Open Access

ARTICLE

Evaluation of Tubing Integrity with Rectangular Corrosion under Thermo-Chemical-Mechanical Coupling

Yi Huang^1,*, Ming Luo¹, Zhujun Li¹, Donglei Jiang¹, Ping Xiao¹, Mingyuan Yao², Jia He²

1 CNOOC Co., Ltd. Hainan Branch, Hainan, 570100, China
2 State Key Laboratory of Oil and Gas Reservoir Geology and Exploitation, Southwest Petroleum University, Chengdu, 610500, China

* Corresponding Author: Yi Huang. Email:

(This article belongs to the Special Issue: Fluid and Thermal Dynamics in the Development of Unconventional Resources III)

Fluid Dynamics & Materials Processing 2025, 21(8), 1839-1860. https://doi.org/10.32604/fdmp.2025.065459

Received 13 March 2025; Accepted 21 June 2025; Issue published 12 September 2025

Abstract

This study presents a comprehensive mechanical analysis of P110S oil tubing subjected to thermal and chemical coupling effects, with particular attention to the presence of rectangular corrosion defects. Drawing on the material’s stress–strain constitutive behavior, thermal expansion coefficient, thermal conductivity, and electrochemical test data, the research incorporates geometric nonlinearities arising from large deformations induced by corrosion. A detailed three-dimensional finite element (FE) model of the corroded P110S tubing is developed to simulate its response under complex loading conditions. The proposed model is rigorously validated through full-scale burst experiments and analytical calculations based on theoretical formulations. Building upon this validation, the Extended Finite Element Method (XFEM) and a failure criterion grounded in damage evolution mechanics are applied to investigate the mechanical behavior of the tubing under the coupled influences of temperature, stress, and chemical corrosion. Special emphasis is placed on the role of rectangular corrosion features in determining failure mechanisms. To further elucidate the impact of multiple interacting parameters, a sensitivity analysis is performed by integrating grey correlation theory with simulation outcomes. Based on these findings, the study systematically explores the elastic–plastic deformation process, crack initiation and propagation behavior, and the burst failure response of tubing specimens with varying axial lengths and depths of corrosion. The proposed methodology provides a robust predictive framework for petroleum engineers to evaluate fracture pressure, diagnose failure modes, assess operational risks, and optimize production strategies.

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Keywords

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