Research Progress on Failure Mechanisms and Protection Technologies for Wellhead Valves in Ultra-High-Pressure Gas Wells

ZHANG Laibin; WU Shengnan; LIAO Haowen; ZHANG Xuliang

doi:10.27022/j.issn2097-7697.2026.01.002

Journal of Special Equipment ›› 2026, Vol. 1 ›› Issue (1) : 9-21. DOI: 10.27022/j.issn2097-7697.2026.01.002

Research Progress on Failure Mechanisms and Protection Technologies for Wellhead Valves in Ultra-High-Pressure Gas Wells

ZHANG Laibin^1,2,3, WU Shengnan^1,2,3, LIAO Haowen^1,2,3, ZHANG Xuliang^1,2,3,4

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Abstract

The accelerated development of deep and ultra-deep gas reservoirs characterized by high temperature, high pressure, high sulfur content, and sand production has exposed gas production wellhead valves to extreme service conditions, including large pressure-drop throttling, severe erosion, and multi-medium coupled corrosion. Under such environments, valve operational reliability has become a critical factor constraining safe, stable, and efficient gas field production. Focusing on typical operating conditions of ultra-high-pressure gas wells, this paper systematically summarizes the dominant failure modes and damage evolution characteristics of wellhead valves, with particular emphasis on the mechanisms of flow-path erosion, cavitation erosion, corrosion fatigue, and their coupled interactions. On this basis, recent research progress in structural optimization design, erosion- and corrosion-resistant materials and surface enhancement technologies, as well as online condition monitoring and inspection methods for ultra-high-pressure wellhead valves is comprehensively reviewed. In light of the increasing demand for equipment reliability in deep gas reservoir development, future technological trends are identified as follows: (i) long-life-oriented design targeting extreme service conditions, with breakthroughs in high-performance materials and surface strengthening technologies; (ii) a transition from performance improvement of individual valves to coordinated, modular, and integrated design of valve-manifold systems; and (iii) the development of intelligent operation and maintenance frameworks based on big data and digital twin technologies to enable state perception, damage evolution analysis, and life prediction, thereby shifting maintenance strategies from reactive to predictive and intelligent modes. The findings provide technical support for the localization and high-end development of wellhead equipment, as well as for ensuring intrinsic safety and high-efficiency exploitation of deep gas fields.

Key words

Ultra-high-pressure gas wells / Wellhead valves / Extreme service conditions / Structural optimization / Condition monitoring and maintenance

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ZHANG Laibin, WU Shengnan, LIAO Haowen, ZHANG Xuliang. Research Progress on Failure Mechanisms and Protection Technologies for Wellhead Valves in Ultra-High-Pressure Gas Wells[J]. Journal of Special Equipment, 2026, 1(1): 9-21. https://doi.org/10.27022/j.issn2097-7697.2026.01.002

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