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Original Paper | Open Access

Research on the solid particle erosion wear of pipe steel for hydraulic fracturing based on experiments and numerical simulations

Si-Qi Yanga,b, Jian-Chun Fanb(), Ming-Tao Liuc, De-Ning Lid, Jun-Liang Lie, Li-Hong Hana(), Jian-Jun Wanga, Shang-Yu Yanga, Si-Wei Daib, Lai-Bin Zhangb
State Key Laboratory of Oil and Gas Equipment, CNPC Tubular Goods Research Institute, Xi'an, 710077, Shaanxi, China
Key Laboratory of Oil and Gas Safety and Emergency Technology, China University of Petroleum, Beijing, 102249, China
Oil Production Technology Research Institute of Liaohe Oilfield Company, Panjin, 124010, Liaoning, China
Tianjin Gas Storage Branch, PetroChina Dagang Oilfield Company, Tianjin, 300280, China
Petroleum Production Engineering Research Institute, Daqing Oilfield Company, Daqing, 163712, Heilongjiang, China

Edited by Jie Hao and Meng-Jiao Zhou

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Abstract

Erosion wear is a common failure mode in the oil and gas industry. In the hydraulic fracturing, the fracturing pipes are not only in high-pressure working environment, but also suffer from the impact of the high-speed solid particles in the fracturing fluid. Beneath such complex conditions, the vulnerable components of the pipe system are prone to perforation or even burst accidents, which has become one of the most serious risks at the fracturing site. Unfortunately, it is not yet fully understood the erosion mechanism of pipe steel for hydraulic fracturing. Therefore, this article provides a detailed analysis of the erosion behavior of fracturing pipes under complex working conditions based on experiments and numerical simulations. Firstly, we conducted erosion experiments on AISI 4135 steel for fracturing pipes to investigate the erosion characteristics of the material. The effects of impact angle, flow velocity and applied stress on erosion wear were comprehensively considered. Then a particle impact dynamic model of erosion wear was developed based on the experimental parameters, and the evolution process of particle erosion under different impact angles, impact velocities and applied stress was analyzed. By combining the erosion characteristics, the micro-structure of the eroded area, and the micro-mechanics of erosion damage, the erosion mechanism of pipe steel under fracturing conditions was studied in detail for the first time. Under high-pressure operating conditions, it was demonstrated through experiments and numerical simulations that the size of the micro-defects in the eroded area increased as the applied stress increased, resulting in more severe erosion wear of fracturing pipes.

Keywords

Erosion wearApplied stressParticle impact dynamicsErosion mechanism

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Petroleum Science
Volume 21 Issue 4,
August 2024
Pages 2779-2792
DOI: 10.1016/j.petsci.2024.03.019
Cite this article:
Yang S-Q, Fan J-C, Liu M-T, et al. Research on the solid particle erosion wear of pipe steel for hydraulic fracturing based on experiments and numerical simulations. Petroleum Science, 2024, 21(4): 2779-2792. https://doi.org/10.1016/j.petsci.2024.03.019
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