Design and Optimization of Land-Based Test Scheme for Leakage Emergency Disposal Equipment of Deep-Sea Underwater Production Systems

To construct a land-based full-process simulation test platform for leakage detection and emergency disposal equipment of deep-sea underwater production systems and address the absence of a standardized test environment in the research and development of deep-sea equipment, the similarity criteria of Reynolds and Froude were utilized to design a land-based full-process simulation system encompassing underwater wellheads, Christmas trees, crossover pipes, central manifolds, production risers, transmission risers, and submarine pipelines. This system aims to enable functions such as submarine pipeline leakage detection, manifold leakage localization, sealing performance evaluation of plugging devices, and pressure resistance testing of flexible pipes. The system provided a high-pressure and high-speed flow rate test environment capable of effectively simulating equipment performance under extreme operating conditions. Additionally, numerical simulations of flow field erosion for key system components were conducted using Fluent. Research findings indicate that areas with abrupt changes in fluid flow direction and increased velocity gradients are prone to induce turbulent erosion, particularly at locations where the velocity changes abruptly, resulting in severe erosion. Based on these insights, a structural optimization design strategy was proposed, which significantly mitigated erosion risks. As the industry’s first land-based full-process simulation system for deep-sea underwater production systems, this system offers a standardized test environment for the verification of underwater emergency disposal equipment research and development. Its innovative architecture and testing methods will substantially enhance the efficiency of equipment development and the reliability of testing outcomes.