Session: Regional Issues in Materials and Integrity in Oil and Gas
Analysis of corrosion failures in saltwater disposal system components due to degradation of internal coating (C2026-00322)
Wednesday, March 18, 2026
3:00 PM - 3:30 PM Central
Location: 371 DE
Earn .5 PDH
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Saltwater disposal systems are essential infrastructure in upstream oil and gas operations, but they are highly vulnerable to internal corrosion due to the aggressive corrosive and erosive properties of produced water. This paper presents a detailed metallurgical investigation of multiple component failures—including a perforated Tee and two spools—retrieved from a saltwater disposal system operated in West Texas. The study utilized a combination of visual inspection, metallography, XRD, SEM, and EDS analyses to determine the root causes of failure. The findings revealed that all failures originated from the internal surfaces of the components, specifically at weld joints and heat-affected zones (HAZ), where the internal epoxy lining was either compromised or absent. Corrosion products such as akaganeite, siderite, and magnetite were identified, indicating the presence of halide-rich environments, carbonic acid, and low-oxygen conditions. In several cases, the internal lining was found to be thin, nonuniform, or blistered due to poor surface preparation or post-manufacturing modifications, which facilitated underfilm corrosion. This paper discusses the mechanisms of corrosion observed, the role of internal lining integrity, and the metallurgical characteristics of the affected materials.
