Corrosion Failure Analysis of Downhole Pump Components After Short Service in Oil Production

• Published in: Journal of failure analysis and prevention 2024-02, Vol.24 (1), p.116-127
• Main Authors: El-Fattah, Hanan Abd, Khalifa, Waleed
• Format: Article
• Language: English
• Subjects: Carbon steel; Carbon steels; Corrosion; Corrosion products; Failure analysis; Ferric chloride; Housing; Iron carbonate; Mechanical analysis; Optical microscopes; Petroleum industry; Pitting (corrosion); Pumps; Seawater; Stainless steels
• ISSN: 1547-7029; 1864-1245
• DOI: 10.1007/s11668-023-01812-7

Submersed downhole pump systems used in oil industry field are working and subjected to attacker environment. Rich aquas, chloride, and sulfide environments present a tough chemical condition. This work investigated a failure case study of two submersed downhole pumps that were worked in sea water in oil industry. Pump 1 and pump 2 failed after 196 and 60 days, respectively. Every pump had head and hosing made from carbon steel and compression ring made from stainless steel. Compression ring was not affected by corrosion, but head and housing were. Investigations were made for carbon steel head and housing by mechanical analysis, visual examination, optical microscope, and scanning electron microscope (SEM) for imaging and EDS. Results show a corrosion for the whole surface of two pumps and pitting corrosion in many positions. Many corrosion products are formed such as FeCO3, Fe2O3, and FeCl3. The corrosive products were the main reason for failure which formed due to working conditions and environment.