Performance Influencing Factors and Research Progress of Packer Rubber under HPHT and Corrosive Downhole Conditions

Abstract The packer is an indispensable sealing tool in oil and gas well completion and intervention operations; its sealing performance directly affects downhole safety and efficient hydrocarbon production. As the core sealing component of the packer, the packer rubber must maintain stable performance in extreme downhole environments characterized by high temperature, high pressure, strong corrosion, and long service life. This paper systematically reviews, from the perspectives of material properties, aging behavior, stress relaxation, corrosion effects, and structural design, the key factors affecting packer rubber sealing performance. It also analyzes recent domestic and international advances in the design and development of high-performance packer rubbers. Studies show that high-performance elastomers such as AFLAS and FKM exhibit superior mechanical strength and chemical stability in high-temperature, high-corrosion environments compared to conventional HNBR. During service, however, rubber materials tend to undergo stress relaxation, causing a significant drop in contact stress and a concomitant decline in sealing performance. Furthermore, downhole fluid corrosion leads to rubber embrittlement and strength degradation, which in turn can trigger seal failure. On the structural side, optimizing compression ratios, controlling interface friction, and introducing anti-“shoulder extrusion” features all effectively enhance sealing reliability. Under multiphysics coupling, numerical simulations combined with experimental validation are currently the prime means of improving service-life prediction accuracy and design optimization efficiency. In summary, improving packer rubber performance requires coordinated optimization of material selection, structural compatibility, and mechanical behavior control. The findings in this review provide important guidance for designing packer sealing elements under complex well conditions and offer key technical support for intelligent completions and green, efficient oilfield development. Keywords: packer rubber; high temperature and high pressure; sealing performance; stress relaxation; corrosive environment; elastomer materials; structural optimization; multiphysics coupling