Diagnostic, Predication and Control of MIC in the Oil and Gas Industry

ICorr Aberdeen April 16 2013 Torben Lund Skovhus, PhD Team Leader DTI Oil & Gas Life Science Danish Technological Institute Contacts: tls@dti.dk / +45 72 20 18 27

Visitor…

Torben Lund Skovhus Team Leader, Ph.D.

Operations Support

Oilfield Microbiologist

Consultant & Advisor

Agenda

What is new under the sun?

Drivers for looking at MIC in a more scientific way

MMM in brief – molecular biology in a few minutes

Sample types, sampling kits and how to handle samples for

MMM analysis

Linking MIC monitoring based on MMM with the RBI program

Control of MIC in oilfield systems – Testing Biocides

Q&A‟s

MIC: What is new under the sun?

1) Now microbes can be truly quantified in solid

samples (e.g. corrosion products, biofilm, debris)

2) Now the activity of microbes that influence

corrosion but are non-culturable can be determined

3) Now we can establish a true link between

microbial abundance of key organisms and

corrosion

This technology jump gives us a unique tool for

MIC prediction and for optimizing control strategies

Strength of Analytic Platform

MPN Method

MMM based

based technology

(e.g. qPCR)

To

tal

cell

s

Meth

an

og

en

s

SR

A

SR

B

No correlation to MIC Risk

Good correlation to MIC Risk

Should be part of RBI programs!

Solid

Sample

Maturing assets means increased water

production:

Scale and microbial fouling

Souring

Corrosion - 20-50 % microbially related

Consequense to operators:

• Lost production

• Lower oil price (sulfur)

• Increased expenses to biocides,

scavengers, inhibitors, maintenance

• Satefy issues: Risk to personnel

DK: 45 mill. m3/yr

DRIVERS: THE WATER CHALLENGE

Fast (mm/yr)

Black box compared to traditional corrosion

Hard to diagnose (until now…)

Recent, publicly known cases:

Dong pipeline rupture, replacement cost 200

mill. DKK

Valhall shut down, lost production 2 bill. NOK

Statoil Tordis flowline, replacement cost

unknown

Maersk Oil Gorm pipeline rupture, repair cost

unknown

BIOCORROSION IS TRICKY..

Concepts of measuring microbes in oil fields

NACE Standard TM0194-2004

”Field Monitoring of Bacterial Growth in Oilfield Systems”

Dilute sample and observe at what dilution SRB are no longer present

SRB are highly oxygen sensitive and most die immediately when exposed

to atmospheric air

Less than 1% of the

microorganisms (e.g.

SRB) detected

Not suitable for solid

samples

Origin of Troublesome Microbes

Causing Souring and MIC

Archaeoglobus

Sulfate Reducing Bacteria (SRB)

Sulfate Reducing Archaea (SRA)

Methanogens

Fermentative Sulfide Producing Prokaryotes

MIC Model: Activity of SRP (SRB & SRA)

and Methanogens

Net Reactions:

Sulfate Reduction (blue) 4Fe0 + 3H2S + SO42- + 2H

+ 4FeS + 4H2O

Methane Production (red) 4Fe0 + 4H2S + CO2 4FeS + 2H2O + CH4

S2-

Fe0

Fe2+

SO42-

H2S

e-

CH4

CO2

H+

H2

FeS

SRP

Methanogens

Larsen et al. NACE Corrosion 2010, Paper No. 10252

FISH

DAPI

qPCR

SAMPLE

DNA/RNA EXTRAC.

Work flow for routine MMM

MMM = Molecular Microbiological Methods

Enumeration of microorganisms

– what is included?

MPN (culturing)

FISH

DAPI

qPCR

Microbial sample

Active

Inactive

Dead

K. Sørensen, J. Larsen and T. L. Skovhus

In Applied Microbiology and Molecular

Biology in Oil Field Systems (Springer, 2011)

Method

(MMM)

Method

based on

Living Cells

counted

Dead Cells

counted

Scale/

wax Information yielded

MPN Cultivation Some No No Number of bacteria able to grow in

enrichment medium

DAPI Microscopy Yes Yes Yes/no Total cell counts (live and dead)

qFISH Microscopy Yes No Yes/no

Total numbers of live Bacteria

Total numbers of live Archaea

Total numbers of live SRB

Total numbers of live SRA

qPCR PCR Yes Yes Yes

Numbers of total Bacteria

Numbers of total Archaea

Numbers of SRB

Numbers of SRA

qPCR: - high-throughput

- low cost

- rapid analysis

- all kinds of samples

Choice of technique

NACE-TM0212-2012

New NACE Standard:

“Detection, Testing,

and Evaluation of

Microbiologically

Influenced Corrosion

(MIC) on Internal

Surfaces of Pipelines”

NACE-TM0212-2012*

*) Free to NACE members

via the Store at NACE.org

Type of samples

Water

Solids

Probes/coupons

IQ Kit® Water

DTI provides equipment and instruction (in box +

electronically)

Technicians offshore samples close to helicopter departure

hands over to logistics operator in airport for air/land trsp.

(DHL, FedEx, UPS, etc.)

Arrival in lab, analysis offset

IQ Kit® for North Sea shipment (<48hr)

IQ Kit® for World Wide shipment (1-2 weeks)

DTI follows up during process

Normally, first times takes coordination effort, afterwards

smooth operation

Transportation of kits to offshore platform

Return samples from platform to shore

IQ Kit® Solids – e.g. pigging samples

DNA analysis

Sample retrieval & trsp. DTI RISK DATABASE Empirical data from North Sea assets

RISK ASSESMENT

System data

• Water cut

• Temperature

• Materials

• Water data

MITIGATION STRATEGY:

- Mechanical cleaning

- Chemicals

- Recommendations

- Follow-up meetings

Chemical

analysis

0

200

400

600

800

1000

1200

1400

-15 -10 -5 0 5 10

TS

S (

mg

L-1

)

Time relative to pig arrival (min)

TSS in water during pigging

IQ Kit® Coupons – MIC, pitting and general corrosion

DNA analysis

RISK ASSESMENT

System data

• Temperature

• Materials

• Water data

MITIGATION STRATEGY:

- Mechanical cleaning

- Chemicals

- Recommendations

- Follow-up meetings

Chemical

analysis

Scanning for

pits and TWL

Data from one coupon:

- General Corrosion

- MIC (qPCR/X-Ray)

- Pitting Corrosion

Monitoring Program

Water – Trends // Hotspot ID // Growth potential in system // Where to focus biocide use

Solids – Can be related directly to MIC Risk // Corrosion and System Integrity // RBI

Removable Surfaces – Can be related directly to MIC Risk // Pitting // General Corrosion

Mitigation

Reporting

qPCR Transport Sampling

CORROSION PRODUCTS PIGGING DEBRIS BIOFILM & SLIME

INTEGRITY MANAGEMENT & MICROBIAL CONTROL

Better choice of new materials for future asset design

Improved choice of anti-microbial strategies

Optimized pigging and cleaning programs

Reduced costs on maintenance and chemical budgets

MIC Threat Assessment

Improving Risk Based Inspection with

Molecular Microbiological Methods

NACE Paper 2247, March 2013

South Arne Overview

Commission production 1999

Fractured chalk reservoir

13 Oil producers

7 Water injectors

Extension of field to north

Operated by HESS Denmark

NORWAY

DENMARK

UK

NL

58o

56o

55o

57o

6o 5o 4o 3 7o 8o 9o

Nybro

1

10

Fredericia3

The Challenge

Microbial monitoring - Planning - Inspection - Reporting - Corrective actions Same processes Get planning and evaluation processes aligned Work with aligned KPIs

Corrosion

and

Integrity

Management

Chem

ical S

taff

Corro

sio

n E

ngin

eer

Microbiologist

Com

municate

Data sharing C

omm

unicat

e

Dat

a sh

aring

Communicate

Data sharing

Risk Based Inspection

Standard DNV-RP-G101

Structured approach to general corrosion

Database for hot spots

Risk Pof (Probability of failure, PoF)

CoF (Consequence of failure, CoF)

Matrix

Challenge is microbiologically influenced corrosion

Very simplistic approach so far…

South Arne Process System

Oil Traditional 3 stage process Daily production 15,000 bbl/d 1st stage 78°C / 172°F Run down oil 38°C / 100°F

Produced Water (PW) Hydrocyclones PW Coolers Tout = 45°C / 113°F Degasser

Water injection Produced Water Sulfate reduced seawater Mixed -> scaling

3rd

Stage

Coalescer

LP 1

Test

1st

Stage

Degasser

Gas Export

Oil Export

Produced Water

Reinjection

2nd

Stage

IPGas

Drying

LP 2

HP

Microbial Monitoring @ South Arne

- MPN (TM0194-2004) vs. MMM (TM0212-2012)

- End of false zero points

- Parallel programs to prove reliability

Planktonic

Samples

Temperature

45°C / 113°F

MIC and RBI (coalescer case)

MIC and RBI (coalescer case)

MIC and RBI (coalescer case)

MIC and RBI (coalescer case)

Routine scan of vessel Area around nozzle heavily corroded

Bottom of vessel attacked by MIC

Not identified as a hot spot for MIC RBI program had not identified

”new” microbial monitoring not discussed

Review of available data Increased Growth (Microbial program)

Solids loading of coalescer (Thermography)

MIC and RBI (coalescer case)

Actions

Install bypass opportunity for vessel

Epoxy Repair Nozzle area

Routinely clean vessels for solids

Increase focus on biocide program

Enforce improved monitoring with MMM

Changed mindset

Program put in place – ensure it is efficient

Transfer learnings between diciplines is a must

Benefits of MMM monitoring

Surveillance Analyze Correct Surveillance

0

2

4

6

8

10

12

14

16

0.00E+00

2.00E+05

4.00E+05

6.00E+05

8.00E+05

1.00E+06

1.20E+06

1.40E+06

Wal

l Th

ickn

ess

[m

m]

Tro

ub

leso

me

Mic

rob

es

[ce

lls/m

l]

Quarterly Microbial Datapoints [Time, Quarters]

Troublesome Microbe

Wall Thickness Scan

South Arne – Monitoring Strategy

Communication Activities not communicated to vendors

Merge initiatives on RBI, MMM, Mitigation

Framework for decision and campaigns

Corrosion and Integrity

Management

Benefits:

Greater Value

Integrated teams

Learning culture

Improved Corrosion and

Integrity Management

MMM/MIC Evaluation - $

Mitigating activities - $$$

RBI – $$$

Corrosion Engineers

Integrity Specialists

Microbiologists

Chemical Engineers

Chemical Engineers

Production Operators

Vendors

apr jul okt

Corrosion and integrity management plan

RBI

MMM/MIC

MITIGATION

Corrosion

and Integrity

team

Vendor 1

Ven

dor 2V

endor 3

Work

Inte

rnal

Quarterly

Shop

Experts

Phone Meeting

Conclusions from NACE paper

Move towards new standards for South Arne

– No baseline from monitoring program

– New baseline initially by cases

– Corrective action decision process

– Same evaluation as other inspections

– DNV-RP-G101 does not capture MIC sufficiently - yet

Work ahead

– Execute work program

– Benefits from coordinating activities

– Active use of vendor experience

– Awareness of good microbiology samples

State-of-the-art Biocide Testing for E&P Companies

How to better control MIC, Souring and Biofouling

What actions can be taken to prevent microbes?

MATERIALS/COATINGS CHEMICALS CLEANING

Overview of ways to test effect of biocides

Source: Skovhus, Biofouling Methods (in press)

Optimizing microbial control

Biocide screening

• Ranking of biocides

offered by vendors

• Selection of „Best in

Class‟ biocide

Test dosage regime

• Dosage concentration

• Dosage frequency

• Dosage duration

Field test

• Validated biocide

effect in full-scale

production system

Sustained control

• Routine monitoring

• Sustained microbial

control

• Continual MIC risk

assessment

Process flow

Biocide testing

Ex. 1: Biocide ranking

4 biocides tested

Continuous dosage, at low and high conc.

Tested on produced water from system

Output:

Ranking of biocides

Test of biocide efficacy against organisms from system

Cells

Time

- biocide

+ biocide

Effect on growth

• Total cells

• SRB

• SRA

• Methanogens

• Nub

• Etc.

Meta

bolit

es

Time

- biocide

+ biocide

Effect on activity

• SRB + SRA

• Methanogens

Biocide testing

Ref. Tekna 2012 Geilo Symposium

Ex. 2: Test in pipeline simulator

Batch treatment

Tested on biofilm from system

Monitoring re-growth and activity after biofilm treatment

Output:

Test of biocide efficacy against biofilm

Test of biofilm re-growth following biocide treatment

Optimization of biocide dosage regime (dosage concentration and frequency)

Re-gain of activity

• SRB + SRA

• Methanogens

Scanned coupon surface

Corrosion analysis

• Corrosion rates

• Pitting (SEM)

A

ctivity

Time

+ biocide

Re-growth

Biocide testing

Ref. NACE paper C2012-0001279

Experimental Setup (1)

Ref. NACE paper C2012-0001279

Experimental Setup (2)

Ref. NACE paper C2012-0001279

Field monitoring with Corrosion Coupons

MIC, pitting and general corrosion

DNA analysis

RISK ASSESMENT

System data

• Temperature

• Materials

• Water data

MITIGATION STRATEGY:

- Mechanical cleaning

- Chemicals

- Recommendations

- Follow-up meetings

Chemical

analysis

Scanning for

pits and TWL

Data from one coupon:

- General Corrosion

- MIC (qPCR/X-Ray)

- Pitting Corrosion

DTI OIL & GAS SERVICE MODEL DTI SEQ.

DATABASE

MIC Risk Assessment &

Calculation Software

MICRATM

System-tailored MIC

assessment

Routine sampling

Analysis & assessment

Action on ”red light”

Q-meetings to follow-up with client

Monitoring microbiology

Inspection & RBI

Presentation Summary

Take advantage of MMM – now a standard applicable tool to the industry

Measure less – get better data – act on solid ground

We now have a number of published standards available – get to know them

Go to a specialist if your system is out of control - to get it back on track

Different sample types give you different answers – be clear on what you ask

Take hard conclusions on various kind of MIC data – not only microbiologically data

Focus on communication between disciplines (chemistry, engineering, microbiology)

Get alignment in various monitoring programs and planned actions

Define meaningful KPIs and get them to work in the same direction

When spending money on mitigation of microbes – make sure it works (corrosion view)

MMM is just another set of tools in the toolbox – it is how to apply them that matters…

Contacts at DTI Oil & Gas

Torben Lund Skovhus (PhD)

Team Leader, Sales and Business Development

Direct phone +45 72 20 18 27

Fax +45 72 20 18 70

E-mail: tls@dti.dk

DTI Oil & Gas

Web: www.dti.dk/oil

Hotline: +45 72 20 24 50

E-mail: oil@dti.dk