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• The hybrid model has a multiphase flow mechanism and a machine learning model. • The model calculates multiphase transport boundaries to ensure pipeline safety. • The Maximum transportable Gas-Oil Ratio is a boundary under different conditions. • Multiphase transport boundaries cover the entire lifecycle of oilfields. • The average relative error of the hybrid model is less than 4.7%. Developing a safe Multiphase Transport Boundary (MTB) is crucial due to the complex flow and heat transfer laws of multiphase transportation of fluids in pipelines. However, there is no efficient, accurate, and widely adaptable method for MTB formulation. This paper proposes a hybrid method based on traditional multiphase flow mechanisms and machine learning models to determine the safe operational MTB for multiphase pipeline transportation processes. The interactive logic enables the efficient and accurate calculation of MTB under real-time measurement data-driven for the proposed new hybrid model. Using a northwest oil field in China as an example, the results indicate that the hybrid model has an average relative error of less than 4.7% compared with simulated data, showing high accuracy. The calculation of a million operating conditions only takes 232 s. The research results can guide promoting the design, operation, and modification of pipeline transportation systems to ensure safety. [ABSTRACT FROM AUTHOR]

• A three-dimensional unsteady state mathematical model of the multi-field coupling of backfill body, tube and fracture was established. • A test bench was designed and built to verify the three-dimensional coupling model. • The effects of a single fracture position, aperture and fractured depth on the heat extraction performance of a full-size BFHEs unit in the fully dry or fully saturated conditions were investigated. • The combined effects of multiple fractures on the performance of a BFHES unit were discussed. Thermal hazards in deep mines can be mined synergistically with the deposit as associated geothermal energy resources. Backfill heat exchangers (BFHEs) as a combination of mine backfilling and ground heat exchanger technology are one of the effective methods to realize ore deposit-geothermal energy synergy mining. However, in the complex environment of deep mines, BFHEs will inevitably suffer from fracture damage during long-term heat storage/release cycle operation, which will affect their working performance. To address this problem, this paper established a scaled-down experimental setup for fractured BFHEs units, and used the experimental data to verify the accuracy of the established three-dimensional transient heat transfer mathematical model of the BFHEs unit. Numerical simulation methods were used to investigate the effects of the position, aperture and fractured depth of a single fracture on the heat extraction performance of the BFHEs unit under fully dry or fully saturated working conditions. Significant differences were found in the effect of different fracture positions on the heat extraction capacity of the BFHEs unit. The extraction of geothermal heat by the BFHEs unit was favored when it was in the middle of two tubes, while the opposite was true for other positions. The effect of fracture on the heat extraction capacity of the BFHEs unit increased linearly with fracture aperture. The effect of the fractured depth was relatively greater in the 1/2–3/4 H b range. The presence of groundwater significantly reduced the effect of the fracture. The effect of the fracture on the heat extraction capacity of the BFHEs unit was reduced by more than 80 % by changing the operating conditions from fully dry to fully saturated condition. The overall effect of a fracture on the heat extraction capacity of the BFHEs unit was not significant, with a 5 mm wide fracture having an effect of no more than 2.5 %, even under the fully dry condition. However, there was a combined effect of multiple fractures, and for a deposit size of 900 × 7 × 80 m, ten 2 mm apertures fractures would results in a maximum reduction of geothermal extraction from BFHEs by 8527 GJ in 10 years, which was equivalent to the heat load of a 13,753 m2 building for one winter in the cold climate of China. [ABSTRACT FROM AUTHOR]