Fluid erosion characteristics of the metal valve in the inflow control devices

Under high-water cut conditions, the surface erosion behavior of metal valves in horizontal well inflow control devices (ICDs) is strongly influenced by fluid type and the flow field structure. Low-velocity erosion experiments are conducted on ICD metal valves under both oil and water conditions to quantify surface damage and erosion depth. Computational fluid dynamics-discrete phase model simulations were performed to analyze internal flow characteristics and particle-wall interactions under varying flow velocities, particle sizes, and pulsating conditions. Results show that water forms pronounced vortex recirculation zones downstream of the metal valves, leading to erosion rates approximately six times higher than in oil. Erosion rates increase with flow velocity and particle size, while the peak velocity dominates erosion severity in pulsating flows. Experimental and numerical analyses reveal that flow field structure, particle inertia, and fluid type govern surface damage. Comparative investigation of different valve materials under oil–water conditions provides quantitative insights into fluid–metal interactions and erosion mechanisms and offers a fundamental understanding of ICD valves' response in zonal water control environments.