During the production of deep oil and gas, scaling, waxing, hydrate ice plugging and other problems easily occur. To solve these problems, reducing the temperature loss of oil pipelines is a feasible method. In order to protect the outer wall coating from being damaged and losing its thermal insulation performance, this paper proposes a developed technology for a novel inner wall coating-insulated oil pipeline. A new temperature-resistant and heat-insulating material aerogel was optimized and developed, and it has an extremely low thermal conductivity of less than 0.055 W/m·K. The influence of different coating processes on the thermal insulation coefficient was analyzed, and a novel inner wall coating-insulated oil pipeline was developed. A testing and evaluation platform for its thermal insulation effect was built, and a finite element model was established to analyze the temperature field distribution. When the thickness of the inner coating was 0.5 mm, the thermal insulation effect of the new oil pipeline improved by about 29%. This technology could be widely used in the production of deep oil and gas, high salinity oil and water reservoirs, thin oil reservoirs, etc., to alleviate scaling and waxing phenomena.

With the escalating intricacy of downhole operational scenarios, encompassing frequent well cycling, acidification, multi-stage fracturing, steam injection, and intensive extraction, the efficacy of traditional casing-string-design methods rooted in strength considerations is progressively unveiling its limitations. Henceforth, it becomes imperative to establish string-design method standards that embrace the entirety of a well’s lifecycle, encompassing the phases of drilling, completion, fracturing, and production operations. Beginning with an analysis of the advantages and limitations of traditional casing-string-design methods, this paper introduces the features of strain and sealing design methods developed for the full lifecycle of the string. The strain design method, a departure from conventional design philosophies, enables the design concept of the controllable deformation of the pipe string. The sealing design method currently stands as the sole standard method for the design of tubing strings. Simultaneously, this paper proposes the establishment of a time dimension-based lifecycle pipe string-design method standard. This approach considers the trend of pipe strength degradation, effectively addressing the safety concerns related to pipe string design in production and operation.

During the process of natural gas development, sustained casing pressure (SCP) frequently occurs within the annulus of the gas wells; we specifically referred to the “A” annular space located between the tubing and the production casing in this paper. SCP in an annulus poses a paramount safety challenge, universally acknowledged as a significant threat to gas field development and production, jeopardizing well integrity, personnel safety, and environmental protection. There are multiple factors that contribute to this issue. Due to the multitude of factors contributing to SCP in an annulus and the unclear mechanisms underlying the pressure buildup in wells, an early assessment of downhole leakage risks remains challenging. Hence, this study focused on a comprehensive analysis of the SCP in the annulus of gas wells. A detailed experimental study on the pressure buildup in an annulus due to tubing leakage below the liquid level was conducted, and the variation patterns of the annulus pressure under various leakage conditions were explored. The findings indicated that the equilibrium attainment time of annulus pressure at the wellhead subsequent to tubing leakage decreases with the increase in the pressure difference between the tubing and the casing, the liquid level height, the leakage orifice diameter, and the quantity, while it increases with the increase in the leakage position and gas temperature. According to the theory of gas fluid dynamics, a predictive model of the annulus pressure buildup with sustained gas leakage below the liquid level was proposed, which was well-validated against experimental results, achieving a model accuracy of over 95%. This study provided a theoretical framework for diagnosing SCP in the annulus of gas wells and developing mitigation strategies, thereby contributing to the advancement of the research field and ensuring the safety of industrial operations.

In the increasingly complex environment of downhole working conditions such as frequent opening and closing of oil and gas wells, acidification/multi-stage fracturing, steam huff and puff, and strong injection and production, the traditional casing string design method standards based on strength design have gradually highlighted their limitations. It is necessary to formulate string design method standards that consider the full life cycle of wells such as drilling and completion, fracturing, and production operations. Starting from the analysis of the advantages and disadvantages of traditional casing string design methods, this paper presents the characteristics of the strain design methods and seal design methods that have been formulated for the life cycle of the string. The strain design method breaks through the traditional design concept and allows the design concept of controllable deformation of the pipe string. The sealing design method is currently the only standard method for the design of tubing strings. At the same time, it further proposes to consider the trend of pipe strength deterioration and establish a time dimension-based life cycle pipe string design method standard, which effectively solves the safety problem of pipe string design in production and operation.

In this work, the microstructure, alloying element distribution, and borocarbide mechanical properties of high-boron multi-component alloy with Fe-2.0 wt.%B-0.4 wt.%C-6.0 wt.%Cr-x wt.%Mo-1.0%Al-1.0 wt.%Si-1.0 wt.%V-0.5 wt.%Mn (x = 0.0, 2.0, 4.0, 6.0, 8.0) are investigated. The theoretical calculation results and experiments indicate that the microstructure of high-boron multi-component alloy consists of ferrite, pearlite as a matrix and borocarbide as a hard phase. As a creative consideration, through the use of first-principles calculations, the comprehensive properties of borocarbide with different molybdenum concentrations have been predicted. The calculations of energy, state density, electron density and elastic constant of Fe₂B crystal cell reveal that substitution of the molybdenum atom in the Fe₂B crystal cell can remarkably improve its thermodynamic stability, bond strength, and covalent trend. For verifying the accuracy of this theoretical calculation, nano-indentation testing is carried out, the results of which indicate that the actual properties of borocarbide present favorable consistency with the theoretical calculations.

During the formation testing in high-temperature (HT) and ultra-high-pressure (UHP) wells, one of the major challenges is packer failure in the downhole caused by high-rate fracturing. In such a case, the axial shrinkage trend of the tubing string could be caused by the sudden drop in temperature, but the actual axial length of the tubing string would not change because of the constraints at wellhead and packer. Therefore, this could lead to the upward pull-out of the packer that is due to excessive load from the tubing string. This out-of-control downhole pressure often leads to irreversible consequences, even well abandonment. An expansion joint, as a movable splicer, has the characteristic of mitigating packer load, which can theoretically enhance packer safety. To study the protective effect of an expansion joint on the packer quantitatively, the microscopic characteristics and macroscopic properties of the tubing material (13Cr110) are obtained through experimental tests. Moreover, the mechanical properties of the material at different temperatures are also tested. Then, the testing results are extended to modeling the finite element model (FEM) of the whole section of tubing string with the expansion joint—casing and simulating its internal force changes under fracturing conditions with different injection rates. Our simulation results indicated that an expansion joint can significantly change the distribution of the internal forces in the tubing string, and this change can effectively reduce the load on the packer. Eventually, a tubing string buckling identification plate that considers the injection rate and expansion joint–packer length is obtained to optimize the placement of an expansion joint in the tubing string. Our work can provide a detailed theoretical reference and basis for an expansion joint in field application.