The Mechanism of Casing Perforation Erosion Under Fracturing-Fluid Flow: An FSI and Strength Criteria Study
Abstract
1. Introduction
2. Methodology
2.1. Governing Equation of Fluid
2.2. Discrete-Phase Transport Model
2.3. Erosion Model
2.4. Governing Equation of Solid
2.5. Fluid–Structure Interaction (FSI) Coupled Governing Equations
3. Fluid–Structure Coupling Numerical Model
3.1. Numerical Model
3.2. Verification
4. Results
4.1. Flow Field Characteristics in the Perforated Section
4.2. Erosion of the Perforation Hole
4.3. Von Mises Stress Analysis of the Casing
4.4. The Maximum Principal Stress and Shear Stress of the Casing
5. Conclusions
- (1)
- During fracturing, the flow cross-section suddenly shrinks at the entrance of the perforation hole, which contributes to an increase in the fracturing fluid’s velocity up to 323.0 m/s at the hole entrance. This acceleration causes the most severe erosion, with a maximum erosion rate of 2.26 × 10−5 kg/(m2·s). The numerical simulation results are consistent with field fracturing tests, showing wall thinning and diameter enlargement at the perforation entrance.
- (2)
- The von Mises stress around the perforation hole is symmetrically distributed along the hole axis. The maximum von Mises stress occurs at the 90° and 270° positions on the inner wall, reaching nearly 750 MPa, which remains below the material yield strength. However, the maximum shear stress reaches 325.18 MPa, exceeding the allowable shear stress of 265.74 MPa (considering a safety factor of 1.25), indicating that shear failure is the primary mechanism initiating erosion damage at the perforation.
- (3)
- Under the impact of fracturing fluid, the casing experiences deformations of 0.11 mm (x-direction), 0.078 mm (y-direction), and 0.38 mm (z-direction), with a total maximum deformation of 0.39 mm. The contact pressure at the first and second interfaces decreases significantly in perforated regions (e.g., from nearly 15 MPa in non-perforated areas to <5 MPa near perforations), indicating a reduction in cement bonding capacity and a potential risk to casing integrity.
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Abbreviations
CFD | Computational Fluid Dynamics |
DPM | Discrete Phase Model |
DDPM | Dense Discrete Phase Model |
FSI | Fluid–Structure Interaction |
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Type | Density (kg/m3) | Elastic Modulus (GPa) | Poisson’s Ratio | Yield Strength (MPa) | Tensile Strength (MPa) | Shear Strength (MPa) |
---|---|---|---|---|---|---|
Casing | 7800 | 210 | 0.30 | 862.00 | 1050.00 | 332.17 |
Cement | 1900 | 5.00 | 0.11 | 45.00 | 4.89 | -- |
Formation | 1800 | 5.20 | 0.22 | -- | -- | -- |
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© 2025 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
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Zhang, H.; Wang, C. The Mechanism of Casing Perforation Erosion Under Fracturing-Fluid Flow: An FSI and Strength Criteria Study. Modelling 2025, 6, 121. https://doi.org/10.3390/modelling6040121
Zhang H, Wang C. The Mechanism of Casing Perforation Erosion Under Fracturing-Fluid Flow: An FSI and Strength Criteria Study. Modelling. 2025; 6(4):121. https://doi.org/10.3390/modelling6040121
Chicago/Turabian StyleZhang, Hui, and Chengwen Wang. 2025. "The Mechanism of Casing Perforation Erosion Under Fracturing-Fluid Flow: An FSI and Strength Criteria Study" Modelling 6, no. 4: 121. https://doi.org/10.3390/modelling6040121
APA StyleZhang, H., & Wang, C. (2025). The Mechanism of Casing Perforation Erosion Under Fracturing-Fluid Flow: An FSI and Strength Criteria Study. Modelling, 6(4), 121. https://doi.org/10.3390/modelling6040121