and the phase difference between the valve opening compensation action and the flow change is analyzed; repeated tests are conducted in a medium containing solid phases to verify the valve core's anti-erosion stability.

[0044] Step 5: Data traceability and report generation. The entire process is recorded via computer terminal, including parameters such as valve command location, actual opening degree, upstream and downstream pressure, medium flow rate, gas phase ratio, and solid concentration corresponding to the timestamp; dynamic curves are generated, such as pressure-opening response curves and flow control deviation distribution curves; and a test report is output.

[0045] For the foregoing embodiments, in order to simplify the description, they are all described as a series of actions. However, those skilled in the art should understand that this application is not limited to the described order of actions, because according to this application, some steps can be performed in other orders or simultaneously. Furthermore, those skilled in the art should also understand that the embodiments described in the specification are preferred embodiments, and the actions involved are not necessarily essential to this application.

[0046] The above embodiments describe the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Modifications and variations made by those skilled in the art without departing from the spirit and scope of this utility model should be protected within the scope of the appended claims.

Claims

1. A testing system for an electrically controlled throttle valve used in pressure-controlled drilling, characterized in that, The test includes a pressure control module (4) and a back pressure module (5) located at both ends of the throttle valve (6) under test. The left side of the pressure control module (4) is connected to the high pressure pump module (1). The right end of the high pressure pump module (1) is connected to the fluid circulation pipeline (9), and the upper end is connected to the solid injection module (2). A gas injection module (3) is also connected between the high pressure pump module (1) and the pressure control module (4). The other end of the gas injection module (3) and the fluid circulation pipeline (9) are connected to the gas-liquid separation device (8). The gas-liquid separation device (8) is finally connected to the other end of the back pressure module (5) to form a loop.

2. The testing system of claim 1, wherein, It also includes a control terminal (7) that connects the various modules of the system.

3. The test system of claim 1, wherein, The high-pressure pump module (1) includes a high-pressure pump (102) and a mud tank (101) that provides liquid supply as a source. The bottom of the mud tank (101) is also equipped with heating and cooling coils to control the fluid temperature.

4. The test system for an electrically controlled choke valve for managed pressure drilling as claimed in claim 1, wherein, The solid injection module (2) includes a solid addition device (201) and a solid concentration monitoring sensor (202) located at the rear end of the solid addition device (201). The solid addition device (201) also includes a storage bin, a feeder and a Venturi injector.

5. The testing system of claim 1, wherein, The gas injection module (3) includes a gas source (301), a gas booster (302), and a mass flow controller (303) that controls the gas flow rate and injection, connected in sequence.

6. The test system for an electrically controlled choke valve for managed pressure drilling of claim 1, wherein, The pressure control module (4) is located at the inlet end of the throttle valve (6) under test, and includes a pressure regulating valve (401), a pressure sensor (402) and a PID controller (403), which form a closed loop.

7. The testing system of claim 1, wherein, The back pressure module (5) is located at the outlet end of the throttle valve (6) under test, and includes a pressure sensor (501), a PID controller (503) and a back pressure valve (502). The pressure sensor (501), the PID controller (503) and the back pressure valve (502) form a closed loop.

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