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© Kinben Innovation | Ver2.0 Rev12 1
© Kinben Innovation | Ver2.0 Rev12 2
Title
Managing Microbiologically Influenced Corrosion
in Oil & Gas Industry Benefits and Challenges
Author
Dr. Mahendara P Singh, Ph.D.
Advisor at Kinben Innovation Pvt. Ltd. Formerly, Chief Research
Manager, Industrial Biotechnology Department R&D Center,
IOCL, Faridabad
© Kinben Innovation | Ver2.0 Rev12 3
Basics of MIC
• Microbes are omnipresent entities.
• They have unquestioned ability to alter material
characteristics.
• This uniqueness of microbes is attributed to
• their “biofilm” forming ability under varying
environmental conditions.
• The biofilms are formed by ‘sticking’ of bugs on the
surface of a metal or material.
• In most of the cases biofilm formation leads to
considerable material damage, known as MIC
• The formation of corrosive materials leads to
damage of metal and its protective surface
MIC is a complex process involving different type of
microorganisms (bacteria, fungi, algae, and
archaea)
MIC bugs are often found in highest concentration
in crevices, stagnant zones, sediments, and
damaged protective coatings
© Kinben Innovation | Ver2.0 Rev12 4
Internal corrosion of a pipeline caused
by MIC. Photo courtesy of Richard
Eckert, DNV GL.
MIC increases corrosion rates,
leading to a premature and
severe type of corrosion. It can
be highly destructive, leading to
disastrous consequences for
industry.
MIC may cause a lifetime
reduction of flow lines from the
designed >20 years to less than
3 years.
© Kinben Innovation | Ver2.0 Rev12
• Around 87% pipeline failures are due to leaks
• 67% due to corrosion
• 50% are internal corrosion
• Up-to 40% internal corrosions are attributed to MIC
(Conservative Estimate)
5
Magnitude of the Problem
© Kinben Innovation | Ver2.0 Rev12
• CI dosing is not the solution against
MIC
• Pigging always does not reduce MIC
pitting threat/occurrence
• Pigging removes the biofilms partially only.
• However pigging can not remove biofilms
and microbes from deep pits
• Lab experiments conducted using pure
SRB strains published by various
research groups often indicate an MIC
pitting rate around 1 mm/yr. Much
more aggressive MIC pitting has been
indicated by field operators.
6
Demystifying MIC mitigation Myths
© Kinben Innovation | Ver2.0 Rev12
The Prudhoe Bay Oil Spill, 2006
A 34” pipeline operated by BP and partners including Exxon Mobil Corp and
ConocoPhillips spilled over 267,000 gallons of crude. It was the biggest oil spill in
Alaska’s history and devastated 7,700 m2 of pristine land. The spill originated from a
1⁄4” hole in the pipeline that was caused by internal MIC.
The company was fined US$ 255 million in addition to the loss of production and
cost of containment. The pipeline was decommissioned and replaced with a 20”
pipeline provided with facilities to enhance inspection and monitoring.
The incident caused shockwaves on the international market and the price of oil on
NYMEX jumped by US$2.22 a barrel while BP shares dropped by 2%.
7
MIC leaving its mark on world…..and Cost
Implications !
© Kinben Innovation | Ver2.0 Rev12 8
Watershed moment for MIC
Investigations by US federal agencies
revealed
• They were injecting CI in the pipeline
• Pigging was done – Even Smart PIGs
were used
• But defects were increasing at fast rate
• Microbial presence with smell of H2S,
SRB and Methanogens
© Kinben Innovation | Ver2.0 Rev12
The Southern California Gas Company
(SoCalGas) provides gas to over 21 million
customers in Los Angeles and Southern
California.
The failure leaked around 109,000 metric
tons of methane over a period of five
months. The incident was the largest
methane leak in US history
More than 8,000 households were
evacuated. The cost to the utility exceeded
USD 2 billion including civil lawsuits
settled for US$ 1.8 billion on 27/9/2021
9
An explosion in the El Paso pipeline in
New Mexico caused a huge crater (around
51 feet wide and 113 feet long), damaged
bridges, and cost the company a US$15.5
million penalty. Damage to property cost
US$1 million. Multiple lives were lost.
© Kinben Innovation | Ver2.0 Rev12
Microbial corrosion was
discovered in 1910
10
Managing the MIC: Challenges
MIC is a puzzle !
Basic Reason
• Microbial complexity
and Diversity
• Interplay among
microbial communities
• Unique protection and
survival ability
© Kinben Innovation | Ver2.0 Rev12
• Traditional techniques of repeated pigging and
corrosion inhibitor dosing is not effective for MIC
mitigation. False Sense of Security !
• No predictive model to forecast MIC progression and its
effects on asset. Only regular monitoring is the solution.
11
Managing the MIC: Challenges
© Kinben Innovation | Ver2.0 Rev12
MIC Threat* Assessment
Reliable diagnosis of MIC to determine
severity to develop response
Biocide Screening and Optimization
Chemicals/biocide screening, dosing
rate and frequency
Chemical compatibility and Failure
analysis
To evaluate overall effectiveness of
chemicals/biocides to beat the bugs
12
Managing the MIC: Way Forward
© Kinben Innovation | Ver2.0 Rev12
MIC is a complex phenomenon
We have discussed some high-profile MIC failures, and it
has enormous economic and social implications if not
taken seriously
A deeper understanding of MIC and multidisciplinary
approach with microbiological, bio technological,
chemistry and engineering interventions are essential to
handle and mitigate the problem
13
Concluding Remarks
© Kinben Innovation | Ver2.0 Rev12
• Regular monitoring
• Microbial analysis of muck
• Chemical analysis of muck
• Correlation with ILI data
14
What to do for realistic Diagnosis of MIC?
© Kinben Innovation | Ver2.0 Rev12
• Microbial profiling for assessing
impact of MIC causing bacteria
• Designing & Execution of Mitigation
strategy for treatment of MIC
• Continuous monitoring of MIC to
devise preventive measures
• Correlation between ILI data and
occurrence of MIC
15
Solutions by Kinben Innovation
Complete Package for
MIC monitoring &
mitigation service
© Kinben Innovation | Ver2.0 Rev12 16
About Kinben Innovation
© Kinben Innovation | Ver2.0 Rev12 17
High Resolution MFL based Inspection Tools
MFL A
MFL C
EGP
© Kinben Innovation | Ver2.0 Rev12 18
Asia’s Most Advanced Pipeline Technology Center
Pull-Through-Test
facility for pipes
from 4” to 56”
diameter
Controlled &
Measured
inspection tool
testing speeds up-
to 5 m/s
Pressure test
facility for pressure
up-to 100 Bar
Defect fabrication
facility on pipes as
per POF guidelines
Testing facility for
Negative Pressure
Wave Leak
Detection System
All tests as per
global Oil and Gas
standards like POF,
API, ASNT etc.

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ACM CHT Best Inspection Practices Kinben Innovation MIC Slideshare.pdf

  • 1. © Kinben Innovation | Ver2.0 Rev12 1
  • 2. © Kinben Innovation | Ver2.0 Rev12 2 Title Managing Microbiologically Influenced Corrosion in Oil & Gas Industry Benefits and Challenges Author Dr. Mahendara P Singh, Ph.D. Advisor at Kinben Innovation Pvt. Ltd. Formerly, Chief Research Manager, Industrial Biotechnology Department R&D Center, IOCL, Faridabad
  • 3. © Kinben Innovation | Ver2.0 Rev12 3 Basics of MIC • Microbes are omnipresent entities. • They have unquestioned ability to alter material characteristics. • This uniqueness of microbes is attributed to • their “biofilm” forming ability under varying environmental conditions. • The biofilms are formed by ‘sticking’ of bugs on the surface of a metal or material. • In most of the cases biofilm formation leads to considerable material damage, known as MIC • The formation of corrosive materials leads to damage of metal and its protective surface MIC is a complex process involving different type of microorganisms (bacteria, fungi, algae, and archaea) MIC bugs are often found in highest concentration in crevices, stagnant zones, sediments, and damaged protective coatings
  • 4. © Kinben Innovation | Ver2.0 Rev12 4 Internal corrosion of a pipeline caused by MIC. Photo courtesy of Richard Eckert, DNV GL. MIC increases corrosion rates, leading to a premature and severe type of corrosion. It can be highly destructive, leading to disastrous consequences for industry. MIC may cause a lifetime reduction of flow lines from the designed >20 years to less than 3 years.
  • 5. © Kinben Innovation | Ver2.0 Rev12 • Around 87% pipeline failures are due to leaks • 67% due to corrosion • 50% are internal corrosion • Up-to 40% internal corrosions are attributed to MIC (Conservative Estimate) 5 Magnitude of the Problem
  • 6. © Kinben Innovation | Ver2.0 Rev12 • CI dosing is not the solution against MIC • Pigging always does not reduce MIC pitting threat/occurrence • Pigging removes the biofilms partially only. • However pigging can not remove biofilms and microbes from deep pits • Lab experiments conducted using pure SRB strains published by various research groups often indicate an MIC pitting rate around 1 mm/yr. Much more aggressive MIC pitting has been indicated by field operators. 6 Demystifying MIC mitigation Myths
  • 7. © Kinben Innovation | Ver2.0 Rev12 The Prudhoe Bay Oil Spill, 2006 A 34” pipeline operated by BP and partners including Exxon Mobil Corp and ConocoPhillips spilled over 267,000 gallons of crude. It was the biggest oil spill in Alaska’s history and devastated 7,700 m2 of pristine land. The spill originated from a 1⁄4” hole in the pipeline that was caused by internal MIC. The company was fined US$ 255 million in addition to the loss of production and cost of containment. The pipeline was decommissioned and replaced with a 20” pipeline provided with facilities to enhance inspection and monitoring. The incident caused shockwaves on the international market and the price of oil on NYMEX jumped by US$2.22 a barrel while BP shares dropped by 2%. 7 MIC leaving its mark on world…..and Cost Implications !
  • 8. © Kinben Innovation | Ver2.0 Rev12 8 Watershed moment for MIC Investigations by US federal agencies revealed • They were injecting CI in the pipeline • Pigging was done – Even Smart PIGs were used • But defects were increasing at fast rate • Microbial presence with smell of H2S, SRB and Methanogens
  • 9. © Kinben Innovation | Ver2.0 Rev12 The Southern California Gas Company (SoCalGas) provides gas to over 21 million customers in Los Angeles and Southern California. The failure leaked around 109,000 metric tons of methane over a period of five months. The incident was the largest methane leak in US history More than 8,000 households were evacuated. The cost to the utility exceeded USD 2 billion including civil lawsuits settled for US$ 1.8 billion on 27/9/2021 9 An explosion in the El Paso pipeline in New Mexico caused a huge crater (around 51 feet wide and 113 feet long), damaged bridges, and cost the company a US$15.5 million penalty. Damage to property cost US$1 million. Multiple lives were lost.
  • 10. © Kinben Innovation | Ver2.0 Rev12 Microbial corrosion was discovered in 1910 10 Managing the MIC: Challenges MIC is a puzzle ! Basic Reason • Microbial complexity and Diversity • Interplay among microbial communities • Unique protection and survival ability
  • 11. © Kinben Innovation | Ver2.0 Rev12 • Traditional techniques of repeated pigging and corrosion inhibitor dosing is not effective for MIC mitigation. False Sense of Security ! • No predictive model to forecast MIC progression and its effects on asset. Only regular monitoring is the solution. 11 Managing the MIC: Challenges
  • 12. © Kinben Innovation | Ver2.0 Rev12 MIC Threat* Assessment Reliable diagnosis of MIC to determine severity to develop response Biocide Screening and Optimization Chemicals/biocide screening, dosing rate and frequency Chemical compatibility and Failure analysis To evaluate overall effectiveness of chemicals/biocides to beat the bugs 12 Managing the MIC: Way Forward
  • 13. © Kinben Innovation | Ver2.0 Rev12 MIC is a complex phenomenon We have discussed some high-profile MIC failures, and it has enormous economic and social implications if not taken seriously A deeper understanding of MIC and multidisciplinary approach with microbiological, bio technological, chemistry and engineering interventions are essential to handle and mitigate the problem 13 Concluding Remarks
  • 14. © Kinben Innovation | Ver2.0 Rev12 • Regular monitoring • Microbial analysis of muck • Chemical analysis of muck • Correlation with ILI data 14 What to do for realistic Diagnosis of MIC?
  • 15. © Kinben Innovation | Ver2.0 Rev12 • Microbial profiling for assessing impact of MIC causing bacteria • Designing & Execution of Mitigation strategy for treatment of MIC • Continuous monitoring of MIC to devise preventive measures • Correlation between ILI data and occurrence of MIC 15 Solutions by Kinben Innovation Complete Package for MIC monitoring & mitigation service
  • 16. © Kinben Innovation | Ver2.0 Rev12 16 About Kinben Innovation
  • 17. © Kinben Innovation | Ver2.0 Rev12 17 High Resolution MFL based Inspection Tools MFL A MFL C EGP
  • 18. © Kinben Innovation | Ver2.0 Rev12 18 Asia’s Most Advanced Pipeline Technology Center Pull-Through-Test facility for pipes from 4” to 56” diameter Controlled & Measured inspection tool testing speeds up- to 5 m/s Pressure test facility for pressure up-to 100 Bar Defect fabrication facility on pipes as per POF guidelines Testing facility for Negative Pressure Wave Leak Detection System All tests as per global Oil and Gas standards like POF, API, ASNT etc.