Research on erosion wear law of four-way flow channel of wellhead fracturing in ultra-deep wells

Abstract

This paper establishes a 1/2 three-dimensional finite element model that considers multiple factors affecting the erosion rate of the four-way fracturing structure on site. The model can simulate the effects of different inlet velocities, dynamic viscosities, outlet quantities, outlet pressures, and channel wall angles on the velocity and streamline distribution of the four-way channel. It is also possible to analyze the effects of different factors such as inlet velocity, sand carrying mass flow rate, inlet quantity, fluid dynamic viscosity, fracturing fluid particle density, fracturing fluid particle diameter, four-way wall hardness, and channel wall inclination angle on the erosion of the inner wall. Through the established model calculation, it was found that as the inlet flow velocity increases, the maximum flow velocity in the channel also increases, and the value is close to 1.8 times the inlet velocity, with the maximum value appearing at the inlet corner. When the inlet velocity of the four-way valve is low, a significant vortex-like flow field appears in the closed flow channel of the four-way valve, which will lead to the accumulation of particles in the fracturing fluid. The calculation shows that the number and velocity of sand containing fracturing fluid inlets have the greatest impact on the erosion rate of the four-way flow channel, and the optimal inclination angle of the flow channel is 9 degrees. Increasing the hardness of the four-way wall can improve the maximum erosion rate of the flow channel wall, but changing the sand particle density and diameter has little significance in reducing the erosion rate of the four-way flow channel. It is recommended to perform corresponding heat treatment on the inner wall of the four-way valve to reduce the impact of sand containing fracturing fluid on wall erosion. This article provides a theoretical basis and guidance for controlling or avoiding erosion and thinning failure of four-way valves and also provides a theoretical basis for the design of wellhead four-way valves and various safe construction operations.