Corrosion Investigation of Downhole Tools in Offshore Heavy Oil Injection-production Wells

YU Xiaotao; FENG Jiaqi; LIU Zhilong; XIN Ye; SUN Jun; WU Ting

doi:10.7643/ issn.1672-9242.2026.05.017

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Equipment Environmental Engineering ›› 2026, Vol. 23 ›› Issue (5) : 148-155. DOI: 10.7643/ issn.1672-9242.2026.05.017

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Corrosion Investigation of Downhole Tools in Offshore Heavy Oil Injection-production Wells

YU Xiaotao¹, FENG Jiaqi², LIU Zhilong¹, XIN Ye¹, SUN Jun¹, WU Ting¹

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Abstract

The work aims to investigate the corrosion failure mechanisms of downhole tool steel 42CrMo and nickel-based alloy hydraulic control pipelines under heavy oil thermal recovery conditions, to propose corresponding corrosion prevention measures. The corrosion behavior of 42CrMo steel and nickel-based alloy hydraulic control pipelines in a heavy oil thermal recovery environment was analyzed with characterization techniques such as XRD and SEM-EDS. Simulation validation experiments were conducted through surface modification methods, including nitriding and coating. The strong oxidizing nature of O₂, combined with the cathodic oxygen reduction reaction, accelerated the dissolution of 42CrMo. A porous and poorly adherent FeOOH layer formed on the surface provided insufficient protection and inhibited the formation of a compact and protective FeCO₃ film, which consequently elevates the corrosion susceptibility of the substrate. Non-uniform iron-oxide coverage promoted the formation of occluded corrosion cells, followed by autocatalytic acidification which accelerated localized corrosion. Nitriding treatment significantly reduced the corrosion rate of 42CrMo. For nickel-based alloy hydraulic control lines, the Cr₂O₃ passive film was initially compromised under high temperature and corrosive media (O₂+H₂S) at scaled locations. Stress corrosion micro-cracks subsequently nucleated at stress-concentration zones under tensile loading. These cracks propagated via fatigue under the combined action of cyclic thermal and vibrational stresses, ultimately led to brittle fracture. To enhance the corrosion resistance of downhole tools in heavy oil thermal recovery operations, it is recommended to further investigate electroplating or coating surface protection technologies for 42CrMo steel. For nickel-based alloy hydraulic control pipelines, it is recommended to delay corrosion cracking by applying nano-coatings.

Key words

heavy oil injection-production well / 42CrMo / downhole tool / hydraulic control line / O₂-CO₂ synergistic effect / stress corrosion / fatigue propagation

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YU Xiaotao, FENG Jiaqi, LIU Zhilong, XIN Ye, SUN Jun, WU Ting. Corrosion Investigation of Downhole Tools in Offshore Heavy Oil Injection-production Wells[J]. Equipment Environmental Engineering. 2026, 23(5): 148-155 https://doi.org/10.7643/ issn.1672-9242.2026.05.017

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