PSI - Issue 80

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2022) 000 – 000

www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 80 (2026) 157–168

© 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Ferri Aliabadi Abstract Severe corrosion in the carbon steel tubing led to fluid leakage and reduced output in an ultra-deep gas well. Analysis using microscopy, XRD, and corrosion testing showed that while materials met API 5CT J55 standards, large-scale wall thinning reduced the tubing’s pressure tolerance below service conditions. Corrosion products included FeCO₃ and Fe₃O₄, with protective scalin g layers of CaCO₃ and crude oil residues. Once disrupted at depth-specific pH and hydrodynamic conditions, the corrosion of the tubing accelerated. Simulations of the localized corrosion rate showed peaks in the first 30 days due to high CO₂, low pH, and increased flow-induced shear stress. © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Professor Ferri Aliabadi Keywords: Oil and Gas, Carbon Steel, Downhole Tubing, Corrosion Inspection. Fracture, Damage and Structural Health Monitoring Experimental and Numerical Assessments of the Corrosion-Induced Failure of a J55 Tubing in an Ultra-Deep Gas Well G. Mubarak a , M. Elkhodbia b , I. Gadala c , I. Barsoum b,d , A. Alfantazi a,* a Department of Chemical Engineering, Khalifa University of Science and Technology, Abu Dhabi, 127788, United Arab Emirates b Department of Mechanical Engineering, School of Engineering, Khalifa University of Science and Technology, Abu Dhabi, 127788, United Arab Emirates c Center for Applied Research, NOVA Chemicals Corporation, 2928 16 St NE, Calgary, AB T2E 7K7, Canada d Department of Engineering Mechanics, Royal Institute of Technology – KTH, Teknikringen 8, Stockholm, 100 44, Sweden a b c d

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* Corresponding author. Tel.: +971 2 312 3471 E-mail address: akram.alfantazi@ku.ac.ae

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Professor Ferri Aliabadi

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of Ferri Aliabadi 10.1016/j.prostr.2026.02.015