new diagnostic, predication and control of mic in the oil and gas … · 2020. 6. 3. ·...
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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: [email protected] / +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: [email protected]
DTI Oil & Gas
Web: www.dti.dk/oil
Hotline: +45 72 20 24 50
E-mail: [email protected]