J Fail. Anal. and Preven. (2008) 8:6068 DOI 10.

1007/s11668-007-9108-3

YP

R-R

Microbial-Inuenced Corrosion (MIC) on an 18 in. API 5L X52 Trunkline

F. Elshawesh K. Abusowa H. Mahfud A. Abderraheem F. Eljweli K. Zyada

Submitted: 17 September 2007 / in revised form: 11 December 2007 / Published online: 29 January 2008 ASM International 2008

Abstract Analysis of failed sections from a 31 km long pipeline show that premature failure was caused by microbial-inuenced corrosion. This case history summarizes the failure analysis and demonstrates the need for extreme care when using untreated water to hydrotest a pipeline. Keywords Trunkline Hydrotest Microbial inuenced corrosion

Background The petroleum production environment is particularly suitable for sulfate-reducing bacteria (SRB), partially because it handles large volumes of oxygen free water, which usually contains all the required nutrients to make the microorganism thrive [1]. Pipelines are one of the most vulnerable facilities in the oil industry to microbial corrosion because of the produced water, hydrostatic testing, and shutdowns [1, 2]. The presence of microorganisms such as planktonic SRB is not the real indication of microbial activity because sessile SRB adhere to the metal surface, forming a biolm. These lms modify the chemistry of metal solution interface and can result in severe microbial corrosion [1]. Pitting caused by bacterial activity is a manifestation of localized microbial-inuenced corrosion (MIC) in iron alloys. SRB are relevant anaerobic microorganisms related to localized corrosion, because they are able to transform
F. Elshawesh (&) K. Abusowa H. Mahfud A. Abderraheem F. Eljweli K. Zyada Libyan Petroleum Institute (LPI), P.O. Box 6431, Tripoli, Libya e-mail: fawzielshawesh@yahoo.com

the sulfate to hydrogen sulde, which is a strong pitting agent. The localized pitting attack is usually manifested by the presence of small deep corrosion pits that are covered with corrosion product [13]. The improper handling and management of hydrostatic water used for pipeline hydrostatic testing can result in MIC and detrimental effects on the pipeline integrity and result in premature failure. Therefore, the sources of water, water chemistry, biocide deployment, and oxygen scavenger need to be considered before and after the hydrostatic testing. Any water remaining within the pipeline needs to be handled carefully, and complete removal is necessary after test termination. There is an old adage that says pump it up or drain it, and this statement is very applicable to any pipeline.

Case History Two pipe joints in long trunkline (31 km) showed severe corrosion and leakage after less than 2 years from commissioning. The leaking area around the two pipe joints was removed and replaced with new pipe joints of the same material. Several samples with severe localized corrosion at both the circumferential weld and the parent metal were subjected to detailed failure analysis. The investigation goal was to establish the main cause(s) of premature failure and provide recommendations to prevent a recurrence of similar failures. The failed trunkline (Fig. 1), made of carbon steel grade API 5L X52, was used to carry untreated crude oil (approx. 28,000 bbl/day) to the separation station before being pumped through the main pipeline. The water cut was reported to range between 6 and 7%. Both CO2 and H2S

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J Fail. Anal. and Preven. (2008) 8:6068 Fig. 1 (a) and (b) General view for the failed 18 API 5L trunkline. Magnication: 29

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were present at concentrations of 350 and 1 to 4 ppm, respectively. The corrosion inhibitor (oil soluble and water dispersible) was injected to combat CO2 corrosion. Chloride ions levels were moderate, reaching 4200 ppm (mg/L). No biocide was injected with the inhibitor. This was because no bacterial growth had been detected during the microbial analysis of water samples frequently collected from the separators. Frequent pipeline pigging (every month) was used to reduce/remove the water and sand gathered at 6 oclock position and to make sure that the corrosion inhibitor is spread over the entire internal surface of the trunkline.

Crude type: very light with high API grade Corrosion inhibitor injected at rate of 15 L/day at manifold upstream of the trunkline Biocides or chemical: none SRB not detected within water samples taken from pipe end; however, was detected at the separators down stream of the trunkline Flow regime: heterogeneous two-phase, turbulent ow Flow velocity: 1.15 ft/s

Operating Condition and Water Chemistry The operating conditions for the failed 18 in trunkline were: The pipe specication and operating parameters can be given as: Trunkline (pipe) made of carbon steel as per API 5L grade X-52 Pipe nominal wall thickness: 0.375 in. Seam welded Total trunkline length: 31 km Installation and commissioning date: 2004 Water used for hydrostatic test: sweet water treated with oxygen scavenger Production rate: 28,000 bbl/day Average pressure: 250 psi Temperature (min/max): (30/61 C) Pipeline pigging: once a month The water chemistry was: Chloride ions: 4200 mg/L Carbon dioxide: 350 ppm Hydrogen sulde: 1 to 4 ppm Water cut: 6 to 7%

The rst and second leaks were detected on 15th and 18th of November 2006. Two leaks occurred at 6 oclock position (5.07.0 oclock positions). The pipe failure took place approximately 1100 m downstream the pig launchers support (PLS). The pipe failures were located at a low elevation with respect to the land topography. Flow regime was calculated using Petrochem. Software: Nominal pipe size: 18 in. Pipe schedule: standard Outside diameter: 18 in. Wall thickness: 0.375 in. Inside diameter: 17.25 in. Area of metal: 20.76 in.2 Transverse internal area: 233.71 in.2 Moment of inertia: 806.7 in.4 Weight of pipe: 70.59 lb/ft Weight of water: 101.18 lb/ft of pipe External surface: 4.712 ft2/foot of pipe Section modulus (2 9 I/OD): 89.6

Pressure drop calculations were: Flow rate: 28,000 bbl/day Density: 0.8151 gm/cm3 Viscosity, centipoises: 2.0 Pipe roughness: 0.00015 Velocity: 1.121 ft/s Pressure drop: 0.009791 psi/100 ft Reynolds number: 61,020 Friction factor: 0.0204

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The results of calculations conrm that the ow within the pipe is turbulent: the Reynolds number was calculated to be 61,020. However, the ow of water at the 6 oclock position may be laminar and not turbulent particularly at the lowest elevation of topography. Visual Observation

Fig. 2(d). The localized corrosion attack was found to be round and not elongated, as is usually seen in ow-induced corrosion in a CO2-containing environment. Small deep holes or pitting corrosion attack were visible within the circumferential weld seam.

Macroscopic Examination Two samples of pipe sections, one with the circumferential weld seam and one remote from the weld, were subjected to metallurgical investigation. The sample remote from weld seam showed severe localized corrosion attack, as shown in Fig. 2(a) to (c). Two corrosion morphologies produced by two different mechanisms seem to have occurred. One form of attack was pitting that perforated the pipe wall thickness as shown in Fig. 2(a). No sign of any role of ow regime (erosion) was apparent. The other form of attack was typical of ow-induced localized erosion/corrosion (FILC), as shown in Fig. 2(b). Both turbulent ow and high ow rate assisted by CO2 corrosion have resulted in attack, as shown in Fig. 2(b) and (c). The as-received samples were coated with a fragile/ brittle scale of iron carbonate. The scale was seen between the 5 and 7 oclock positions, as shown in Fig. 2(c). No sign of a clear black scale of iron sulde was noted. This lack of iron sulde scales can be attributed to the low level of hydrogen sulde. The sample with circumferential weld showed severe preferential corrosion of the weld seam, as shown in
Fig. 2 (a) to (d) General view for the severely corroded pipeline samples. It can be observed that the corrosion was over and remote from the pipeline circumferential weld seam. Magnication: 39

Sample without Circumferential Weld Seam A detailed macroscopic examination was conducted on the as-received pipe samples to assess the extent and morphology of the corrosion attack. Fragile/brittle scale was predominant on pipe samples, as shown in Fig. 3(a) and (b). As mentioned previously, the pipe sample without weld seam showed two different corrosion morphologies. The deep corrosion pit that perforated the pipe wall thickness showed a sloped wall typical of microbial corrosion attack. Small tiny holes around this large pit were seen, as shown in Fig. 4(a) to (f). There were some signs of a black, brown deposit/scale on the examined samples, as shown in Fig. 3 and 4. Localized corrosion attack underneath the deposit was also visible. The corrosion was in form of deep corrosion pits with a small mouth typical of microbial corrosion attack, as shown in Fig. 4(a) to (f). Some of the large pits seem to be formed through the coalescence of several small pits as shown in Fig. 4(a).

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J Fail. Anal. and Preven. (2008) 8:6068 Fig. 3 (a) and (b) Microscopic view for the under-deposit localized corrosion. Magnication: 169

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Fig. 4 (a) to (f) Microscopic view for the localized microbial corrosion. Deep pit covered with corrosion deposit is visible. Magnication: 169

Sample with Circumferential Weld Seam Preferential corrosion attack of the circumferential weld seam was seen on the as-received sample. The corrosion attack initiated at the weld seam and spread over the heataffected zone (HAZ) and parent metal (PM). Small but

deep corrosion pits were seen over the weld seam, as shown in Fig. 5(a) to (f). Some of these pits were covered with the fragile scale and/or corrosion product, as shown in Fig. 5(a) and (b). The morphology of the corrosion attack is typical of microbial corrosion. It is well established that the bacteria

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J Fail. Anal. and Preven. (2008) 8:6068 Table 1 Average hardness readings (HV10) for parent and weld metal samples taken from the failed 18 in. trunkline Locations Weld Metal, HV10 Parent Metal, HV10 *155

prefer the weld seam because of factors such as residual stresses, rough surfaces, and defects within the weld seam (i.e., crevices, porosity). Hardness Measurements The hardness was measured over the parent and weld metal of the pipe samples using Vickers hardness testing Machine at load of 10 kg to conrm that the carbon steel pipe had the appropriate hardness. The results of average hardness readings are shown in Table 1. The weld hardness (cap ller) is higher than that of the parent metal, and the hardness of the parent metal was found to be typical of API 5L grade X-52. Chemical Analysis Samples from the received pipe sections were subjected to chemical analysis using spark emission spectroscopy. The
Fig. 5 (a) to (f) Microscopic view for the localized microbial corrosion encountered at the circumferential weld seam. Magnication: 209

Average hardness readings *175 (cap) *145 (root)

Table 2 Chemical analysis of API 5L X-52 carbon steel pipe using spark emission Composition, wt.% C 0.293 Mn 1.293 P 0.021 S 0.018 Co 0.009 V 0.01 Ti 0.00

results of chemical analysis are shown in Table 2. The chemical analysis conrms that the pipe samples were made of carbon steel as per API 5L standard specication grade X-52.

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Analytical Chemistry Samples of corrosion product and scale collected from the failed pipe were subjected to detailed analytical chemistry as per ASTM standard D 800-91. The analysis was to detect the presence of chloride ions, carbonates, and sulfates. The results of analysis are shown in Table 4. These results are consistent with the x-ray diffraction showing that the main compound in the analyzed scale/corrosion products was iron carbonate.

Microbiological Analysis
Fig. 6 Typical microstructure of the received pipeline samples. Magnication: 1509

Metallography Several specimens from the received pipe section were cut and prepared for metallographic examination. Samples from the parent weld were examined, and the results are shown in Fig. 6. The pipe microstructure was typical of the ferrite and pearlite microstructure anticipated for the X-52 pipe, and the volume fraction of ferrite/pearlite is consistent with carbon content.

X-ray Diffraction Samples of corrosion product and scale were collected from the failed pipe section and subjected to x-ray diffraction. The results of analysis are shown in Table 3. The collected samples were primarily iron carbonate. Other elements such as Mg and Ca were also reported (MgCaFeCO3). This is expected in presence of CO2, which forms carbonic acid when dissolved in water. The weak acid reacts with steel surface, and the result is a FeCO3 scale. The cohesiveness and coherence of the scale to the pipe surface depends on the operating condition. The brittleness of the scale is expected to accelerate the corrosion attack where the broken areas of scale provide localized anodic sites for corrosion process by CO2 and also trap bacteria. In addition, the ow regime that the pipe saw (high ow rate) is expected to erode the metal surface and result in erosion corrosion.
Table 3 XRD results for the corrosion products/scale collected from the 6 oclock position of 18 in. trunkline Compounds Mg, Ca, FeCO3 (calcium magnesium iron carbonate)

Samples from the dry corrosion deposits and scale were collected from the pipe section and subjected to microbiological analysis to detect any presence of microorganism (bacteria) that might induce/inuence the corrosion process. The test included evaluations for sulfate-reducing bacteria (SRB), iron-related bacteria (IRB), and acid-producing bacteria (APB). The analysis was made using BART medium as selective media and conducted as per test method SM 9215 B/IRB-SRB-BART TM. The results of analysis are shown in Table 5. Both the iron and sulfate-reducing bacteria were detected within the collected corrosion product, as shown in Fig. 7(a) and (b). The dangerous SRB was detected when 1 mL from grown subculture in BART (iron-related bacteria) was centrifuged at 20,000 rpm for 30 min. After that, 0.5 mL of supernatant was transferred into API sulfate agar. After 24 h, SRB were found, as shown in Fig. 7(b). The presence of SRB was also conrmed microscopically, as shown in Fig. 8(a) and (b). The detection of SRB is consistent with the results of visual and macroscopic examination that indicated that

Table 4 Results of the chemical analysis for the collected corrosion/ scale product Concentration, wt.% Chloride ions (Cl-) 0.28 Carbonate (FeCO3) 52.2
Sulfate SO2 4

0.15

Table 5 Results of microbiological analysis of corrosion products/ scale collected from trunkline bottom Bacteria Detected Iron-related bacteria (IRB) Acid-producing bacteria (APB) Sulfate-reducing bacteria (SRB) Results and Remarks Present with high count 540,000 cfu/mL was detected after 24 h from inoculation Not detected Detected

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66 Fig. 7 General view for the bacteria kit test results where both sulphate reducing bacteria (SRB) and iron bacteria (IB) were detected

J Fail. Anal. and Preven. (2008) 8:6068

Fig. 8 Microscopic view for the detected SRB within the collected corrosion deposit as a function of time. Magnication: 1509

the corrosion attack was typical of microbial-inuenced corrosion caused by the presence of SRB bacteria. To conrm these results, two water samples from the separators were also subjected to microbiological analysis. The results conrm the absence of SRB and acid-producing bacteria (APB). The iron bacteria (IRB) were detected in pronounced amount. This test usually assesses the presence of planktonic bacteria and not the sessile bacteria that may have been attached to the metal surface and well protected by biolms. The technical data along with the evaluations of the pipeline samples indicate the presence of SRB in the separators downstream in the trunkline. This means SRB are present within the trunkline, and their presence is consistent with the results from the corrosion deposits. Generally, the iron bacteria rst attach to the pipe surface and subsequently oxidize the steel. This results in consumption of oxygen underneath the biolm and creates a safe haven for SRB to grow and produce its by-products (hydrogen sulde), which will stimulate the corrosion process.

Fig. 9 Biomass sample and water samples collected from trunkline receiver end

On-Site Microbial Activity Based on the investigation, the role of microbial activity was expected to be vital to the corrosion processes; therefore, a eld trip was arranged to assess the microbial growth/activity at different locations within the failed

trunkline (Fig. 9), separator, water wells, and manifold. The microbial analysis was conducted on the water samples collected from various sites as well as on the corrosion product and water after the pigging operation. The sample locations and results of analysis were: Sampling locations: Pig biomass (water and sludge) Water source well Separator and dehydrator Manifold

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J Fail. Anal. and Preven. (2008) 8:6068 Table 6 Results of microbial analysis collected from different locations Sample Description Pig biomass, sludge and water Separators Dehydrator Manifold Water well source SRB Bacteria 104 cfu/mL 103 cfu/mL 10 cfu/mL Nil Nil
3

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Iron-Related Bacteria (IRB) 540,000 cfu/mL, water and sludge samples 14,000 cfu/mL 14,000 cfu/mL Nil Nil

The following test method was applied in the microbiological biomass and water analysis: BART medium Commercial medium B 326 sulfate API medium

Results on the water and pig biomass samples (Table 6) conrm that a high count of SRB and IB are present. This is in complete agreement with the results obtained from the corrosion products collected from the failed pipe section. The microbiological test results showed no bacterial activity in the oil wells with highest water cut, the water source well, and in the water well used in the hydrostatic testing. It was reported during the site visit that the hydrotest water was transported by trucks before being injected into the trunkline. This result suggests that the source of bacteria that led to the corrosion damage may be the water transported by the trucks. In addition, the transported hydrotest water was not treated with the biocide before being injected into the trunkline. The only treatment was the injection of an oxygen scavenger to reduce the overall corrosion activity. However, the oxygen scavenger should create a favorable condition for microorganisms such as SRB to grow and establish colonies on the pipe surface.

Discussion The results of the investigation conrm the fact that the corrosion and premature failure of pipeline samples was caused by localized corrosion attack. Two different corrosion mechanisms namely microbial corrosion and CO2 corrosion have acted together and resulted in severe attack and failure of trunkline. However, the role of bacteria is expected to be the most pronounced. The calculation of ow regime conrms that the ow within the trunkline was generally turbulent with a calculated Reynolds number around 61,000. However, the water ow at the surface of the pipe in the trunkline was laminar and not turbulent. The two-phase ow is expected to be

pronounced over places with low trunkline elevation where the corrosion rate is maximum. The presence of microorganisms, biolms, and CO2 in the water at the 6 oclock position accelerated the corrosion process. The CO2 in water results in formation of weak carbonic acid. This acid reacts with the metal surface, producing iron carbonate scale (FeCO3). The scale is expected to be noncoherent and porous due to low working temperature. This results in easy breakdown and removal of the scale. The locations where the scale has failed will act as a potential anodic site inducing corrosion (dissolution) by the weak carbonic acid. However, the rate of the localized corrosion is expected to be slow due to low CO2 concentration. Nevertheless, the role of ow was seen on the examined samples. Clear grooves, an erosion-like corrosion attack, as a result of turbulent ow were visible. This is not always the case since the ow most likely is laminar over the area near the pipeline surface. In all cases the extent of the attack was inuenced by the presence of bacteria. Pipeline samples with a circumferential weld showed severe corrosion attack over the weld seam between the 5 and 7 oclock positions. The corrosion-induced pit was round and not elongated as usually seen when the ow velocity is high. Based on these facts, microbial-inuenced corrosion in addition to CO2 and water chemistry (i.e., high chloride ions) was considered. The microbiological analysis of the corrosion products conrm the presence of iron-related bacteria (IRB) and the sulfate-reducing bacteria (SRB). It is worth mentioning that there was some difculty in detection of SRB using normal test procedure; however, the bacterial activity was conrmed by the microbiological analysis of pig biomass (removed water and sludge). The presence of SRB was also conrmed using special optical microscope. The microscopic examination of the pipeline samples conrm the presence of deep tunneled and bottleneck type of microbial corrosion over the welded and nonwelded areas. Most of the observed corrosion pits were deep with small mouth covered with thick reddish brown corrosion products. The low ow velocity at the pipeline surface assisted in establishment of the biolm, which in turn produced an environment that acted as a safe haven for the sulfate-reducing bacteria to grow (sessile bacteria). The hydrogen sulde produced by the SRB produced an environment that caused severe localized corrosion attack. The method used to monitor the biological activity within the pipeline and around facilities has aggravated the problem by failing to detect the bacteria. Frequency of pigging (once a month) was not enough to clean the pipeline surface from bacteria, and the lack of biocides provided a safe haven for bacterial growth.

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In conclusion, the source of the bacterial activity in the current case was not the produced water but the contaminated water used during the hydrostatic testing. On-site visits and microbiological analysis suggest that the untreated water (no added biocides) remaining inside the pipe during the hydrostatic testing and before commissioning was the main source of microorganisms (i.e., SRB and IB).

Conclusions Premature failure of 18 inch trunkline can be attributed to the presence of micro-organisms such SRB and IRB. The presence of low partial pressure of CO2 may assist the corrosion process; however, its contribution is not considered essential. Although the ow regime is turbulent (Re & 61,000) inside the trunkline, the water ow at the 6 oclock position was laminar. This has created a favorable condition for microorganisms to grow, attach to the metal surface, form biolms, and build safe places for SRBs to grow on the pipeline surface. Maximum corrosion attack is expected to be over locations of lowest pipe elevation because the location maximizes the collection of water. Weak, porous, and noncoherent iron carbonate scale on the trunkline has created proper anodic sites for corrosion attack by CO2 and helps bacteria colonization. Lack of proper microbial tests, the lack of biocides, and failure to detect microorganisms in early stages have aggravated the problems. Lack of techniques to properly clean the water and any other material attached to the pipeline surface after termination of the hydrostatic testing resulted in conditions detrimental to the pipeline integrity. Proper chemical and microbial analysis should be made on the collected material from the pipe pigging. This will help detect the microbial activity. The analysis of water samples may not be sufcient to obtain full information on the bacterial activity. Lack of proper treatment of the water used to hydrotest the pipe may have created favorable conditions for microorganisms such as SRB and IB to grow and establish inside the trunkline.

However, caution needs to be taken when dealing with the microbial corrosion attack where the corrosion pits are not open. In fact, the corrosion attack is in form of small tunneled pits with small open mouth (bottleneck corrosion attack), thus making it difcult to treat the existing pipeline. The trunkline needs to be properly cleaned using a special type of pig. The cleaning shall ensure proper cleaning or removal of corrosion deposits and disrupt or destroy the biolm on the pipe surface (5 to 7 oclock positions). An extensive pigging operation using brush pigs followed by preferably a slug of biocide between two isolating pigs needs to be done two to three times. If the slug of biocide is not possible, dose the pipeline after each pig run and repeat for three to ve times (every week) for 3 to 5 weeks. Analysis of the uids during the pigging operation near the time the pig arrives should provide good indication of the level of bacteria. Pigging operation should be conducted using brush pigs and not sphere or disk pigs. Alternatively, use a brush pig in addition to the sphere or disk pigs. Trial tests should be conducted for several types of biocides and select the best performers to reduce the microorganism activity to a minimum. Chock (at the beginning) and batch treatment need to be considered. For cleaning purposes, a high dose of biocide (depending on type of biocide) needs to be injected for 2 h and alternately between the two cleaning pigs. Biocide treatment should consider the biolm disruption and kill as much as possible from the sessile bacteria colonies. Slug of biocide mixture between two pigs needs to be considered. The brush pigs will disrupt the biolm, the biocide will kill the bacteria, and the pigs will remove the biomass. A corrosion-management program should be implemented that includes corrosion monitoring (i.e., probes, coupons etc.).

Acknowledgments The authors would like to thank Dr. Khalifa Esaklul for the fruitful technical discussion and extend their thanks to the microbiology lab staff, particularly Mrs A. ElQadawy and A. Benhaliem for their patient and endless help and assistance in order to complete part of microbiological investigation successfully.

References
1. Kobrin, G.: In: Dexter S.C. (ed.) Proc. International Conference on Biological Induced Corrosion, p. 32. National Association of Corrosion Engineers, Houston, TX (1986). 2. Failure Analysis and Prevention, vol. 11, 9th edn. Metals Handbook. ASM International, Materials Park, OH (2002). 3. During, E.D.D.: Corrosion Atlas. Elsevier Science, Amsterdam, The Netherlands (1997).

Recommendations Immediate action needs to be taken to assess the extent of the corrosion attack within the trunkline (31 km), particularly over areas conducive to water collection.

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