Fluid energy pulse test system

• US 6,591,201 B1
• Filed: 09/25/2001
• Issued: 07/08/2003
• Est. Priority Date: 09/28/2000
• Status: Expired due to Term

• Current Assignee: Thomas Allen Hyde
• Original Assignee: Thomas Allen Hyde
• Inventors: Hyde, Thomas Allen
• Primary Examiner(s): Barlow, John
• Assistant Examiner(s): Walling, Meagan S.
• Application Number:
  US09/963,608
• Time in Patent Office: 651 Days
• Field of Search: 702/45, 702/46, 702/47, 702/50, 702/51, 700/281, 700/282, 700/301, 73/615.6, 73/530.1, 731/68
• US Class Current: 702/45
• CPC Class Codes: G01F 25/10 of flowmeters

Abstract

The Fluid Energy Pulse Test System [FEPTS] comprises apparatus and methods, using high-pressure, high-fluid-flow-rate or low-pressure-low-fluid-flow-rate energy pulses in tests to collect data for the evaluation of transient, ramp, steady state, or near steady state dynamic performance characteristics of fluid control devices and fluid systems. Positively increasing and negatively decreasing energy pulses can be generated independently or concurrently during a test. Effects of one or more energy pulses on the dynamic operation of a tested device or system are controlled by the selection of energy pulse variables, including pulse number, pulse type, pulse strength, pulse delay, pulse duration, pulse frequency, and pulse delivery (either an explosive delivery up to at least 243.84 meters per second, or a slow delivery at greater than zero meters per second). Fluid impulse, step, ramp, or frequency input functions, or combinations thereof, perturb the dynamic modes of operation of a fluid control device or fluid system under test. Test data are acquired in an open-, partly-open-, or closed-to-the-atmosphere environment. A test chamber (56) permits rapid insertion and removal of fluid control devices. Complete fluid systems can be tested. Measurement accuracy is met by precisely metered flow rates, short sampling intervals, and calibrated transducers. Graphs of transient, steady state, or near steady state fluid pressure, differential pressure, temperature, and flow rate data are computer-generated in real time. FEPTS tests can be performed by one person. The small, compact, and mobile apparatus can be placed at field sites. FEPTS tests use less than one percent of the energy required by current continuous-flow test technology.

Claims

1. A fluid pressure, fluid flow rate apparatus of predetermined size with means to test the dynamic performance of fluid control devices and fluid systems, including gas-lift valves, said apparatus having means to generate fluid pressure, fluid flow rate energy pulses with precise, reproducible physical characteristics, said apparatus having means to acquire opening and closing pressures of pressure-sensitive fluid control devices, such as gas-lift valves, and to acquire device upstream, downstream, and differential pressure, fluid temperature, and fluid flow rate data, said apparatus having means to generate, by computer, diagnostic presentations of said data suitable for evaluating performance characteristics, said apparatus to be placeable at manufacturing, rebuilding, and/or field locations such as off-shore oil platforms, to test the dynamic performance of individual fluid control devices, including gas-lift valves, after manufacture, before installation, after removal, before rebuilding, and/or after rebuilding, whereby said fluid control devices are used in industries, such as the petroleum industry, to produce hydrocarbons from underground reservoirs, and whereby said apparatus provides economic value to said industries by said testing and placement, said apparatus comprising:

(a) a high-pressure, high-fluid-flow-rate or low-pressure-low-fluid-flow rate source of energy;

(b) means to generate high-pressure, high-fluid-flow-rate or low-pressure, low-fluid flow rate energy pulses of predetermined number, predetermined strength, predetermined time delay, and predetermined duration;

(c) means to enclose a fluid control device in a pressure test chamber so that each said device, including a gas-lift valve, can be quickly installed, within thirty seconds, tested, and quickly removed from said chamber;

(d) means to seal and secure a fluid control device within a pressure test chamber, so that a first pressure-tight seal is created upstream or downstream and a second pressure-tight seal is created downstream or upstream by one or more spacers, a forcing member, and O-ring seals, whereby diverse fluid control devices can be installed in said test chamber with internal high pressure-tight fluid seals;

(e) means to connect a fluid system, comprising multiple fluid control devices and fluid sub-systems, in place of a fluid device test chamber, to high pressure upstream and downstream pipes;

(f) means to acquire data from pressure, differential pressure, temperature, and fluid flow rate transducers which measure dynamic performance characteristics of tested fluid control devices or fluid systems; and

,

(g) means to present acquired data in a format suitable for evaluating the dynamic performance of said fluid control devices and fluid systems, including gas-lift valves, under test.

2. The apparatus of claim 1 operated by a single individual.

3. The apparatus of claim 1 further comprising:

(a) a plurality of fluid reservoir tanks, including main fluid storage reservoir tanks, upstream fluid storage reservoir tanks, and downstream fluid storage reservoir tanks, wherein each multiple tank fluid storage reservoir is further segregated into a smaller plurality of fluid storage reservoir tanks connected by pipes and segregated by valves;

(b) means to fill fluid storage reservoir tanks with a fluid to a required pressure;

(c) means to transfer fluid from main storage reservoir tanks to upstream storage reservoir tanks at a first desired pressure and to transfer fluid to downstream storage reservoir tanks at a second desired pressure;

(d) a fluid device test chamber for a fluid control device or a fluid system connected by means between upstream fluid reservoir tanks and downstream fluid reservoir tanks;

(e) a plurality of electro-pneumatic control valves, electro-magnetic control valves, and motor controlled valve position set valves providing means to deliver fluid precisely from an upstream or downstream fluid reservoir to a fluid control device placed into a test chamber, or to a fluid system under test, or to exhaust fluid precisely from said test chamber or fluid system to an upstream or downstream fluid reservoir, which may be the atmosphere;

(f) means to regulate low pressure fluid power to operate electro-pneumatic control valves;

(g) means to connect electro-pneumatic and electro-magnetic fluid control valves and motor-controlled, valve positioning set valves to fluid reservoirs, and to a fluid control device test chamber or a fluid system;

(h) a plurality of pressure transducers, temperature transducers, differential pressure transducers, and flow rate transducers for producing a plurality of analog signals in response to pressure, temperature, differential pressure, and flow rate variations;

(i) a plurality of signal conditioning means to calibrate the plurality of analog signals;

(j) an analog to digital conversion means to receive analog signals from signal conditioning means and to convert analog signals into digital signals;

(k) a digital computer means to specify test criteria, including data file name, sampling rate, test duration, and input and exhaust energy functions; and

which computer means also to receive digital data signals, store said data signals, and prepare graphical representations of said data signals;

(l) a digital computer means to establish and initiate a test sequence to test a fluid control device or fluid system by providing control signal means to deliver fluid energy pulses from, or to receive fluid energy pulses into, a fluid reservoir precisely, and, further, by providing means to control precisely the opening and closing operations of electro-pneumatic control valves and electro-magnetic control valves, and, yet further, by providing means to position motor-controlled, valve positioning set valves precisely;

(m) means to shift control among computer programs, either automatically within a single computer, or by an electrical signal automatically sent from one digital computer to another, or by a an electrical signal manually sent from one computer to another, in order to enter test parameters, to receive digital data generated by transducers, and to initiate data acquisition;

(n) means to generate analog power signals from a low-power-output digital computer signal to said control valves and set valves, wherein said digital computer generates a low-power electrical signal which is converted into a high-power electrical signal to activate said control valves and set valves; and

,

(o) means to override digital computer controls of control valves and set valves with manually switched electrical signals for operating said control valves and set valves.

4. The apparatus of claim 3 wherein a pressure transducer is in fluid communication with main fluid storage reservoir, a pressure transducer is in fluid communication with upstream fluid storage reservoir, a pressure transducer is in fluid communication with downstream fluid storage reservoir, a pressure transducer is in fluid communication with upstream test chamber or fluid system, a pressure transducer is in fluid communication with downstream test chamber or fluid system, a differential pressure transducer is in fluid communication and connected across said test chamber or fluid system, a temperature transducer is in fluid communication upstream and a temperature transducer is in fluid communication downstream of said test chamber or fluid system, and a fluid flow rate transducer is in fluid communication upstream or downstream of said test chamber or fluid system.

5. The apparatus of claim 3 wherein a first control valve and set valve assembly is in fluid communication with an upstream reservoir and a downstream test chamber or fluid system, a second control valve and set valve assembly is in bypass fluid communication with said upstream reservoir and said downstream test chamber or fluid system, a third control valve and set valve assembly is in fluid communication with the upstream test chamber or fluid system and a downstream receiving reservoir, and a fourth control valve and set valve assembly is in bypass fluid communication with said upstream test chamber or fluid system and said downstream receiving reservoir.

6. The apparatus of claim 3 wherein a first control valve and set valve assembly is in fluid communication with upstream, of said assembly, and downstream, of said assembly, apparatus components and a second control valve and set valve assembly is in bypass fluid communication with said upstream and said downstream apparatus components, said first control and set valve assembly may generate slow flow velocity to create slow fluid velocity dynamic performance characteristics, while the said second control and set valve assembly may generate explosive or fast flow velocity to create fast velocity dynamic performance characteristics for a fluid control device within a test chamber or a fluid system, whereby said slow and fast velocities in air can be between zero and at least 243.84 meters per second (800 feet per second).

7. The apparatus of claim 3 wherein testing a fluid control device inside a test chamber or a fluid system is carried out by a predetermined procedure conducted manually, by digital computer automatic control, or by a combination of manual and digital computer automatic control such that the test period may be of predetermined length subject to stored capacity of fluid energy in apparatus reservoirs and whereby said testing is accompanied, and/or followed, by the generation of data that describe dynamic performance characteristics of fluid pressure, fluid differential pressure, fluid temperature, and fluid flow rate of a fluid control device within said test chamber or the dynamic performance characteristics of a fluid system.

8. The apparatus of claim 3 wherein a remote control means initiates a test and stops a test by controlling the apparatus start-up sequence of electrical power, selecting a testing sequence, and shutting down electrical power to the apparatus whereby said remote control provides safety to an operator of the apparatus when inherently dangerous predetermined high fluid pressures and high fluid flow rates are present.

9. The apparatus of claim 3 wherein control of fluid energy delivered to or exhausted from a fluid control device in a test chamber, or a fluid system, is accomplished precisely by a motor connected to a set valve stem which positions said set valve to a percentage openness in the range of zero percent to one hundred percent, in predetermined one-tenth of one-percent increments, and by a bang-bang action on the same set valve or another control valve to permit fluid flow, and whereby said precise control is needed in order to activate the dynamic modes of performance of said fluid control device or fluid system under test, and whereby said dynamic modes of performance may be dependent upon the design of a particular fluid control device or fluid system, and which dynamic performance characteristics may occur only for said particular fluid control device or fluid system, and only over a small range of a few percentage numbers of the position of a set valve.

10. The apparatus of claim 3 wherein a means to measure the position of a plurality of set valves in one-tenth of one-percent increments of openness of said set valves for fluid energy delivery upstream or downstream, and fluid energy exhaust upstream or downstream, of a fluid control device in a test chamber, or a fluid system, and which means to measure provides feedback of set valve positions to a test operator and to a second digital computer, whereby said operator or said computer can determine if an adequate response has been generated by the position of said set valves.

11. The apparatus of claim 3 wherein a test chamber in fluid communication with upstream fluid and downstream fluid, comprising an upper chamber body, an adjustable top screw cap with high pressure “

O”

ring seal, a lower chamber body, a bottom insert with a plurality of high pressure “

O”

ring seals, and a union between said upper chamber and said lower chamber with radial arms and high pressure “

O”

ring seal and which union is opened to accommodate a fluid control device and closed to secure a high pressure seal for said fluid control device by predetermined means with a plurality of “

O”

rings, and whereby said fluid control device can be installed and removed from said test chamber quickly and without disturbing other fluid connections, thereby providing the benefit of testing many high-pressure, high-fluid-flow-rate or low-pressure, low-fluid-flow-rate fluid control devices or fluid systems quickly and economically.

12. A method of testing and evaluating the dynamic performance of fluid control devices or fluid systems rapidly, the method comprising steps:

(a) selecting a device or system to be tested;

(b) selecting a pipe configuration to define an open-, partially-open-, or closed-to-the-atmosphere test condition to correspond to a predetermined test plan;

(c) connecting a fluid control device test chamber between upstream and downstream storage reservoirs or to the atmosphere, opening said chamber, inserting a fluid control device into said chamber, and closing said chamber, or connecting a fluid system between upstream and downstream storage reservoirs or to the atmosphere;

(d) setting test initial conditions, including upstream reservoir pressure, downstream reservoir pressure, upstream test chamber pressure, downstream test chamber pressure, and initial fluid flow rate;

(e) using a digital computer or processor to select data file name, test duration, digital sampling rate, and automatic or manual control;

(f) using a digital computer or processor to create a testing sequence for control valves and for positioning set valves, or to select a predetermined test sequence from a library of computer-stored test sequences, which include fluid energy pulse initiation, pulse delay, pulse duration, number of pulses, and pulse period, with pulse strength determined by reservoir pressure;

(g) selecting reservoir volumes to supply or receive fluid during testing, with said volumes determining how energy in the upstream and/or downstream reservoirs will increase, decrease, or remain constant, and/or how pressures in the upstream or downstream reservoirs will increase, decrease, or remain constant;

(h) connecting pipes to configure fluid pathways for the open-, partly- open-, or closed-to-the-atmosphere test conditions; and

,

(i) starting a test;

observing the dynamic responses of pressure, differential pressure, temperature, and flow rate; and

generating graphical presentations of these data.

13. The method of claim 12, including selecting a test duration for a predetermined time for a single energy pulse or for multiple energy pulses, said pulse(s) lasting from milliseconds to minutes depending upon upstream reservoir capacity, and said pulse strength precisely controlled and propagated within an apparatus with explosive force and fast- flow velocity in milliseconds, or said pulses precisely controlled and propagated within an apparatus with minute force in milliseconds or minutes, in fluid slow motion, to generate and evaluate tested fluid control device or fluid control system slow velocity or fast velocity dynamic performance characteristics, whereby said slow and fast velocities in air can be between zero and at least 243.84 meters per second (800 feet per second).

14. The method of claim 12, including specifying the delivery of fluid energy to a fluid control device within a fluid test chamber or to a fluid system, which delivery is characterized as an impulse function of energy, a step function of energy, a ramp function of energy, or a frequency function of energy depending upon how an input fluid flow delivery scheme is designed.

15. The method of claim 12, including retesting a fluid control device within a test chamber, or a fluid system, using precisely the same initial conditions, test set-up configuration, and means to acquire dynamic performance test data.

16. The method of claim 12, including using a digital computer to store records of prior tests conducted on similarly manufactured fluid control devices and systems and for comparing test data, conducted by precisely the same testing method, on the dynamic characteristics of said devices and systems to determine if said devices and systems are performing as expected by the user.

17. The method of claim 12, including using digital data acquired by a digital computer in real time to identify in real time test events, such as peak pressure events, substantial increase or decrease in pressure events from a set pressure initiation of differential pressure events, reduction to 101.3 kPa (0.0 psig) of differential pressure events, initiation of fluid flow events, and cessation of fluid flow events;

and to obtain raw tabular data and graphical data of such test events without requiring a complete set of test data to be generated.

18. The method of claim 12, including digital computer computation of power and energy supplied to a fluid control device or fluid system over a test period, and power and energy subsequently delivered by said device or system over a test period, whereby said power and energy data demonstrate performance efficiency of said device or system, when subjected to different input energy pulse functions that are based upon fluid flow rate and fluid pressure.

19. The method of claim 12, including digital computer-generated graphical presentations of fluid pressure, fluid temperature, and fluid flow rate data for a fluid control device tested in a test chamber, or a tested fluid system, which graphs include presentations with time abscissa of open-, partly-open-, or closed-to-the-atmosphere pressure and flow rate, and parametric presentations, in which time is implicit, of pressures and of flow rate.

20. The method of claim 12, including acquiring high-pressure, high-fluid-flow-rate or low-pressure, low-fluid-flow-rate data by energy pulses using a small compressor or bottles of fluid, without requiring a large high pressure compressor or a large fluid storage reservoir for determining the dynamic performance of fluid control devices or fluid systems, and which method is portable from one apparatus to another, comprising the further steps of:

(a) performing multiple tests on a single fluid control device or fluid system;

(b) completing tests of a single fluid control device or fluid system within seconds as compared to the use of large compressors, large storage reservoirs, and complicated, time-consuming test procedures that require large facilities and large economic investment, and which, because of economic factors, prohibit the testing of many high-pressure, high-fluid-flow-rate or low-pressure, low-fluid-flow-rate fluid control devicesor fluid systems;

(c) evaluating test results derived from an open-to-the-atmosphere test system, a partly-open-to-the-atmosphere test system, or a closed-to-the-atmosphere test system, as applicable for a particular test; and

,

(d) determining, by comparing dynamic performance test data, if a tested fluid control device or fluid system is performing according to manufacturer'"'"'s specifications, is failing due to deterioration of said device or system components, or is performing satisfactorily by the standards of a given user of said device or system, whereby performance characteristics of tested fluid control devices or fluid systems will be known and said devices or systems can be accepted or rejected with confidence.